The fuel pump assembly has both the fuel level sender and the main fuel pump. Unfortunately, if one component goes bad you have to replace the entire assembly.
The good news is that the assembly can be replaced rather quickly.
The first step is to depressurize the fuel lines and tank. To do this, pull the fuel pump fuse out of the fuse box and try to start the car.
It may start but it should quickly stall as the fuel pressure drops.
Now pull up the backseat bottom and locate the circular flap in the carpet. Under the carpet is a metal sealing ring. I have a plastic body panel tool that I use to pry on things without causing any damage. If you don't have these, then be careful with a flat tip screwdriver.
|Now you can disconnect the electrical plug and fuel lines.
The electrical plug is the typical SAAB style where you use a screwdriver to pull out the red, locking mechanism.
You do not have to remove the grey plug connected to the fuel pump assembly.
Next, loosen the screw for the bracket that holds down the fuel lines and move it out of the way. NOTE: This bracket is crucial and was part of a safety recall. Without this bracket, the fuel lines can pop out, spray fuel around and potentialy start a fire!
Take a mental picture on where the fuel lines are located as to not confuse them later on.
Now CAREFULLY pull up the fuel lines. The plastic can become brittle and doesn't handle brute force very well. The best way is to slowly twist and pull them up, while keeping the yellow tab out of the way.
If you do break one you will be in for a much bigger job. I cover this scenario over in the fuel pump section for the 9000 seriers.
There is a large ring that holds the fuel pump assembly to the fuel tank. The best way to remove this ring is by making a home-made tool.
You basically buy a small length of metal from a hardware store, bend it to form a U, and then insert a bolt at the top. This will fit over the fuel lines and give you some leverage to rotate the ring.
|Lay down a some rags around the carpet in case any fuel spills out of the pump.|
Take the pump out and lift it a bit, then turn it clockwise about 1/4 of the way and tilt it at an angle and wiggle it out.
When itʼs almost out turn it backwards and pour the gas inside the pump back into the tank. If you try to take it out too fast youʼll spill gas everywhere.
Once the old pump is out you can swap over the gray connector and replace the big, black seal around the outside of the tank (it should have come with the fuel pump kit).
Install the new pump in the tank. The pump is on a metal spring arm, so it wonʼt go all the way to the bottom.
You will have to push down on the top and then install the new screw ring(the one with the special tool).
This does not have to be super tight. Just tight enough to keep the pump in place.
Before installing the fuel lines, very lightly coat the rubber seals on the fuel lines with some petroleum jelly. This helps the fuel lines go into place much easier. Be sure the bracket for the fuel lines is installed. Some cars may be missing this piece as it was a safety recall piece. It is very important to have this in place as the lines could pop up on their own!
Now reconnect the main electrical plug and start the car. It will take some cranking before the car will start. The pump container needs to fill and then the lines need to pressurized. Once the car starts, carefully inspect the fuel lines for leaks.
Now reinstall the cover and put the back seat back down!