Fuel Level Transmitter - Adapter Kit
84saab02SUBJECT:
REVISED INSTRUCTIONS, ADAPTING M83 FUEL LEVEL TRANSMITTER TO M81-82 CARS
ISSUE: 08/84-700
FILE IN S.I.MANUAL:
VOLUME: I
SECTION: 3
PAGE: 80
SUPERSEDES S.I. 11/83-653
An adapter kit (P/N 85-46-491) with revised installation instructions and electrical hardware is now available. The new kit replaces earlier versions and was designed to simplify the installation process and provide electrical connections similar to those found in the Recall 257 (S.I. 05/84-688, Volume II). We recommend that Recall 257 be performed in conjunction with this installation.
Parts Required:
Adapter Kit - 85-46-491
Recall 257 Wiring Kit - 85-47-002
The Fuel Level Adapter Kit was originally introduced to alleviate recurring problems with sticking fuel level transmitters in 1981-82 900 models when the use of gasohol or any alcohol enhanced fuels was unavoidable. The introduction of the adapter kit allowed for the installation of a M83 VDO fuel level transmitter which proved to be more resistant to alcohol-enhanced fuels than the original M81-82 SKANDIA transmitter.
Spare Parts List:
Adapter Kit (P/N 85-46-491) contains the following parts:
Adapter Relay 85-89-400
Rear cable harness 85-46-509
Cable, ignition switch 85-46-764
Gray, blue cable harness 85-46-772
Bolt 79-22-354
Connector 85-21-668
INSTALLATION INSTRUCTIONS
1. Perform Recall 257 using wiring kit P/N 85-47-002 (Recall S.I. 05/84-688).
2. Disconnect negative lead from battery.
3. Raise the seat cushion of the rear seat and fit the adapter relay to the seat beam.
4. Near the seat beam cut the grey wire running from the fuel level transmitter to the fuel gauge in half.
Connect the grey cable to position "G" of the adapter relay and its red crimp connector to the gray cable running from the fuel level transmitter.
Connect the blue cable to position "A" of the relay and its red crimp connector to the grey cable running to the fuel gauge.
Use Saab special crimping tool (P/N 78-60-695) when making crimp connections.
5. Connect the red wire to the green/white wire of the ignition switch via the piggyback terminal and connect the other end to position 15 of the relay. The shift console must be removed for this operation.
6. Connect the black wire to position 31 of the relay and run the wire into the luggage compartment to the fuel level transmitter.
7. Cut off the existing connector at the fuel level transmitter. Connect the new harness to the appropriate wire (see drawing).
Crimp together the red/grey and grey cable using the yellow AMP crimp connector and special terminal crimping tool.
Connect the black wire of the new harness into the black ground cable of the fuel level transmitter harness using the yellow AMP connector. When the Recall 257 has been performed the blue 3M connector is not used.
8. Fit a new fuel level transmitter (P/N 93-61-965) and gasket (P/N 75-10-134). Remove the protective shipping wire from the sending unit before installation.
Warranty Information:
If an owner has already had 2 or more original-type fuel level transmitters replaced under warranty (new car, parts, etc.) and the problem with alcohol in the gasoline will continue, you may fit a later type as described in this S.I.
Use Failure Code 23420-02-0-04-06. Maximum allowable time is 1.0 hour which can be entered as straight time. Complete the claim according to parts warranty instructions for the mileage and warranty date. Enter a history of parts replacement in the claims explanation area. Only part numbers 85-46-491, 93-61-965 and 75-10-134 may be claimed.
WIRING DIAGRAM