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20:37, 15 November 2009 ==Overview==
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.
===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.
===Part Numbers===
* Long (stock) Belt
** Saab # 4904728 - eEuroparts.com
** Dayco # 5061038 (103.25 inches) - AdvanceAuto
* Short Belt
** Dayco # 5060970 (~97 inches) - AdvanceAuto
** Goodyear # 4060967 (96.75) - AdvanceAuto
* Upper Idler
** Saab # 4356127, plasic pulley - eEuroparts.com
*** Saab # 7978216, hex bolt - Saab Dealer
** Aluminum pulley - www.wazeepulleys.com
* Lower Idler Kit
** Saab # 4960290 (torx bolt & washer, 94-mid/97) - eEuroparts.com
** Saab # 4752960 (hex bolt, 2 washers, mid/97-98) - eEuroparts.com
* Tensioner Kit
** Saab # 5172184 (w. washer and bolt) - eEuroparts.com