

| Subject: | Cooling Systems |
| From: | Dan Aldrich |
| Date: | Fri, 12 Feb 1999 10:01:21 -0700 |
While this is written for SAABS, a lot of it applies to any motor. I'm using the Mercedes Benz factory coolant on my SAAB with no problems. It's $10/gallon, so not all that more than Wal-Mart specials. Hope this helps. -Dan COOLING SYSTEM SERVICE SAAB 900 and 9000 > COOLANTS Engine coolant should be maintained to promote both its >effectiveness and the longevity of the engine and the entire cooling >system. Over time, and with those occasional top offs, the coolant becomes >unknown and begins to break down. Phosphates and silicates and produced >aluminum oxides fall out of suspension building up and promoting >electrolysis, pitting of the aluminum surfaces and the main gaskets and >seals. The deposits of these phosphates and oxides in the layers of the >head gasket splits it like ice in pavement. Concentration becomes unknown >and thus its freezing point unknown. Mixing common ethylene glycol and the >newer, supposedly environmental friendly, propylene glycol, produces a mix >with a specific gravity unreadable by ball drop type testers meant for >either one or the other of the coolants. Use one or the other, but do not >mix. Because of this, you might want to keep a little of what you're using >around, just in case. We have found increased life and fewer failures of >any kind in the cooling systems after using Mercedes Benz factory coolant. >It is phosphate free and pH buffered with inhibitors to aid in the >prevention of electrolysis. When servicing cars that have been using it, >the difference in the appearance of the internal cooling system is >noticeable. Upon thermostat replacement, the aluminum is not covered with >the white aluminum oxide or pitted from electrolysis as is common with the >green coolants routinely used by some. The coolant of your choice, unless >it specifically states otherwise on the container, should be kept at the >least concentration necessary to insure proper cold weather protection for >its expected needs. As close to a 50% coolant to water mix as you can get >is best, as long as the coolant's label's freezing point chart is followed >to insure adequate protection. Running pure coolant is not a very good >idea, more is not better. Particulates are more apt to form at higher >concentrations. We service the cooling system on our customers cars every >30K miles with a drain, a flush, a thermostat replacement, a tightening of >all the cooling hose clamps, pressure test for leaks, inspection of all >hoses and replacement of any upper hoses (top radiator and bypass hose at >rear of head) that are over three years old, fan operation, coolant refill >and relay upgrades. THERMOSTAT (Look here for more info and pictures) >Thermostats are considered a maintenance item in our book. They operate by >use of a fixed volume of wax that expands a calculated amount at certain >temperatures, pushing them open. Each cooling system cycle works the >thermostat, exposing it first to temperatures above what it is set to open >at, then, after it gets hot and opens, it is flooded shortly with much >cooler water, so it closes. It oscillates between open and closed as the >engine is driven to maintain an even cooling system temp. The thermostat >works more than its commonly perceived opening once per trip. This wears >them. You can see evidence on the brass bodies of thermostat where they >begin to cock and bind in their travel. Let them catch here just once, and >it could take out the engine. While you are examining the thermostat, look >at the top of it, where the chamber holding the wax is sealed. Most older >thermostats, failed and not yet failed, show evidence of leakage of the wax >here. Since that wax is calculated in its volume and expansion rate, any >leakage changes its properties and amount of opening. Overheating by >running low of coolant can subject the thermostat to much higher than >normal temps which could rupture its seal and allow the wax out, or >overheat the wax to the point it changes in its character. Anytime the car >overheats, I would consider replacing the thermostat, the trust is gone. >The thermostat in a 900 sits under the housing that the upper radiator hose >attaches to on the engine. 8 V's have easy access via two 13 mm bolts. 16 >Vs' require the removal of the AIC valve to service the thermostat. Unplug >the valve, remove its two hoses, and then remove the 10 mm bolt holding it >in its bracket. Set it out of the way (now would be an excellent time to >clean its shutter wheel with carb cleaner). Now you can remove the two 12 >mm bolts holding the housing and access the thermostat. On a 9000, the >thermostat sets on the rear of the head on the driver's side, still under a >housing to which the upper radiator hose connects, more of a task to access >than the 900s though. There are various things attached to this housing, >from fuel pressure regulators with their 4 mm Allen's to DI ground wires >and brackets on later 2.3 engines with 4 mm Allen's or 10 mm bolts. Often >it is time and knuckle saving to remove at least the rubber bellows going >to the throttle housing. 2.3's require removal of some throttle housing >hoses to get to the thermostat so that it can be accessed and cleaned >properly on the mounting surfaces. On cars with a rubber seal for the >thermostat gasket (all except the early 8 Vs), clean the housing surfaces >with a brush. No sealant should be necessary for the gasket. Make sure that >the bolts are clean, wire brush their threads and use an anti seize >compound on them to prevent future troubles. Install the thermostat so that >the brass air bleeder valve on it is at the highest point. Turn the lower >plate so its hole is in alignment with the brass fitting hole. On 16 V >thermostats, turn and position the hole in the bottom plate to align with >the bleeder on the top of the thermostat. This allows all the air to leave >the system. Though the 9000 has no bleeder port to the exterior, its >thermostat design allows it to empty air to the reservoir, if the >thermostat is properly aligned. Use a factory thermostat. In all but the >coldest climates, we recommend the 82 degree Celsius thermostat under the >part number 8817538 for 16 V engines. The 8 V has its own thermostat, >number 9337551. Do not install a 8 V thermostat in a 16 valve engine. The >16 V has a special design and it is for this reason also that we don't >recommend aftermarket thermostats. Too much depends on such a relatively >inexpensive part. The three position design of the Saab thermostat allows >proper operation of the cooling system. Some attempts at copying it have >resultedc in overheating or loss of cabin heat when the car gets warm. >Either requires doing the thermostat again, so why not go ahead and put >what was designed for the car there, not just one that fits the hole. >COOLING FANS Check the operation of the cooling fans. On 900s, the sensor >is in the upper left hand corner of the radiator with two wires connecting >to it. Disconnect the two wires and touch them together. With the key on, >both fans should run. 91 and up 900 S's should be checked for the >modification and replacement of the cooling fan relays if only one fan >runs. < CONTACT US FOR DETAILS> LOOK HERE FOR WIRING INFO >> cars, the >modified relay is both less expensive and more reliable than the relay that >is there. To check the high speed operation on equipped 9000s, first >engage low speed as above and then remove the relay in position F of the >same fuse box and jump the 1 pin (+30) to both the 2 (87) and 3 (87B) >terminals. This should generate warp drive captain. If the fuses for the >cooling fan haven't been updated, change them to 30A in the fuse box under >the hood, as per factory bulletin 03/89-1127 Running Change Upgraded Fuse >For The Cooling Fan. For all 900s and Early 9000s with the two wire fan >sensor, we strongly suggest you swap the original fan sensor that turns the >fans on the first time at 92 degrees Celsius for one that turns them on at >82 degrees. When used with a factory 82 degree thermostat(8817538), this >avoids the temperature overshoot problem seen when getting in traffic after >highway driving, and maintains the gauge reading at about halfway. The >sensor simply screws into and out of the radiator and the wires plug right >up. We use a sensor made by Wahler for VW. You can get this sensor from a >VW dealer under the part number 823959481D, or from us if you can't find >it. That is a pretty old VW part number now, but it is what we order it >under. We have not found a cooler direct replacement for later 9000s with >the two stage fan, but are searching. You can rewire them to accept the >cooler old style switch, but that is detailed in another page on this site. > FLUSHING, FILLING, BLEEDING To flush the cooling system, find a >suitable pan to catch the old coolant. Drain it first from the radiator >drain. Be careful if the petcock seems tight not to damage the radiator. On >900s, the drain is on the right lower front of the radiator. Early ones >have a 17 mm petcock with a 22 mm support hex. Later ones have a 24 mm >plastic petcock. 9000s' have a petcock accessible from the bottom on the >right side. They are hard to get to without removing the under panels and >can become brittle and break. You might find it easier to remove the bottom >hose on the water pump, below the AC compressor. Make sure on cars with >manual heat controls, that the temperature selection on the heater is set >to hot. This opens the hot water valve and allows the flushing of the >heater circuit and core. On 9000s, the heater circuit is open all the time, >there is no need to set the temperature. After the most of the old coolant >has drained, open the heater circuit by removing a heater hose and >inserting a garden hose.Then you can proceed to flush the system by running >water through the system until it comes out clear. This can take up to an >hour. On a 900 with an 8 V engine, we remove the coolant hose running to >the center of the intake and flushing through it into the heater. On 16 V >900s, remove the hose coming up from behind the AC compressor off a pipe >running to the front of the head, flush through the end of that hose. On >the 9000s' removing the smaller hose connecting to the rear of the head >(facing the left side of the car) allows its heater core to be flushed >through that hose. We flush the systems with the thermostat removed and >replace it when finished. Swapping the point at which you place the garden >hose, from the initial heater hose for the majority of the heavy work, to >the reservoir to rinse it and its hoses, to the top radiator hose, anywhere >you can stick it in the open system, will make sure no old coolant gets >left lying around. When it all looks nice and clear, let the engine drain. >Then shut up anything you have opened, getting the system ready for its new >coolant. Pour in the required amount of coolant, making sure to leave the >manual heat controls on hot. On a 900, there is an air bleeder port on the >thermostat housing. It has two 11 mm (7/16") hexes. Hold the lower one and >loosen the top one to allow trapped air to escape the system. Fill with the >coolant/water mixture until the reservoir is to the max line on 9000s and >until a steady stream of coolant comes out of the air bleeder port on a >900. Then shut the bleeder port on a 900 and fill to the max line of the >reservoir. Check for leaks. Then start the car and let it idle. Pay >attention to the reservoir. If air comes up (it will), re adjust the level. >Run the car until the fans cycle once. You might want to reopen the bleeder >screw on a 900 after the car runs a few minutes just to make sure there is >no trapped air. After the fans cycle, recheck and adjust the level at MAX >if necessary. Replace the radiator cap and run the car until the fans cycle >again and shut it off. Let it sit for 15-20 minutes and check for leaks >after the system builds all the pressure it should. After a complete cool >down, recheck the level. Do this again just to be sure after another >temperature cycle. 4 Attachment Converted: "c:\eudora light >3.05\attach\ymason.vcf"
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