Saab 2000-06

Fuel Pressure Regulator

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Removal & Installation



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.


NOTE
To minimize any remaining fuel pressure, remove the fuel pump fuse no. 32 while the engine is idling. Turn off the ignition once the engine has stopped. Re-install the fuse.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Charge air pipe by performing the following:
     




    1. Disconnect the connector from the pressure/temperature sensor
    2.  
    3. Remove the screw securing the bypass pipe to the turbo unit inlet pipe
    4.  
    5. Undo the hose clips on the throttle body and charge air hose
    6.  
    7. Remove the screw securing the charge air pipe to the cylinder head attachment
    8.  
    9. For M/T vehicles: Remove the venture hose from the charger pipe

      Vacuum hose from the fuel pressure regulator
       
      Screw and open the clamp
       
      Fuel pressure regulator
       

    10.  

  6.  

To install:

  1. Lubricate the fuel pressure regulator O-ring with petroleum jelly.
  2.  
  3. To complete installation, reverse remaining removal procedure.
  4.  
  5. Inspect for leaks and repair as necessary.
  6.  

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
Be particularly observant regarding cleanliness when working on the fuel system. Loss of function may occur due to very small particles. Prevent dirt and grime from entering the fuel system by cleaning the connections and plugging pipes and lines during disassembly. Use 82 92 948 Plugs, A/C system assembly. Keep components free from contaminants during storage.


NOTE
Reduce the fuel pressure by removing fuse 2 for the fuel pump while the engine is running (fuse 2 is located in the main fuse box in front of the battery). Once the engine has stopped, turn the ignition key to LOCK and re-install the fuse.



Click image to see an enlarged view

Fig. Locating fuse 2

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the upper engine cover.
  6.  
  7. Remove the cover over the ignition coils.
  8.  
  9. Remove the nuts on the cable duct.

    Click image to see an enlarged view

    Fig. Removing vacuum hose (5), regulator bolts (6) and regulator (7)

  10.  
  11. Remove the vacuum hose.
  12.  
  13. Carefully move the coolant pipe to one side. Undo the fuel pressure regulator bolts, remove the front bolt and loosen the rear bolt about 5 mm.
  14.  
  15. Remove the fuel pressure regulator. Collect any fuel spill with a rag.
  16.  

To install:

  1. Fit the new O-rings to the fuel rail. Lubricate sparingly with Vaseline, Klüber Syntheso Pro AA2 or equivalent.
  2.  
  3. To complete installation, reverse remaining removal procedure.
  4.  
  5. Connect an exhaust extractor, start the engine and check its operation. Check for leaks.
  6.  

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.


NOTE
Reduce the fuel pressure by removing fuse 19 for the fuel pump while the engine is running . Once the engine has stopped, turn the ignition key to LOCK and re-install the fuse.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Connectors from the oxygen sensor and crankshaft position sensor
     
    Vacuum hose
     
    Bolt and open the clamp
     
    Gently work the pressure regulator loose and remove it
     

  6.  
  7. To install, reverse removal procedure. Lubricate O-ring with non-acidic Vaseline before fitting.
  8.  
  9. Start the engine and check its operation. Check for leaks.
  10.  

 
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