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Home >> Saab >> 1986 >> 9000 L4-1985cc 2.0L DOHC >> Repair and Diagnosis >> Lighting and Horns >> Backup Lamp >> Backup Lamp Switch >> Technical Service Bulletins >> All Technical Service Bulletins >> Recall - Overheating of Backup Light Switch >> Revised Procedures >> Recall Modification Procedure 1

Recall Modification Procedure 1

All 1986-89 Vehicles and Certain 1990 Vehicles (VIN L1000001-L1011813) and L2000001-L2008735) with a campaign plate that has NOT been marked in either location "C3" or "C4".

IMPORTANT NOTE
Disregard the instruction sheet supplied in the Recall Modification Kit. Follow the instructions supplied in this PSI:

^ Some steps apply only to certain model years

^ Read each step carefully

1. Remove the trim piece over the handbrake lever.





2. Mark a guide line on the right hand side of the air duct just behind the center bulkhead of the console and rearward along the right edge of the console. See Figure 1. This line will provide the proper installation position for the relay so it will not interfere with refitting the center console.

3. Remove the center console between the front seats following the instructions in Service Manual Section 8:2 Interior Equipment, Pages 853-9 to 853-12. HOWEVER, to avoid scratching the upholstery on the seat backs, move both front seats to maximum rearward travel and recline the seat backs before lifting the console.





4. 1990 MODELS ONLY: Remove the screw that holds the air duct in place. Move the air duct 8 mm to the rear. Drill a new hole (4 mm) in the support bracket beneath the air duct. See Figure 2. Do not reinstall the screw until Step 7 below. Moving the air duct prevents the duct from exerting pressure against the wiring harness and connector at the neutral safety switch.





5. Remove the electrical connector the neutral safety (left-hand) switch. See Figure 3.

6. 1986-89 MODELS ONLY: Remove the screw that holds the air duct and lift up the duct a little. See Figure 3. Remove the tape holding the wiring harness to the floor and inspect the harness for damage. Repair any damage before proceeding. Change the routing of the harness to the right side of the air duct. See Figure 4. The harness should be located in a depression in the bottom of the air duct on the right side to prevent any further damage.

7. Remove the neutral safety switch (see Figure 4) and replace it with a new one, P/N 4062980. Reinstall the screw that holds the air duct.





8. The terminals in the five-pin connector (removed from the neutral safety switch) must be removed and inserted into the new eight-pin connector supplied with the kit. To remove the terminals from the connector housing, use connector terminal removal tool, P/N 8580094) (Figure 5-A), or, if this tool is not available, you can make a removal tool by modifying a small pocket screwdriver (Figure 5-B).

9. Remove the terminal from pin one of the five-pin connector that was disconnected from the neutral safety switch. Insert this wire into pin one of the square eight-pin connector (P/N 91 24 090) provided in the kit. Remove the other terminals one at a time from the five-pin connector and insert them into the eight-pin connector (Figure 6), retaining the same wiring sequence (i.e., pin 1 on the five-pin connector to pin 1 on the eight-pin connector, pin 2 to pin 2, 3 to 3, etc.).

NOTE
Inspect each terminal before inserting it into the eight-pin connector. The locking tabs will usually be compressed after using the removal tool and will require a slight bend upwards. If a wire terminal is damaged during removal, it must be replaced with a new terminal. Two extra terminals are provided with each recall kit (Terminal PIN 91 20 775 for the small diameter wire and P/N 91 20 783 for the large diameter wire).





10. Position the relay (P/N 95 63 099) on the air duct so that the mounting tab will be located behind and to the left of the guide lines marked in Step 2 (Figure 7). Fasten the relay to the duct using the screw (T25 Torx) provided in the kit. The screw can be started directly into the duct without first drilling a hole. Be careful not to overtighten.

11. Connect the wiring harness supplied in the kit to the new eight-pin connector, to the relay and to the new neutral safety switch (Figure 8). The wide shoulder on the switch connector should be at the top.

12. Connect the black ground wire from the harness to the upper locating screw on the neutral safety switch (Figure 8).

13. Secure the wiring harness leading to the new relay as follows:

a. On 1986-89 models, use the small tie strap to fasten the relay harness to the existing harness (Figure 9).

b. On 1990 models, use the small tie strap to attach the harness to the hole in the rear of the air duct.

14. Position the eight-pin connector in front of the air duct and in between the shift lever bracket as shown in Figure 8.

CAUTION
The unsheathed wires leading to the eight-pin connector should be routed underneath the connector so that they do not chafe on the shift lever bracket.

Secure the new wiring harness and the connector by fastening the long tie strap (supplied in the kit) around the left branch of the air duct. See Figure 9.

15. After being fastened, the eight-pin connector should not interfere with the sliding cover piece on the selector trim panel. This can be checked by sliding the cover over the selector lever and locating the front edge against the center console. See Figure 9. Move the lever back to the "D1" position and check for clearance. If necessary, the sliding trim piece can be trimmed a maximum of 8 mm.

16. Reassemble the center console. Before reinstalling the handbrake lever trim plate, inspect to make sure that the console does not press down on the relay or the eight-pin connector.
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