Changing the Coolant tank in the V6

[sgould]

I got fed up with the random low coolant warnings, so I bought a new tank from Saabits.  It's a Professional Parts Sweden item, but at ⅓ of the price of a new Saab one, it's worth a go.  I've had other parts from PPS and had no issues so far.  The heater matrix has noe lastest longer than the original from the factory...

It's turned out to be a bit of a saga. The WIS just says "lift and remove"   It sort of does but it's restricted by the pipe at the bottom.  It's held in by a standard O ring connection with a wire retaining clip.  These clips are easy to undo, if you can get to them, but the one under the tank has a protection ridge so it can only be accessed in the narrow gap between the clip and the tank.  In the end I disconnected the two heater pipes to allow the tank to be lifted enough to see what was going on.  The connection has a locating lug so the connector can't be rotated to free it before pulling off, so it needed levering.  But it's out and disconnected.  I've just got to put it all back together.

The level sensor reed switch is removable.  I got it out but there's no obvious issue, so it may be the float is bad, but that's sealed inside.

[sgould]

Spoke too soon   The spigot on the bottom or the connection to the outlet pipe is badly moulded.  Even after filing it smooth, the retaining clip won't fully engage.  I'll have another look in the morning and see if I can fix it.

[sgould]

I tried fixing it, and I think I have found the problem, but after trying, and probably fixing it, it feels like a bodge, and SWMBO is unhappy about risking it, especially as we are taking the car to IntSaab 2025 in August.  So it's going bak and we will bite the bullet and buy a "genuine" Saab part from whivever Hedin has found to make them.

Apart from the general finish, the big problem is in the fixing of the main pipe connection at the bottom.  It's an O-ring seal and the pipe is held in place by a U shaped clip.  The clip fits into grooves either side of the spigot on the tank.  The PPS part has vestigal grooves and the clip wouldn't seat properly.  I filed the grooves deeper and it wi  probably stay in place, but it's still not 100%


Pictures of the old and new, showing the grooves (or lack of them) either side.

[sgould]

All done.  A short test shows no leaks.

I popped over to Harlow and picked up a "genuine" Saab part from Saab Parts UK / Saabtech Parts Europe.  I used them a fir bit when they were in Welwyn Garden City.  Harlow is a bit further, but not a lot. 

Once back home and checked over, it all went in very quickly.   She's taken the car to a gig tonight, we shall see if I've done it right...

[sgould]

The tank is fine, but while resetting the radio etc. after the battery earth issue, I caught a whiff of coolant.

It turns out that the coolant tank hose has failed.  It looks fine but it has failed in the traditional way.  Cracked inside and leaking through the fabric reinforcement layer.  I wiped the end of the hose, but coolant leaks out if you squeeze it.