Fuel Pump Access Cover and Fuel Pump Tank Ring - Saab 9-5 Bulletin Board - Saabnet.com
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Fuel Pump Access Cover and Fuel Pump Tank Ring
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Posted by K. Daehnke [Email] (more from K. Daehnke) on Tue, 21 Dec 2010 10:46:10 Share Post by Email
In Reply to: Fold the rear seat bottoms up., John Myers, Sun, 19 Dec 2010 08:27:55
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Just in case you do have to remove the fuel pump.....Yes, the fuel pump is accessible from under the rear seat, but the access cover through the car body metal and rubber gasket rim can be near impossible to get back into place. I think my indie mechanic used a screw driver to pry it out and managed to ripple the edge of the hole in the metal. You'll need a special tool or some creative and delicate mechanics to carefully unscrew the plastic ring that holds the fuel pump into the plastic fuel tank. You need to get a fairly uniform grip around the ring instead of trying to turn it with one of the small radial fins around the inner side of the ring. Remember, plastic = breaks easily!

I've had good luck with a homemade tool from a section of PVC plumbing pipe. 4" diameter I think, and 4" length is OK. Hopefully you have good table saw and then you can put 1" deep radial cuts into one end of the pipe to exactly match the number of plastic fins on the fuel pump. At the other end of the pipe section, drill 1/2 " dia holes opposite each other and use these for inserting a large screwdriver or metal rod to use as a handle to turn the tool and unscrew the puel pump ring.

All of this assumes you have first disconnected the battery and fuel pump power wires and carefully eased the fuel supply and return lines out. MAke sure you have the car doors open and doing this in the open air is even better. Gas fumes are dangerous! Depending on your year, you might have the recommended metal clamp that secures the fuel lines down into their connections. Getting the fuel pump out requires lifting and tilting it just right to clear several hang up points inside the tank. There will certainly be some dripping fuel, so make sure you have some plastic sheeting and paper towels to protect the carpet and a bucket to quickly put the pump into and not leak anymore.

Hopefully, your fuel pump is fine, or if you need to replace it, you can successfully reverse the removal process with the replacement. Best of luck!

Kirk D

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