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Seen lots of past posts regarding the next-to-impossible replacement of the lower radiator hose. I was changing out a leaking heater bypass valve, and decided to be proactive and renew the upper, lower and heater supply hoses (2002 9-5 Aero wagon). It all went great - until I got to the lower radiator hose! I had to remove: the mass airflow sensor and outlet snorkle, the recirculation line and valve (turbo over-pressure I think), and the plastic splash shields on the bottom of the car. Unbolted and pulled aside: the waste gate pressure control valve and lines, the radiator overflow hose, the upper radiator hose, the turbo air outlet hose (at the intercooler inlet), the air cleaner inlet elbow (plastic),and the fan shroud and fans. Even with all this stuff pulled aside, space is still very tight.
Getting the hose off: involved a very long set of pliers to undo the factory upper clamp (at the engine), and a Dremel tool with cut-off disc to cut loose the factory lower clamp (at the radiator). There is NO way to remove the lower clamp without cutting it! Managed to pull the old hose out through the top.
Getting the new hose on: involves threading 30 pound test fishing monofilament (2 pieces) through the lower end of the new hose, about 4 or 5 mm from the end of the hose (outboard of where the hose clamp will go) at about 8 o’clock and 11 o’clock. Make sure the mono is long enough to run forward through the grill to clear the front of the car. Snake the new hose with screw-type hose clamps loosely attached into the space. Have your lovely assistant (your willing or at least bribeable wife / girlfriend) pull on the monofilament lines as you coerce the hose onto the radiator nipple. Assume your best yoga position and push the upper end of the hose onto the engine block nipple. Tighten the new screw-type clamps, and you’re done!
**DO NOT ATTEMPT THIS if you have large hands / arms – you’ll never get into the space required – bite the bullet and call the Dealer!
Happy SAABing!
posted by 216.227.1...
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