I have a '99 9-5 on which I replaced the block-side O-ring with a Viton one in too-large a size (221 I think) back in 2011. I sanded down the OD until it just barely could be tapped in w. rubber mallet. I was doing it in an unheated garage in December, and I did not have time to shop O-ring sizes in Viton. That car now has 45K miles and approaching six years on its Graf pump without failure - but it's a sample of one.
As prevention, I replaced the WP's and all seals on each of my two daughters's 2006 9-5's about two years ago; both jobs within 2 or 3 months of each other. I tried to use a fluoroelastomer O-ring, but it cut while installing, so I used standard O-rings covered in Permatex Blue Ultra. The first of those is now leaking at 25 months and about 22K miles (plus two winters). From your posts and my experience, I expect I'll need to do this job on my other daughter's car soon.
I purchased Viton O-rings from McMaster Carr in 218,219,220, and 221 sizes (all SAE/inch sizing). I got the 220 and 221 sizes from Swedecar's post on O-rings for 9-5 and 9-3 water pumps. I will try all four on the pipe-to-block after everything is cleaned and polished, and I'll use the size that fits most snugly without sanding or hammering. I plan to use a Gleitmo equivalent anti-corrosion lube for installation. I'll pressure test before I re-assemble the ancillaries - and I will report on what size worked best for me. These O-rings have a spec shelf life of 10 years and are not very expensive: 68 to 72 cents each in 10-packs. If this works, I will be happy ! But it is a multi-year experiment.
Hope that your job went well last weekend.
Mark in Marine
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