Pump Kit Installation Procedures
Figure 1.:
1. Disconnect the ground cable from the battery.
2. Drain the engine coolant from the radiator drain.
3. Remove the engine coolant expansion tank.
4. Cut the tie strap which secures the hoses leading to the heater control valve (Figure 1).
Figure 5. Attaching the lower coolant hose to the "T.":
Note
Before proceeding wfth Steps 5 and 6, refer to Figure 5 on Page 3. The hose cuts you will make in the next two steps will permit the installation of the "T" connector as shown In Figure 5.
Figure 2. Shorten the lower heater hose.:
5. Remove the control valve end of the lower heater hose (the other end may be left attached) and cut it off 20 cm (7-3/4 in.) from the end as shown in Figure 2. The piece which has been cut off may be discarded.
Figure 3.:
6. Leaving the hose in place, remove a 2 cm (3/4 in.) section from the upper heater hose starting 18 cm (7 in.) from the end as shown in Figure 3.
Figure 4. Installing the "T" piece into the upper hose.:
7. Slide two of the larger hose clamps supplied in the kit onto each side of the upper hose and insert the "T" connector between the two hose pieces as shown in Figure 4.
Figure 5. Attaching the lower coolant hose to the "T.":
8. Slide another large hose clamp onto the remaining portion of the lower hose and insert the hose onto the nipple of the "T" connectors as shown in Figure 5.
Figure 6. Installing the mounting bracket on the pump.:
9. Press the mounting bracket onto the circulation pump as illustrated in Figure 6 (if necessary, use silicone to ease installation). Press the bushing into the hole on the mouriting bracket.
Figure 7.:
10. Mount the hoses from the kit to the pump using the smaller size hose clamps supplied with the kit (Figure 7). Do not tighten the clamps yet.
Figure 8. The pump located in the engine bay.:
11. Position the pump in the car as shown in Figure
8. Install the longer hose to the lower connection of the heater valve and the shorter hose to the bottom of the "T" connector.
12. Check that the hoses and hose clamps do not chafe or rub on anything and that the kick-down cable on automatic transmission cars does not rub against the circulation pump.
Figure 9. Drllllng a mounting hole for the pump:
13. Mark the location for drilling the mounting hole for the pump as illustrated in Figure 9.
14. Drill the mounting hole with a 3.5 mm (1/8 in.) drill.
15. Rust protect the hole using touch-up paint.
Figure 10. Make sure the pump is horizontal and does not contact the car body.:
16. Mount the pump using the sheet metal screw from the kit. Make sure that the pump is positioned horizontally and that it does not make contact with the body (Figure 10).
17. Tighten all of the hose clamps. Start at the firewall and work forward.
Figure 11. Fasten the hoses together with tie straps.:
18. Secure the hoses with tie straps as shown in Figure 11. Make sure the hose clamps do not chafe the hoses.
Figure 12. Connecting the pump wiring harness to the fuse block.:
19. Connect the electric wiring harness to the pump and route it as shown in Figure 12.
20. Loosen the fuse block and lift it to gain access to the wiring.
21. Cut the tie strap securing the harness bundle and pass the pump harness through the grommet in the inner fender into the lower portion of the fuse box.
22. Connect the pump harness plus wire (whitegreen) to the positive distribution terminal (159).
23. Connect the pump harness ground wire (black) to the negative distribution terminal (158).
24. Reinstall the fuse block.
Figure 13. Fastening the wiring harness in the car.:
25. Secure the pump harness with tie straps to the hood release cable as shown in Figure 13. Also secure the wiring harness bundle with a tie strap.
26. Reinstall the expansion tank.
27. Connect the battery ground cable.
28. Refill the cooling system with coolant and bleed. Check for leaks.
29. Turn the ignition key on and check that the pump operates.
Warranty Information:
For warranty claims, use Failure Coding 85438-71-0-01-01. Labor time allowance is Op. No. 85438 (0.6 hour).
Note: Add Failure Code 85438 ("Circulation pump, interior heater") and Labor Operation number 85438, ("Install circulation pump"), 16V, 85-, 0.6 hour to page 8-53 of your 900 Failure Code/Flat Rate Manuals.
Saab-Line (DCS) Dealers: Please update your Failed Part and Operation Number Tables.