Saab 2000-06

Fuel Pump

Print

Removal & Installation



9-3

CAUTION
The fuel injection system remains under pressure, even after the engine has been tuned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Negative battery cableFuel into a suitable containerRubber hoses from the tank. Plug the openingsFuel filter clampMetal straps holding fuel tank. Support the tank from below with a pole jack or other suitable device.

    Negative battery cable
     
    Fuel into a suitable container
     
    Rubber hoses from the tank. Plug the openings
     
    Fuel filter clamp
     
    Metal straps holding fuel tank. Support the tank from below with a pole jack or other suitable device.
     

  4.  
  5. Carefully lower the tank, right side first, until the top is visible.
  6.  
  7. Remove or disconnect the following: Two wiring connectors to pumpFuel pressure and return linesThe fuel tankRetaining ring

    Two wiring connectors to pump
     
    Fuel pressure and return lines
     
    The fuel tank
     
    Retaining ring
     

  8.  
  9. Lift the pump about 2 inches, then rotate clockwise about 80° and remove
  10.  


    Click image to see an enlarged view

    Fig. Removing the fuel pump


To install:

  1. Install or connect the following: Fuel pump and new O-ringRetaining ring and torque the ring to 55 ft. lbs. (75 Nm)

    Fuel pump and new O-ring
     
    Retaining ring and torque the ring to 55 ft. lbs. (75 Nm)
     

  2.  
  3. Raise fuel tank and support with appropriate stands. Fuel linesElectrical connectorsMetal strapsRubber hoses to tankFuel filter clamp

    Fuel lines
     
    Electrical connectors
     
    Metal straps
     
    Rubber hoses to tank
     
    Fuel filter clamp
     

  4.  
  5. Lower the car and refill the tank.
  6.  
  7. Reconnect the negative battery cable and check that the system is operating properly and that there are no fuel leaks.
  8.  


CAUTION
The fuel injection system remains under pressure, even after the engine has been tuned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Fuel into a suitable container
     
    Rubber hoses from the tank. Plug the openings
     
    Fuel filter clamp
     
    Metal straps holding fuel tank. Support the tank from below with a pole jack or other suitable device.
     

  4.  
  5. Carefully lower the tank, right side first, until the top is visible.
  6.  
  7. Remove or disconnect the following:

    Two wiring connectors to pump
     
    Fuel pressure and return lines
     
    The fuel tank
     
    Retaining ring
     

  8.  
  9. Lift the pump about 2 inches, then rotate clockwise about 80° and remove

    Click image to see an enlarged view

    Fig. Removing the fuel pump

  10.  

To install:

  1. Install or connect the following:

    Fuel pump and new O-ring
     
    Retaining ring and torque the ring to 55 ft. lbs. (75 Nm)
     

  2.  
  3. Raise fuel tank and support with appropriate stands.

    Fuel lines
     
    Electrical connectors
     
    Metal straps
     
    Rubber hoses to tank
     
    Fuel filter clamp
     

  4.  
  5. Lower the car and refill the tank.
  6.  
  7. Reconnect the negative battery cable and check that the system is operating properly and that there are no fuel leaks.
  8.  

9-5

CAUTION
The fuel injection system remains under pressure, even after the engine has been tuned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Raise the rear seat cushions and fold the carpeting out of the way.
  6.  
  7. Remove or disconnect the following: Negative battery cableFuel pump coverUpper connector from the fuel pump

    Negative battery cable
     
    Fuel pump cover
     
    Upper connector from the fuel pump
     

  8.  
  9. Carefully loosen the check valves and fuel lines from the pump. Move the yellow hooks to one side. The check valves are connected to the pump with quick release couplings.
  10.  
  11. The white check valve is the delivery side of the valve and marked -Pressure-. The black check valve is the return side of the valve and is marked -Return- on the fuel pump. Screw ring with tool 83-94-462 and lift the fuel pump until the upper section is slightly above the fuel tank

    Screw ring with tool 83-94-462 and lift the fuel pump until the upper section is slightly above the fuel tank
     

  12.  
  13. Rotate the fuel pump approximately 80 degrees and remove the pump from the fuel tank.
  14.  


    Click image to see an enlarged view

    Fig. Remove the Pressure and Return valves from the top of the fuel pump


To install:

  1. Clean the sealing surfaces on the fuel pump and fuel tank.
  2.  
  3. Install or connect the following: New O-ring in the groove on the fuel tank and carefully lower the fuel pump into position. Make certain that the marks on the fuel pump and tank are opposite one another and press the pump into position.Screw ring and torque the ring to 55 ft. lbs. (75 Nm)Check valves to the fuel pump with new O-rings. Make certain that the valves are properly positionedFuel lines and upper connectorNegative battery cable

    New O-ring in the groove on the fuel tank and carefully lower the fuel pump into position. Make certain that the marks on the fuel pump and tank are opposite one another and press the pump into position.
     
    Screw ring and torque the ring to 55 ft. lbs. (75 Nm)
     
    Check valves to the fuel pump with new O-rings. Make certain that the valves are properly positioned
     
    Fuel lines and upper connector
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and proper operation of the fuel pump and repair if necessary.
  6.  
  7. Install the fuel pump cover.
  8.  
  9. Reposition the carpeting and the rear seat cushions.
  10.  


CAUTION
The fuel injection system remains under pressure, even after the engine has been tuned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Raise the rear seat cushions and fold the carpeting out of the way.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fuel pump cover
     
    Upper connector from the fuel pump
     

  8.  
  9. Carefully loosen the check valves and fuel lines from the pump. Move the yellow hooks to one side. The check valves are connected to the pump with quick release couplings.
  10.  
  11. The white check valve is the delivery side of the valve and marked -Pressure-. The black check valve is the return side of the valve and is marked -Return- on the fuel pump.

    Screw ring with tool 83-94-462 and lift the fuel pump until the upper section is slightly above the fuel tank
     

  12.  
  13. Rotate the fuel pump approximately 80 degrees and remove the pump from the fuel tank.

    Click image to see an enlarged view

    Fig. Remove the Pressure and Return valves from the top of the fuel pump

  14.  

To install:

  1. Clean the sealing surfaces on the fuel pump and fuel tank.
  2.  
  3. Install or connect the following:

    New O-ring in the groove on the fuel tank and carefully lower the fuel pump into position. Make certain that the marks on the fuel pump and tank are opposite one another and press the pump into position.
     
    Screw ring and torque the ring to 55 ft. lbs. (75 Nm)
     
    Check valves to the fuel pump with new O-rings. Make certain that the valves are properly positioned
     
    Fuel lines and upper connector
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and proper operation of the fuel pump and repair if necessary.
  6.  
  7. Install the fuel pump cover.
  8.  
  9. Reposition the carpeting and the rear seat cushions.
  10.  

9-5 Models
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Raise the rear seat cushions and fold the carpeting out of the way.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fuel pump cover
     
    Upper connector from the fuel pump
     

  8.  
  9. Carefully loosen the check valves and fuel lines from the pump. Move the yellow hooks to one side. The check valves are connected to the pump with quick release couplings.
  10.  
  11. The white check valve is the delivery side of the valve and marked -Pressure-. The black check valve is the return side of the valve and is marked -Return- on the fuel pump.

    Screw ring with Tool 83-94-462 and lift the fuel pump until the upper section is slightly above the fuel tank
     

  12.  
  13. Rotate the fuel pump approximately 80 degrees and remove the pump from the fuel tank.

    Click image to see an enlarged view

    Fig. Remove the Pressure and Return valves from the top of the fuel pump

  14.  

To install:

  1. Clean the sealing surfaces on the fuel pump and fuel tank.
  2.  
  3. Install or connect the following:

    New O-ring in the groove on the fuel tank and carefully lower the fuel pump into position. Make certain that the marks on the fuel pump and tank are opposite one another and press the pump into position.
     
    Screw ring and torque the ring to 55 ft. lbs. (75 Nm)
     
    Check valves to the fuel pump with new O-rings. Make certain that the valves are properly positioned
     
    Fuel lines and upper connector
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and proper operation of the fuel pump and repair if necessary.
  6.  
  7. Install the fuel pump cover.
  8.  
  9. Reposition the carpeting and the rear seat cushions.
  10.  

900 And 9-3 Models

CAUTION
The fuel injection system remains under pressure, even after the engine has been tuned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Fuel into a suitable container
     
    Rubber hoses from the tank. Plug the openings.
     
    Fuel filter clamp
     
    Metal straps holding fuel tank. Support the tank from below with a pole jack or other suitable device.
     

  4.  
  5. Carefully lower the tank, right side first, until the top is visible.

    Two wiring connectors to pump
     
    Fuel pressure and return lines
     
    The fuel tank
     
    Retaining ring
     

  6.  
  7. Lift the pump about 2 inches, then rotate clockwise about 80° and remove

    Click image to see an enlarged view

    Fig. Removing the fuel pump

  8.  

To install:

  1. Install or connect the following:

    Fuel pump and new O-ring
     
    Retaining ring and torque the ring to 55 ft. lbs. (75 Nm)
     

  2.  
  3. Raise fuel tank and support with appropriate stands.

    Fuel lines
     
    Electrical connectors
     
    Metal straps
     
    Rubber hoses to tank
     
    Fuel filter clamp
     

  4.  
  5. Lower the car and refill the tank.
  6.  
  7. Reconnect the negative battery cable and check that the system is operating properly and that there are no fuel leaks.
  8.  

9000 Models
Bosch Fuel Pump

CAUTION
The fuel injection system remains under pressure, even after the engine has been tuned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable. Tape or tie off the cable so that it cannot be reconnected during this procedure.
     
    Carpet in the trunk
     
    Floor panel
     
    Oblong cover plate over fuel pump
     
    Electrical harness connector and move the cover aside
     
    Fuel lines at the fuel pump. Place the fuel lines off to the side. Soak up any fuel released with a shop towel.
     
    Large threaded ring securing the pump to the tank
     
    Fuel pump. Tilt it out of the tank and to the right, being careful not to damage the arm for the fuel level sender.

    Click image to see an enlarged view

    Fig. Removing threaded ring-9000

     

  6.  

To install:

  1. Install or connect the following:

    New O-ring in the groove on top of tank
     
    Fuel pump and align the mark on the pump with the mark on the tank. This must be done for the fuel sender to operate properly.
     
    Large threaded ring holding the pump to the tank and torque to 40 ft. lb. (55 Nm). Check that the alignment of the marks are still in line. A tolerance of 5° is permissible.
     
    New O-rings and fuel lines to the pump
     
    Electrical connector and the clip
     
    Negative battery cable
     
    Access plate in the trunk floor. Pay careful attention that the plate seals properly so that no exhaust fumes can enter the cabin.
     
    Floor panel
     
    Carpet in trunk
     

  2.  

Walbro Fuel Pump
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable. Tape or tie off the cable so it cannot contact the battery terminals.
     
    Trunk carpet
     
    Floor panel in the trunk
     
    Cover plate to gain access to the fuel pump
     
    Electrical wiring at the fuel pump
     
    Protective plate over the fuel line fittings
     
    Fuel lines at the fuel pump. Use angled needle-nose pliers or similar tool. Use a shop towel to absorb any fuel released.
     

  6.  
  7. Move the fuel lines and wiring harness to the side.
  8.  
  9. Place Tool 83-94-397 over the fuel pump. Place the chain supplied with the tool through the 2 load securing brackets on the trunk floor and secure each end with a screwdriver or similar tool.

    Large threaded ring that holds the pump in the tank. Remove the and tools and finish removing the ring by hand.
     
    Rubber seal
     
    Fuel pump. Tilt the top part of it forward and to the left. Allow the fuel to run out of the pump before removing it from the trunk.
     

  10.  

To install:

Click image to see an enlarged view

Fig. Positioning of tool and chains for tightening the retaining ring-Walbro pump

  1. Wipe clean the sealing area of the opening in the fuel tank.
  2.  
  3. Install or connect the following:

    Fuel pump. Be careful not to damage to the fuel level float arm. Once in the tank, line up the marks on the tank and pump.
     
    Large threaded ring. Coat it with petroleum jelly and place on top of the fuel pump with the mark on the ring lined up with the mark on the fuel tank.
     

  4.  
  5. Press down hard and rotate the ring 90°.
  6.  
  7. Reinstall special Tool 83-94-397, with the chain situated for tightening.
  8.  
  9. Tighten the ring until it will no longer turn.
  10.  
  11. Check that the pump did not rotate more than 30° from the alignment marks.
  12.  
  13. Install or connect the following:

    Fuel lines using new O-rings. The return line is connected to the nipple closest to the front of the vehicle while the feed line is connected closest to the rear of the vehicle.
     
    Electrical connections
     
    Protective plate over the fuel line fittings
     
    Negative battery cable
     
    Access plate in the trunk floor. Pay careful attention that the plate seals properly so that no exhaust fumes can enter the cabin.
     
    Floor panel
     
    Trunk carpet
     

  14.  

 
label.common.footer.alt.autozoneLogo