My windshield washer fluid bottle kept leaking. Its a silly problem to have however you dont realize how much you use a thing until it is broken. We I had previously removed the bottle and discovered that one of the mounting studs had, over time, deveoped a leak right where the stud meets the plastic tank.

This bothered me for 2 reasons.

1. Why did saab choose a plastic fluid reservoir that has metal mounting studs protruding from inside the plastic tank. Each mounting stud was also about 4 inches long! You can bet with this kind of design that the tank is destined to shift its weight, put some stress on the plastic to mounting stud joint, then develop a nice leak. Poor design Saab :(
2. Why make the tank so dang hard to get to. The tank is buried in between the wheel well and the engine compartment. It is only accessible for removal from the underside of the car after having removed 2 plastic access panels. Not only that, the mounting bolts can not be undone while the engine is in place. I had to cut one of the mounting studs to get the tank out. Poor design Saab :( Next time go with a smaller tank in a better location.

Anyways enough of my complaining. I had previously removed the tank, applied some plastic glue to the leaking location, and installed the tank back in the car. The patch lasted a couple weeks but eventually gave away and the leak came back.

I vowed to myself that the next time I removed that tank, I would fix it such that I would never have to remove it again. I think I have made good on that claim.

• First, I removed the tank then cut out both mounting studs. 
• Next I used a heat gun to mould 2 new plastic pieces to the shape of the tank to cover the holes.
• I then glued the plastic panels in place using plastic weld.
• Next I melted the edges of the plastic patch and the tank to fuse them together.
• Finally I applied liberable amounts of silicon sealant to the inside of the tank over the back of my new plastic patch pices

If this thing leaks after all that, I may be driven to sell the car.

While I was down there working on the tank, I noticed that 1 of the 3 nuts that holds the exhaust system on to the turbo was missing. It was not loose, it was flat out gone!

I went ahead and replaced the missing bolt, as well as the one of other ones that was slightly stripped and hard to tighten. This should help my exhaust to be slightly quieter.

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Smll Med Lrg	Smll Med Lrg	Smll Med Lrg stupid stupid washer fluid reservoir design, mounting studs cut out and patch applied	Smll Med Lrg you can get the idea that with this design, failure was imminent
Smll Med Lrg also replaced fluid pump grommet as a matter of course	Smll Med Lrg the old ones were slightly cracked	Smll Med Lrg used silicon on inside of the tank as well as plastic weld on the outside	Smll Med Lrg siliconed the grommets just in case
Smll Med Lrg	Smll Med Lrg liberabl amounts of silicon makes the white plastic slightly dark	Smll Med Lrg also replaced a missing exhaust hanger