DIY Fuel Pump Replacement on a SAAB 9-3

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When the fuel pump begins to go bad on the Saab 9-3, the car may be hard to start. It may also start to act as if it is going to stall when it is running. If you begin to notice things like this when you are driving, you may need to replace the fuel pump. If the fuel pump stops altogether, your Saab will sit where it is until you make the repair. The fuel pump on the Saab 9-3 is in the fuel tank, but the average person can still replace the fuel pump in about two hours.

Things You'll Need

  • Wrench set
  • Drain pan
  • Fuel line plugs
  • Wheel chocks
  • Automobile jack
  • 2 jack stands
  • Regular screwdriver
  • Socket set
  • Open the engine compartment on the Saab. Prop the hood open using the prop rod. Loosen the nut on the negative battery terminal with a wrench and remove the cable from the battery. Raise the rear of the Saab using the automobile jack. Place a jack stand under the car near the jacking point and raise it to the frame of the vehicle.

  • Disconnect the fuel hose from the fuel tank and drain the fuel into a drain pan. Plug the fuel hose with a fuel line plug. Disconnect the clamp from the fuel filter using a screwdriver. Remove the fuel filter from the system. Place a jack stand under the fuel tank to support it. Remove the bolts from the fuel tank straps using a socket and ratchet.

  • Lower the right side of the fuel tank from the car first until you are able to see the top of it. Disconnect the wiring harness from the sending unit. Disconnect the fuel return lines using a wrench. Lower the fuel tank from the Saab and remove it from under the vehicle.

  • Remove the pump retaining ring from the fuel tank. Raise the fuel pump a couple of inches and turn it about 80 degrees to remove it from the tank. Remove and discard the O-ring since it will swell and not fit properly when it is exposed. Install a new O-ring. Insert the new fuel pump into the tank and twist it so it will go down into place.

  • Install the fuel pump retaining ring and twist it to lock it into place. Move the fuel tank under the automobile and raise the left side. Support it with a jack stand. Connect the wiring harness to the sending unit. Connect the fuel return lines and tighten with a wrench. Raise the tank the rest of the way into place.

  • Install the fuel tank straps. Tighten the bolts with a socket and ratchet. Connect the fuel hose and tighten the clamp with a screwdriver. Install the fuel filter and tighten the clamp with a screwdriver. Remove both jack stands from under the Saab. Lower the car to the ground. Connect the negative cable to the battery and tighten the terminal nut with a wrench.

Tips & Warnings

  • When working on the Saab fuel system, always work in well-ventilated areas and never work around an open flame or while smoking.

References

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