Re: How do I replace the fuel pump? - Saab 900 Bulletin Board - Saabnet.com
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Re: How do I replace the fuel pump?
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Posted by JohnK (more from JohnK) on Thu, 7 Jun 2001 12:42:38 Share Post by Email
In Reply to: How do I replace the fuel pump?, Liam, Thu, 7 Jun 2001 12:14:06
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Remove the ring, you can get it off without breaking more than 1 or 2 tabs, without the special tool, by prying with a big screwdriver and tapping the tabs at the base with a hammer and screwdriver. Pull the fuel lines off the pump housing. Lift the pump out of the hole gently, it doesn't pull straight out, wiggle it around. Replace the pump and you're supposed to use a new o-ring under the fastning ring. Sobstory has Walbro pumps much cheaper than the dealer, but you have to buy the check valve separately. Save $200.

Now the fun begins, because on a 1990, the old pump had an integral check valve and the new pump does not. The $7 elbow check valve replaces the non-check valve elbow in the fuel supply line. The official way to replace is to cut off the fuel line at the old elbow and force the new elbow check valve one into the hard plastic fuel line with a special tool. The special tool is just like the block vises that come with tubing flaring kits. It firmly holds the fuel line while you force the elbow nipple into the line with a big channel lock pliers.
Plan B is much easier. Cut the elbow next to the fitting, not the line, to leave the nipple in the line. Get 3 inches of high pressure fuel line hose (5/16 id which ever fits the nipple best) and clamp the new jumper hose onto the check valve nipple and over the fule line with the sub of old nipple inside. The nipple stub gives you somthing to squeeze against with the hose clamp.

Then plug in the fuel lines (use new o-ring on the return line elbow), put the cover and trunk floor in and you're ready to go.

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