Fuel level sender replacement notes - Saab 9-3SS Bulletin Board - Saabnet.com
The banner above is an advertisment - if it asks you to download software, please ignore.
Site News - 3/26 M Car Covers (by State of Nine) | 12/12 Make Amazon Pay Saabnet!

[General | Members | C900 | 9000 | NG900 & OG93 | 93 | 95 | NG95 | 99 | Sonett | Vintage Models | Clubs | Other Cars | FAQs | Gifts | Member Photo Galleries | Member Directory | Classifieds | Manuals | *Buddy Registry | *Mileage Registry | Polls | What's New | Raffle | Photo of the Month | Sponsors]

93 Bulletin Board
2003-2011 [Subscribe to Daily Digest]
(Search Author's Posts: e.g. Keyword:username)*Members Only


[Main 93 Bulletin Board | BBFAQ | Prev by Date | Next by Date | Post Followup ] Member Login / Signup - Members see fewer ads. - Latest Member Gallery Photos
Fuel level sender replacement notes
Like This Post: - Subscribe to Daily Digest for this Bulletin Board
Posted by Gene N [Email] (#1094) [Profile/Gallery] (more from Gene N) on Sat, 25 Aug 2018 11:23:57 Share Post by Email
Alert me when someone posts in this thread:
Members do not see ads below this line. - Help Keep This Site Online - Signup

Replaced the fuel level sensor on my 2005 Linear with 100k miles yesterday, about 4 hours total. I ran the tank down to one gallon to make it easier to remove the tank. Pete's excellent description (see link below) of the replacement of the fuel pump covers most of it, but I wanted to add a few extra things.

I had the OTC tool that Pete linked to, but I had already purchased it over a year ago when the gauge first started acting up. The fuel gauge would read empty for the first 100 miles, then jump to 3/4 and work for the rest of the tank. I just put up with it for a year.

I had problems with all of the quick disconnect fittings, and even though I tried to be careful, I managed to break the locking mechanism on 3 out 5 of them. I guess that 14 year-old plastic is going to do that. I set that problem aside, and went to work on the fuel filler pipe. I struggled for a while trying to get my fat hands up in there to remove the filler hose and vent pipe. I finally removed the rear sway bar and that gave me enough room to get the pipes off so I could remove the straps and lower the tank to the ground. I struggled with the OTC ring removal tool for a while, but just couldn't get enough torque to loosen the ring. I turned the tank on its side with the fuel pump closest to the ground and was able to release the ring by pushing down on the breaker bar. Once the fuel pump was out (another quick release connector to fool with inside the pump), I was able to replace the sensor. I used the original A/C Delco part (SK1184), and was able to find it online for $35 instead of $60 for the SAAB part. Apparently the sensor also fits a 2009 Chevy Malibu. The only tricky part is you have to disassemble a connector inside the pump, push out the two pins for the old sensor, push in the wires for the new sensor and reassemble the connector. Grease the new pump O-ring, fit the pump and install the lock ring. I used the same technique to install the lock ring as I did removing it. In Pete's description he was only able to get the ring to the first click. Pushing down on the breaker bar with the tank on its side I was able to get the ring to the second click and fully engaged.

After fitting the tank back into the car, I attached the quick release fittings to the fuel lines and fuel vapor lines. I was able substitute zip ties for the broken locking pieces, feeding the tie through the slots in fitting and tightening the zip tie after the fitting was installed. It did the job of locking the fitting and it should last as long as the original. I installed the filler hose and vent pipe.

Reinstalling the sway bar requires both wheels off the ground. Fit the bushing holders into the rear subframe and lower the bar and bolt both sides. I had problems with the spring being in way of the bolt that attaches the link to the hub. I was able get around this by jacking up the wheel slightly until I could push the socket extension through the spring.

If this happens again, I will replace the whole pump. With only 100K miles on this pump, I thought it was worth the risk of only replacing the sensor.

Keep in mind that even though I ran the tank down to one gallon and removed the fuel pump fuse while the car was running, I still had plenty of gasoline on the floor of the garage, especially when I pulled the pump out of the tank.

Pete's thread

->Posting last edited on Fri, 7 Sep 2018 04:52:53.


Posts in this Thread:
Alert me when someone posts in this thread:
Members do not see ads below this line. - Help Keep This Site Online - Signup
Post a Followup

No Site Registration is Required to Post - Site Membership is optional (Member Features List), but helps to keep the site online
for all Saabers. If the site helps you, please consider helping the site by becoming a member.

Name: Member Login / Signup - Members see fewer ads. - Latest Member Gallery Photos
E-Mail: (Optional)
Re-Enter E-Mail: (Confidential & Secure - Not revealed to other users!)
Note: Please check your spam folder for BB responses.

Subject:

Posting rules are simple - No for sale/wanted ads may be posted here - use the site classifieds.
You may not cross-post your message to multiple BBs.
Not permitted: political/religious topics and being disrespectful (personal attacks, insults, etc...).
Site Members do not see any red text, inline ad links, bottom of page anchor ads, box ads, or anti-spam check.

Message: (please no for sale/wanted classifieds - post those in the Saabnet.com Classifieds)
Links are now automatically made active, no need for any special code (or use the Option Link field below) - don't put links in () or end with a '.'
To add inline images to your post, use [img]http://www.domain.com/img.jpg[endimg] (or use the Optional Image Link field below).


Links are now automatically made active, no need for any special code (or use the Option Link field below) - don't put links in () or end with a '.'
To add inline images to your post above, use [img]http://www.domain.com/img.jpg[endimg] (or use the Optional Image Link field below).

Optional Link: (e.g. http://www.saabnet.com/)
Link Title: (Optional)
Optional Photo/Image Link: (e.g. http://www.saabnet.com/img.jpg)
Photo/Image to Upload: (Please be patient while file uploads)





StateOfNine.com
SaabClub.com
Jak Stoll Performance
M Car Covers
Ad Available

The content on this site may not be republished without permission. Copyright © 1988-2024 - The Saab Network - saabnet.com.
For usage guidelines, see the Mission & Privacy Notice.
[Contact | Site Map | Saabnet.com on Facebook | Saabnet.com on Twitter | Shop Amazon via TSN | Site Donations]

Random Saabnet.com Member Gallery Photos (Click Image)

This is a moderated bulletin board - Posting is a privilege, not a right. Unsolicited commercial postings are not allowed (no spam). Please, no For Sale or Wanted postings, SERIOUSLY. Classifieds are to be listed in The Saab Network Classifieds pages. This is a problem solving forum for over 250,000 Saab owners, so expect to see problems discussed here even though our cars are generally very reliable. This is not an anything goes type of forum. Saabnet.com has been a moderated forum since 1988. For usage guidelines, see the Saabnet.com Mission and Purpose Page. Please remember that you are not anonymous. Site Contact | Site Donations | Other Sites by SP - Poverty2Prosperity.org | Run Club Menlo Park | ScreenBot



Site Members do not see red text instructions, bottom of the page anchor ads, or box ads.
Click here to see all the Site Membership Benefits!