| The serpentine belt, idler and tensioner pulleys should be inspected
every service interval and in theory, replaced every 60k miles, but a pulley
bearing often fails earlier. Cost of replacing two pulleys and the
belt can be $200-300 for parts and labor plus towing. Alternatives include
replacement as preventive maintenance (about $100 for a new belt and two
pulleys), the short belt conversion ($60-70 for one pulley and the belt),
and aluminum pulleys with replacable bearings. Repacking the
pulley bearings is also possible. Click any image below for a larger pic. |
 |
Short
Belt
After the short belt conversion, using the Saab oem upper idler pulley,
lower idler pulley bypassed, using Michel Briand's web site with instructions
and pics: Short
Belt Mod
This is not a complete fix, because the remaining upper idler is still
the one most likely to fail. |
 |
Aluminum
Pulley
Short belt with aluminum pulley, oversized by about 10 mm. First
version required machining to make it fit. An exact fit is now available,
with a standard size 2603 replaceable bearing from Wazee
Pulleys |
 |
Aluminum
Idler - Closeup
74-mm diameter x 25 mm wide
2603 bearing, 40-mm OD, 17-mm ID
Bearing insert, 17-mm OD, 10-mm ID
Steel washer, about 15-mm OD
Bolt, M8x125, Saab stock |
 |
Short Belt
Length
The normally recommended 97-inch "short" belt is a little long on my
car, the line indicating correct tensioner arm position is just outside
the limit marks. A slightly shorter belt like the Goodyear Gatorback
96.75" (2455mm) is a better fit. |
 |
OEM Upper
Idler
Grooved upper idler pulley, plastic, Saab
64-mm diameter x 24-mm wide
Bearing, 44-mm OD, 8-mm bore
Bolt, M8x125, 13-mm head, 35-mm length, w. 5-mm lead and floating washer |
 |
Lower
Idler
Smooth lower idler pulley, plastic, Dayco
80-mm diameter x 24-mm wide
2603 bearing, 40-mm OD, 17-mm bore
Bolt, M8x125, 13-mm head, 25-mm length w. two retaining washers used
to center bolt (sold as a kit) |
 |
Tensioner
Pulley
Smooth tensioner pulley, metal, Saab
90-mm diameter x 24-mm wide
2603 bearing, 40-mm OD, 17-mm bore
Bolt, 22-mm head, 8-mm shaft, T40, 22-mm long w. one retaining washer,
sold as a kit. New replacement kit shown on the left. |
| Long (stock) Belt |
Saab # 4904728
Dayco # 5061038 (103.25 inches) |
eEuroparts.com
AdvanceAuto |
$ 27
$ 35
|
| Short Belt |
Dayco # 5060970 (~97 inches)
Goodyear # 4060967 (96.75) |
AdvanceAuto |
$ 28
$ 36 |
| Upper Idler |
Saab # 4356127, plasic pulley
Saab # 7978216, hex bolt |
eEuroparts.com
Saab dealer |
$ 35
$ 3
|
|
Aluminum pulley |
wazeepulleys.com |
$ 38
|
| Lower Idler Kit |
Saab # 4960290 (torx bolt & washer, 94-mid/97)
or # 4752960 (hex bolt, 2 washers, mid/97-98) |
eEuroparts.com |
$ 35
|
| Tensioner Kit |
Saab # 5172184 (w. washer and bolt) |
eEuroparts.com |
$ 44
|
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