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Gavin & Zeke,
The stretched wiring problem sounds very interesting. Last night I finally got down and tested around the thermal sensor, and I've concluded it is fried. (Shorting ground to LS fan started the fan right up, even with the scorched relay in place.)
I swore I wouldn't reveal stuff from Alldatadiy, but I kind of figured this out for myself, thought I'd pass it on:
If your relay has 4 terminals labelled 30, 86, 85 and 87, it is a wildly popular relay in Saabs. In the 9k's, it can be used for the LS fan in a pinch, it definitly runs the foglights, and in the 900s it does a bunch of things. I know this same relay was in my 99's, Sonett and 96, so one of these in the glove box might be really smart. (In 99's, a dead one with 30 permanently shorted to 87 was a GREAT emergency fuel-pump relay spare)
The relays pins:
85 & 86 are the coil. If they measure OPEN, the coil's bad. ON the socket, one of these is USUALLY hot, since in many cases Saab uses a "switched ground" system.
30 is the supply for the load
87 is the load.
Relays with an "87b" appear to have TWO load-circuits, and "87a" appears to have two coil-triggers, but take this last with a grain of salt.
Brutal experience on my 91 9kt leads to the sensor using black as ground, Blue as low-speed fan and White as high-speed fan. (BTW, the blue maybe Blu/Wht stripe, the white maybe Wht/blue stripe. Really hard to see down there...)
FINALLY,
The thermo switch from my 86 900s fit pretty well, and needed a simple wiring harness made from the old one. HOWEVER, this temporary fix only allows me to have a LOW SPEED fan, so I'll have made a new one before we get above 70 Deg. F. highs.
OOh, one more: I believe Gavin might (only MIGHT, I've yet to dissect it) be mistaken on the thermistor: My initial tearing apart of the thermosensor indicates it is a bimetal-strip setup.
Naturally, I will be building my own with a pair of redundant thermistors and a small box that'll allow me to set the trigger-temps and hystereisis (sp) myself...
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