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Hey Allen I am a realllllyyyyyy slow worker and am still working on replacing my switch because I have had many interruptions.
The oil from the oil pressure switch is not black and gunky as is the oil from the PCV leak, it is usually fresh clean oil looks like PS oil or just new oil because it is freshly filtered oil before circulating into the engine.
Here is how I finally got the starter off 1. remove the battery and the support tray. 2. Then the 10 mm bolt which hold the starter wire under the the metal harness suppory by the lifting lug (an 18 inch extendion is helpful here). 3. Then a short 18 mm socket on a hinge handle will allow he bolt to be cracked loose remove the hinge handle. 4. Go under the car remove the solenoid wire and power wire (10 mm and 13mm Respectively). 5. Remove the nut(14mm) on the bottom of the starter boss & cut the zip tie. 6. now upstairs slip a universal into the 18mm socket and attach a 24 inch extension on and ratchet the bolt out. My hands are large so it is too tight for me to reach the bolt with my fingers but if your hand is small and piano fingers you can remove it by hand. It is a a long bolt so a lot of screwing around here. The starter will fall off and it can be removed by passing it above by the right wheel well or from below by the converter. The sensor has one of those push to seat type connectors and is difficuly to separate. My sensor lead wire, on the car side, had the problem I have found on several other cars "Black wire disease" so this pretty much shot me down. As soon as I tried to separate it, the wire failed at the car side connector and all the insulation and protective jacket came off. I am now in the process of replacing the entire wire back up through the harness. Now that is a problem! any way the sensor is 15/16 or 24 mm. since no sensor socket could be found I made one. An offset box end may work if the handle is cut off. Take a deep 6 point 15/16 socket and machine or grind a small slot (1/8-3/16) from the throat up 2 inches at one of the flats this will allow the pigtail lead and connector to hang out while tightening. the new sensor will have a crush washer so finger tight+ about a 45 degree turn is sufficient. I use a little gray silicone sealer just to make sure. Use a cheap socket as they are usually lower quality heat steel and easier to machine the slot. Make the connection and reverse the installation. Put the lower starter nut on finger tight then install the upper bolt and torque it tight - as close to 40 ft pounds as you can. working through a universal does not allow reading to be accurate so you may just have to torque it as tight as possible with a 12 inch hinge handle. Go under and finish up the install. don't forget to torque the bottom starter bolt. Good luck and happy SAABing
posted by 70.246.99...
, Sun, 16 Mar 2008 08:29:37
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