Friday, June 27, 2008

crankshaft position sensor installation

How to remove and replace the crankshaft position sensor or "CPS" on the SAAB 9-5

Start with a completely cold engine. You will be right against the exhaust during this repair and it's going to be uncomfortable enough without adding some 2nd degree burns to your hands.

Unhook and remove the battery and battery tray from the car. Removal isn't essential, but it will make it easier to route the wire bundle at the end of the install. Unhook the battery to prevent electrical problems at the very least.

Remove the diverter valve (DV) from the intake and the aluminum recycle tube from the turbo. Remove the aluminum heat shield between the engine and turbo. There is one nut and two clips holding it.

The CPS is located on the lower left front of the engine, near the transmission and behind the catalytic converter. You might spray the one Torx screw with some liquid wrench.

Use a T30 Torx bit and whatever contraption you can find in the way of a wrench setup that fits the area to remove the one screw on the lower right of the CPS heat shield. I used a small ratcheting "L" shaped screwdriver to loosen the screw and then used my fingers an a 3/8in Torx socket once the screw was loose.

The heat shield will come off with the screw. The Crankshaft position sensor will come out with a slight twisting/rocking motion as you pull. Follow the cable to the right of the throttle body near the firewall. The connector was the first of three in a row (light blue in the photo below). It unhooks like all SAAB connectors, with a small screwdriver prying the red lock loose. There is a metal cuff that holds the cable to a pipe midway between the CPS and the connector. It can be pulled off with your fingers.

Clean the hole where the CPS goes and make sure the rubber washer on the old CPS is out. You don't want two washers in that hole.

Push the new crankshaft position sensor into the hole. It will go most of the way with little effort, but a hard push/twisting motion will be needed to completely seat it. Really cram it in there and line up the screw holes as best as you can. You will want to thread the screw without the shield first, just to make sure your holes are lined up first. Then remove the screw again, add the heat shield, and re-thread the screw back into place. This will take some effort and time. The screw will not want to start threading and the area is really tight.

Once the screw is finger tight, use your T30 size Torx wrench setup to tighten it the rest of the way.

Re-route the wire bundle back to its cradle next to the throttle body and install the metal cuff  onto the cable/pipe. Reconnect the cable to the car, install the battery, heat shield, and everything else removed for this project. Clean up the area, put your tools away, and start the car.

Wednesday, June 25, 2008

Craftsman Torque Wrench

I borrowed a torque wrench from my father. He had the original packaging, including the insert card.

From Amazon:
Craftsman Torque Wrench

Saturday, June 7, 2008

SAAB Related Roundup

I've been bad about having things to post here, but not getting around to posting them. A lot of these items don't really need their own post. I figure I'll post them all and save some time.

New Direct Ignition Cassette:

My cassette was not part of the recent recall, but I was getting the usual misfire codes that signal a DIC on the way out. So I bit the bullet and purchased a new cassette. No more CEL and the car now runs so much smoother that I'm embarrassed I let it go without repair for what little time I did.

Update on Harrah's Car Museum Shirt:

I received a brown envelope that was either originally purchased along with the t-shirt or it came with the t-shirt, I'm not sure which. I'm updating that post, but wanted to share anyways.

Tornado Warning:

I'm what I suspect is one of the few people in the world who have worked on a SAAB during a tornado warning. The sirens went off as I was installing the ignition cassette. I finished up, went inside, turned on the TV. I found my wife in the basement, but she was unaware of the tornado warning because she was playing video games very loudly at the time. Naturally I also went outside and took some photos of the "scary looking clouds" overhead. We got horizontal rain, light wind damage, and a little road flooding; but the radar indicated tornado never materialized. Not that I'm complaining.

And finally,

Reverse Diverter Valve

I purchased some silicone vacuum line along with the new ignition cassette so I could replace the line on the DV. This also gave me the extra length I needed to install the DV in reverse, as recommended in THE GREAT Diverter Valve FACE OFF. This has made a huge improvement in the sound of the DV releasing. I suggest anyone looking to get that "turbo sound" from their T7 SAAB to first get an open air intake, and second get a performance diverter valve installed in reverse. I'll be updating my DV and intake posts to add this information.