Step 1. The Alternator and Intake manifold are first removed from the engine.

Step 2. The waterpump cover is removed.

Step 3. The original waterpump is removed.

The original waterpump is removed by means of a special Saab puller. It resembles a standard gear puller. It threads onto the top of the pump shaft and seats on the water pump cover bolt holes. It may be possible to fabricate a puller.

Step 4. The waterpump cavity is cleaned.

The cavity is thoroughly cleaned. A long magnet can be used to retrieve any broken pieces of gear if the pump gears sheared.

Step 5. Install the metal freeze plug.

A small amount of Loctite 518 sealant is used when installing the plug. The plug is tapped into place using a hammer and a small block of wood. The plug will eventually seat on the lower ridge of the cavity.

Step 6. Install the expandable rubber plug.

The rubber freeze plug works by turning the nut at the top which compresses the rubber part forcing it outward. It is sometimes easier to start the nut on a work bench, then squeeze it into the cavity and expand it until it is snug. Once installed, the bottom of the plug should be visible thorough the weep-hole (see photo).

The upper cavity sealed with the expandable rubber freeze plug.