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Replacing the Oil Pressure Sensor on a 1998 900SET
rem_mod
February 11, 2006
I hope that this will be helpful to others who may need to replace their oil pressure sensor.
A few weeks ago, I noticed that the oil pressure warning light (the red oil can) on my dash was not lit when I turned the ignition on and before starting my car. I suspected the oil pressure sensor since that is the most common failure mode. The oil pressure sensor is located under the intake manifold on the rear of the engine block, toward the firewall. The oil pressure sensor has one wire attached via a .25 male tab connection on the sensor, and a mating .25 female tab connection on the wire. The oil pressure sensor can just be reached from the top of the engine compartment by reaching under the intake manifold.
I had my wife sit in the car with the ignition switch turned to the on position (but the engine not running) as I reached around the intake manifold, removed the oil pressure sensor wire, and grounded the wire to the engine block. The dash oil pressure warning light lit up when I grounded the wire, which confirmed that the oil pressure sensor was faulty.
I ordered a replacement oil pressure sensor (which was less than $5) from eEuroparts.com along with a few other items I needed (cabin filter, etc.) to make the order worthwhile, and to get free shipping. The oil pressure sensor I received was 22mm or 7/8 across the flats and had an aluminum crush washer to seal the threads. The new oil pressure sensor needed a deep wall socket to be able to clear the .25 male tab connector. As I had a 7/8 deep wall socket, I thought no problem. I put the car up on Rhino Ramps and crawled under. I could just see the oil pressure sensor and could reach it by maneuvering my hand up past the catalytic converter. I cleaned the area around the oil pressure sensor with a rag to prevent getting any contaminants in the opening.
As I attempted to insert the 7/8 deep wall socket over the oil pressure sensor I realized two things. One was that the OEM oil pressure sensor was 24mm or 15/16 across the flats, and the second was that the oil dipstick tube was too close to the oil pressure sensor to allow me to use the deep wall socket.
I found a 1/2 drive 24mm regular socket and slipped it over the OEM oil pressure sensor. Unfortunately, the .25 male tab stuck up into the 1/2 drive hole so I could not attach the 6 extension and ratchet wrench. No real problem as the OEM oil pressure sensor was scrap anyway, so I just bent the .25 male tab over and then used my ratchet wrench to remove the OEM oil pressure sensor.
Now the problem was how to install the new oil pressure sensor. As I had already wasted a good half-hour getting the OEM oil pressure sensor out, I took the easiest way I could think of and used a hacksaw to cut about 3/4 of the end of my 7/8 deep wall socket. This allowed the socket to fit under the dipstick tube and still be deep enough to clear the top of the oil pressure sensor. I ran the new oil pressure sensor down until just snug and then made about 1/2-turn more to ensure a good seal with the crush washer (similar to installing spark plugs or the oil pan drain plug).
Now my oil pressure light works again and I have a custom 7/8 semi-deep wall socket for the next time I need it. With my luck, the next sensor I get will be 24mm. :o)
REM in Seattle
2005 Saab 9-3 Aero Convertible; 5-speed; 8000 miles
1998 Saab 900SET; 5-door; Automatic; 82,000 miles
1984 Saab 900T; 3-door; 5-speed; 242,000 miles (RIP)
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