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Old 04-26-2016, 03:37 PM  
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2002 Aero radiator replacement

2004 9-5 Aero automatic

Looks like I need a new radiator... bad endcap.

I noticed the SID alarm for low coolant last night, and today when I went to check it out the expansion tank was empty. I just replaced the coolant temperature sensor a couple weeks ago, and the coolant level was topped off. I squeezed the upper radiator hose a few times to listen for gushing coolant in the expansion tank... heard none, and looked under the car for a leak.

Yikes, there was a steady, but small flow of coolant coming out of the passenger side. After putting the car on jack-stands, removing the lower engine cover, and squeezing the upper radiator hose again, I can see a decent leak from where the aluminum radiator core is connected to the plastic endcap.

Here's a couple pics:





At this point I'm 99.9999% sure it's a bad radiator, and wondering where you guys have purchased replacements from?

Also, is there a concise tutorial or FAQ for replacement? (preferably with pictures and/or complete sentences describing the procedure)

Thanks.
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1986 900S wrecked
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1987 900 SPG parts car
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1997 9000 Aero sold
2004 9-5 Aero sold

Last edited by DanF.; 04-26-2016 at 04:03 PM. Reason: 2004, not 2002.
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Old 04-26-2016, 05:20 PM  
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I just did a Nissens for $153.79 that worked well: 2002 SAAB 9-5 2.3L L4 Turbocharged Radiator | RockAuto
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First T7 19T turbo setup. First T7 Deka 80lb. injector setup.
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Old 04-26-2016, 06:09 PM  
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Would this work? I'm not sure about the inlet/outlet ports for the auto. transmission oil cooler lines, and I'm feeling a little defeated to walk out to my car and look.


Amazon Amazon
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1986 900S wrecked
1987 900T wrecked
1988 900 SPG sold
1987 900T parts car
1987 900 SPG parts car
1991 900T sold
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2004 9-5 Aero sold
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Old 04-26-2016, 07:26 PM  
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I can't say on that Spectra, but the Nissans was an exact drop in replacement for our 2000 Aero auto. It took maybe an hour and a half or two hours to do without rushing. They did a good job leaving enough room and it comes out pretty easily after you pull the TB inlet pipe and cooling fan(s) shroud.

Those copper fittings you see in the pic are for the auto trans fluid connections.
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Old 04-27-2016, 07:13 AM  
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Thanks for the advice, I bought a Nissen radiator this morning.
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1986 900S wrecked
1987 900T wrecked
1988 900 SPG sold
1987 900T parts car
1987 900 SPG parts car
1991 900T sold
1997 9000 Aero sold
2004 9-5 Aero sold
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Old 04-28-2016, 06:08 AM  
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SPI Is decent. I used to sell these to the classic car guys, and especially G-Body guys.
Silla is a little less. I bought one a while back for $100. It's been great. The core is a bit smaller on the silla, but I've never had a scare with the water temp. Even with the FMIC messing up airflow in front of it.
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Old 04-29-2016, 08:39 AM  
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Installed the new Nissen radiator yesterday afternoon. I also replaced the thermostat while I was dicking around in there. As usual, it was a pain in the butt to get to most of the nuts/bolts/screws to get everything out. Putting it back together only took 1/8 the time. So, I was par for the course.

No leaks, or abnormal temps. Yay.


Here's a crappy album of the job: http://imgur.com/a/yEVDz
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1986 900S wrecked
1987 900T wrecked
1988 900 SPG sold
1987 900T parts car
1987 900 SPG parts car
1991 900T sold
1997 9000 Aero sold
2004 9-5 Aero sold

Last edited by DanF.; 04-29-2016 at 08:50 AM.
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