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DIY: Saab Vacuum Line Replacement

Saab 9-5 DIY: Vacuum Line ReplacementSaab 9-5 DIY: Vacuum Line Replacement

his is a detailed guide for replacing the vacuum lines in your Saab by Trionic Seven – YouTube channel for Saab enthusiast.

Instructions should also apply to the Saab 900, Saab 9000 and Saab 9-3, however there might be some minor differences. The old lines are made of rubber which will become brittle with age and eventually break. I choose to use high-quality silicone hoses for the new lines, like this from Ebay (~GBP 2.65 per meter). Silicone is age-resistant and will last the lifetime of the car. Also, I like the color of the blue hoses, however you can buy them in any color depending on your preferences.

I highly recommend replacing the vacuum lines in your Saab. Silicone hoses are cheap, too, and can be found in almost any car parts store (just avoid the very cheapest stuff). Time required is roughly 30 minutes to one hour.

You will need approx. 3 meters (10 ft) of hose with an inner diameter of 4mm. The outer diameter isn’t important, but the hose in this video has an outer diameter of 8mm.

Tools needed: Knife and side cutters. You can also add cable ties over the nipples to make extra sure that the hoses do not let go, however I didn’t do this here. In addition, you can replace the check valve line that goes to the PCV system. If you have still have problems with boost leaks you can check the EVAP line mentioned in the end of the video:

If you need more access to the lines close to the firewall you can move the main harness connector away, check my video on replacing the coolant bypass valve (coming soon) for instructions.

Since I found a loose hose I was quickly able to diagnose and fix my boost leak problems. Now the Saab 9-5 Aero boosts up to 1.1 bars again, a significant improvement.

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