Re: Water Pump - Saab 9-3SS Bulletin Board - Saabnet.com
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Ok, so with that extra information, it is building a case for headgasket.
Pressure left in cooling system when cold in the morning and rough cold start.
But a trained nose would probably pick up a faint smell of exhaust fumes in the coolant tank and also a blue dye test for exhaust in coolant would probably confirm that as well.
So with driving it as many miles as you do and rely on her, you should get to the bottom soon since over-pressurizing the cooling system over and over again will make it start to blow hoses and radiator and wherever it finds a weak link.
Can you even open the cap when engine is hot without coolant spewing out. Right after cooling fans have shut off, you should be able to carefully remove the cap without having coolant come out when tank is half full (normal).
When you talk about half empty and half full, I assume you know that the tank is suppose to be filled to the middle only when engine is cold?
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