Saab 2000-06

Removal & Installation

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9-3



2000-2002 Models

WARNING
Removal of the fuel pressure regulator involves partial dismantling of the car's fuel system. Work only in a well-ventilated area! If approved equipment for the extraction of fuel vapor is available then make sure it is used. Wear suitable gloves! Prolonged contact with fuel can cause skin irritation. Keep a class BE fire extinguisher close by! Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits. Do not smoke in work area. Wear protective goggles.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Place the car on a lift. Make sure the rear right-hand lift-arm pad is placed as far out as possible to facilitate the work. Raise the car.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Detach the rubber hoses and breather line from the tank and plug the tank. Use special tool: 83 94 777
     
    plastic cover on the fuel filter, 2 screws, and undo the clamp securing the fuel filter
     
    Support the tank with a column lift and then the nuts on the tank straps. Unhook the straps
     

  10.  
  11. Carefully lower the tank, right-hand side first, until the top becomes visible.
    NOTE
    Disconnect the fuel lines from the snap fasteners on the tank and body without bending or breaking them.

  12.  
  13. Unplug the electrical connector to the fuel pump.
  14.  
  15. Detach the delivery and return lines from the fuel pump. Lower the tank to working height.
  16.  

To install:

  1. To install, reverse removal procedure.
  2.  
  3. Inspect the O-rings before installing them to the fuel lines. Replace as necessary.
  4.  
  5. Install new rubber hoses the fuel tank.
  6.  
  7. Inspect for leaks.
  8.  

2003-2006 Models

WARNING
Removal of the fuel pressure regulator involves partial dismantling of the car's fuel system. Work only in a well-ventilated area! If approved equipment for the extraction of fuel vapor is available then make sure it is used. Wear suitable gloves! Prolonged contact with fuel can cause skin irritation. Keep a class BE fire extinguisher close by! Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits. Do not smoke in work area. Wear protective goggles.


NOTE
Reduce the fuel pressure by removing fuse 2 when the engine is running (fuse 2 is in the electrical box in front of the battery). When the engine has stopped, turn the ignition key to LOCK and refit the fuse.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Place the car on a lift.
  8.  
  9. Disconnect or remove the following:

    Right rear wheel
     
    Bolts and nuts to the wing liner
     
    Wing liner from the stud bolts
     
    Wing liner from the liner edge starting at the back. Then release the entire liner edge. Remove the wing liner
     
    Rear spoiler shield
     
    Rubber mounts and carefully lower the exhaust system, secure with a strap

    Click image to see an enlarged view

    Fig. Separating fuel connections, vent connections and removing the connector at the evaporative emission canister

     
    Fuel connections and vent connections at the carbon canister. Catch any spilt fuel
     
    Seal the connections to the outlet line from the fuel pump
     
    Connector at the evaporative emission canister
     
    Hose between the filler pipe and tank, and separate the fast coupling on the vent
     

  10.  
  11. Place a single-support lift under the tank, remove the tank straps and fuel tank. Be careful when removing the tank; ensure that no components or connections are damaged.
  12.  

To install:

  1. Remove the filler pipe and change the connection hose between the tank and the filler pipe.
  2.  
  3. Use Vaseline to lubricate the filler pipe connection to the filler cap opening.
  4.  
  5. Fit the filler pipe and tighten the bolts. Check the rubber seal in the filler cap opening, and adjust if necessary.
  6.  
  7. Raise the tank and refit the tank straps. Tighten to: 18 ft. lbs. (25 Nm).
  8.  
  9. To complete installation, reverse remaining removal procedure.
  10.  
  11. Connect and exhaust extractor and start the engine for function test.
  12.  
  13. For 2.8L engines, connect the diagnostic tool and erase any diagnostic trouble codes.
  14.  

9-5




WARNING
Removal of the fuel pressure regulator involves partial dismantling of the car's fuel system. Work only in a well-ventilated area! If approved equipment for the extraction of fuel vapor is available then make sure it is used. Wear suitable gloves! Prolonged contact with fuel can cause skin irritation. Keep a class BE fire extinguisher close by! Be mindful of the danger of sparks caused by short circuits and when connecting and disconnecting leads in electrical circuits. Do not smoke in work area. Wear protective goggles.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Raise the rear seat cushion and fold back the carpet.
    NOTE
    The connector on the fuel pump must not be removed.



    Click image to see an enlarged view

    Fig. Removing fuel pump cover (2) and upper connector (3)

  8.  
  9. Disconnect or remove the following:

    fuel pump cover
     
    upper connector

    Click image to see an enlarged view

    Fig. Removing non-return valves

     

  10.  
  11. Carefully coax the non-return valves and fuel lines away from the pump (push the yellow hooks to one side with a screwdriver). The non-return valves are secured with snap-on couplings to the pump. The white one is for the pressure side and is marked with "Pressure" on the pump. The black one is for the return side and is marked with "Return" on the pump. Place them out of the way under the plate seam.
  12.  
  13. Raise the car.
  14.  
  15. Remove the rear exhaust pipe section.

    Click image to see an enlarged view

    Fig. Unplugging purge pipe with tool: 83 95 26 (8)

  16.  
  17. Unplug the purge pipe with tool: 83 95 26
  18.  
  19. Detach the hoses to the filler pipe by undoing the filler pipe plastic screw.
  20.  
  21. Detach both handbrake cables at the handbrake lever.
  22.  
  23. Place a pillar jack under the tank.
  24.  
  25. Undo the front screws on the straps securing the tank and lower it.
  26.  

To install:


NOTE
When fitting the filler pipe it is important to replace the rubber hoses between the filler pipe and the fuel tank. There is a risk of cracks forming on the hoses after repeated tightening of the hose clips and this can lead to fuel leakage. It is also important to replace the old plastic screw by a new screw of plastic. In the event of a collision, the plastic screw will break thus avoiding any damage to the filler pipe which is also made of plastic.

  1. To install, reverse removal procedure
  2.  
  3. Spray the connectors with Kontakt 61 or equivalent before connecting them.
  4.  
  5. Inspect O-rings when fitting the fuel lines and replace as necessary. Apply acid-free vaseline on the O-rings.
  6.  
  7. Check for leaks.
  8.  

 
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