Tools and Materials Needed:
- Replacement fuel pump
- Fuel line connector clips
- Fuel line disconnect tool
- Screwdriver
- Pliers
- Socket set
- Safety goggles
- Gloves
- Rags
- Gasoline-resistant container
- Fire extinguisher
Safety First:
1. Always ensure your vehicle is parked on level ground with the engine off.
2. Disconnect the negative battery terminal to avoid any electrical accidents.
3. Wear safety goggles and gloves throughout the process to protect yourself.
4. Have a fire extinguisher nearby for emergencies.
Procedure:
1. Locate the Fuel Pump Assembly:
The fuel pump in the Saab 95 is located under the rear seat.
2. Remove the Rear Seat:
- Fold or remove the rear seat according to your vehicle's specific design.
- You'll need to access the fuel pump located beneath it.
3. Disconnect Fuel Lines:
- Identify the fuel supply and return lines.
- Use a fuel line disconnect tool to detach the fuel lines. Make sure to collect any spilled fuel in a gasoline-resistant container.
- Disconnect the fuel filler cap vent line.
- Seal any open fuel lines using plugs to avoid spillage and fumes.
4. Remove the Fuel Sending Unit:
- Loosen the screws or bolts securing the fuel sending unit to the fuel tank.
- Carefully lift the fuel-sending unit out of the fuel tank.
- Disconnect any electrical connectors attached to the fuel-sending unit.
5. Replace the Fuel Pump:
- Inspect the old fuel pump and note down the position of the fuel-level sender.
- Connect the new fuel pump's electrical connector(s) and any other sensors.
- Secure the new fuel pump in place with the screws or bolts you removed earlier.
- Make sure the fuel-level sender is correctly positioned and secured.
6. Reconnecting Fuel Lines:
- Reattach the fuel lines, fuel filler cap vent line, and any connectors.
- Use new fuel line connector clips as necessary.
7. Reinstall the Rear Seat:
- Replace the rear seat in the reverse order it was removed.
8. Turn On the Ignition:
- But don't start the engine. This will help build up fuel pressure in the system.
- Check for any leaks around the fuel lines and connections. Fix them if necessary.
9. Start the Engine:
- Start your vehicle and let it run for a few minutes. Monitor for leaks, strange noises, or any abnormalities.
- If everything seems in order, take your Saab for a short test drive to ensure it's functioning correctly.
Important Tips:
- If you're not confident working with fuel systems, consider seeking professional help from a qualified mechanic.
- Fuel vapors are flammable, so avoid any sources of ignition during the process.
- Be mindful not to drop any parts or objects inside the fuel tank.
By following these steps carefully, you can replace the fuel pump in your 1999 Saab 95. However, it's always advisable to consult a repair manual specific to your vehicle's model for any additional instructions or deviations.
