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I'm posting this for the benefit of anybody else who has replaced a Walbro fuel pump insert on their 9000 (mine is a '92 non-turbo) and subsequently had problems.
To replace a length of clear plastic hose that had to be cut off inside the pump, I used a length of rubber hose and attached it with round stainless steel clamps.
The car ran fine. But then, after about a week, it started to run like hell (almost impossible to start, wouldn't idle, didn't like to rev, etc.). I spent hours trying to diagnose other problems (learning much about Saabs in the process!) and finally decided (I'm a slow learner), "Well, maybe I'd better pull the fuel pump and take a look."
So I did, and discovered that one of the clamps had sliced the rubber hose, causing it to leak (and because the leak was inside the fuel tank, it wasn't visible). So the pump was pushing enough gasoline thorugh the fuel line to make the injectors work a little bit, but not enough to make the car run right.
I replaced the hose (with a slightly smaller diameter -- I think part of my problem was that the original hose was too big), and the car now runs flawlessly.
And the reason I'm stupid is because I ignored the first law of auto mechanics -- when you have a problem, first look at whatever it was you last did. I was so sure that the pump "couldn't" be the problem that I wasted probably eight hours trying to diagnose all these other problems. And I changed a fuel filter and plugs that probably really didn't need changing.
This board was very helpful -- I got many good suggestions.
posted by 66.61.18...
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