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Fuel/Gas Tank/Pump Removal
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Posted by saabmanca [Email] (more from saabmanca) on Fri, 18 Nov 2011 20:18:56 Share Post by Email
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There are a few descriptions of this procedure on this BB but here's what I did to replace the fuel pump on 1997 NG900 SET Conv. (132K miles with pump hard failure - infinite resistance across pump motor).

Parts Replaced : AFT Complete Fuel Pump Assy ($165), Bosch Fuel Filter ($12), 4 x Fuel Filter Sealing Rings ($6);

Time : 2-3 hrs

1/ Get the car up on ramps if you still have motion, axle stands if not. Since most of the work needs to be performed from underneath you'll need the extra clearance.

2/ Disconnect battery.

3/ Remove rear seat cushion by pulling up on front edge

4/ Remove the 4"-5" plastic cap from access hole in floor and disconnect pump and gas level sensor (2 connectors; Brown and Blue).

Working under Car
=================

5/ To remove/store gas I used a small hand pump ($12 from local auto store) and a few 2.5 & 5 gallon containers borrowed from friends. I removed the breather hose from the tank connector (top of tank center) and pushed syphon hose into tank. I managed to pump most of the gas out but for the remainder I went in through the filler connector (bottom of tank, surprisingly no anti-syphon device?) 30 min job but felt longer.

6/ Remove breather hose and filler hose from plastic filler neck. Disconnect small hose (1/4") at connector close to breather hose.

7/ Place catch pan under fuel filter and remove fuel filter (located in front of passenger side rear wheel). Be prepared for some spillage.

8/ Place trolley/floor jack under tank to take weight, use a square of wood between retaining straps to spread load.

9/ Release tank retaining straps (13mm shake-proof nuts) and push brake cable to one side to prevent fouling

10/ Gently lower jack height and tank will drop. It may need some encouragement depending on how much fuel is left in tank. Luckily mine dropped almost straight down.

11/ Remove return fuel hose from pump assy (black connector), the feed hose is already free since it's disconnected at the filter. You may need to unclip the hoses from retaining spots around the tank.

12/ Slide tank out from under car, Tank is now free from car and can be worked on.

13/ You'll need to make/buy a special removal tool. I made one from a 4" pipe fitting per the video on You Tube.

14/ I opted to fit a complete pump assy. Makes the job quicker although a bit more expensive. I'm glad I did since the tubes inside the pump did not seem to want to budge and I could see me fouling something up which I might only discover once everything was back together.

Replacement is reverse of above.

Car took a few cranks to start before bursting back into life. Hope that helps.

posted by 75.36.15...

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