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Discussion Starter #1 (Edited)
1993 9000 CSE Turbo.

Hello Gents,

A little help please. I think my fuel pump just died. The car was running fine. Drove it all day long started and stopped fine. Then when idling in the driveway this afternoon, it just died. The car wanted to start after having tried several times...I assume just the remaining fuel left in the fuel rail. I talked to a local SAAB tech, and he said to remove the fuse to the fuel pump and jumper it to a 12volt source to listen for a buzzing from the rear. NO BUZZ! So, I'm pretty sure the fuel pump is dead.

Is the fuel pump replacement a job for the do-it-yourselfer? If so, where or how do you access the fuel pump? Also, I looked for a replacement pump on THESAABSITE.COM, which one do I need? Part # ? I found this one at AUTOPARTSWAREHOUSE.COM, will it work?

http://www.autopartswarehouse.com/details/QQSaabQQ9000QQDelphiQQFuel_PumpQQ19931998QQDPFE0373.html

Money is tight right now, so I'd hate to send it to a mechanic if I could do the job myself.

Any help would be greatly appreciated! Thanks in advance.
 

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have someone in the car to start it and get under there with a hammer ..while cranking start tapping the tank this will wake the pump up it's NOT a fix but will help diag. the problem...you will have to drop the tank this is going to suck if you have alot of gas in the tank and without t6he proper tools...but it can be done...good luck
 

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My pump died last year

I have a 95 9000 CS and it just stopped without warning and wouldn't start. I didn't know what it was so I had it towed to my mechanic. I actually thought at first it was a dead battery, but that was quickly ruled out. My mechanic is great, but not a Saab specialist; he has been at it for many years, so had a pretty good sense of it.

He determined it was the fuel pump, and was able to access it from the top without dropping the tank. The hose fittings are pressed on with a special tool which he didn't have, and didn't have enough call for to justify purchasing. Also an old brittle plastic connector broke tring to remove it. I was fortunate in finding the whole assembly used. It was from a 900--exactly the same unit. He was able to drop it in without disassembly or special tools. (He did have to fabricate a wrench to unscrew it from the tank itself.) I was pleased that he was able to do it all; saved me from having to go to a dealer and the giant bucks.

Based on what I saw, it would be a pain to do yourself if you were to try to replace the pump instead of the whole assembly. Getting the pump out of the assembly is going to be difficult to do without that special hose tool and with the old brittle plastic fittings. If you wanted to do it yourself I'd recommend trying to find the whole assembly used. (New it is priced thru the roof)

I hope this helps.
 

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I have replaced the fuel pump on my 91' 9000. I was not a very challenging job if you are patient with the process. You can avoid the high cost of buying a whole unit if you take apart the assembly and just replace the pump. This is what I did and it only cost about $150. The only tricky part of the job is removing the two connections at the top of the pump assembly. Use some type of lubricant and spray it into these two connections before attempting to wiggle them back and forth and up at the same time. I had to access mine by removing the trunk floor ( CD model) and would think a hatchback would make this all the more accessible. I was unlucky enough to break one of these connections by rushing and was able to purchase a replacement check valve for $13.
 

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Discussion Starter #6
Thanks guys. I was able to find a nice detailed thread located here...

http://www.saabcentral.com/forums/showthread.php?t=119759

I've already located the pump access panel in the rear hatch underneath the spare tire cover panel. I've already got the 2 hoses off , and just need to fabricate some sort of ring removal tool. I'll be using bar stock just like in the link.

I really think I could've done this job in under a couple of hours if it wasn't for the stupid ring removal issue!

I've never been one to give up! And I'll be damned if I'm goona let this thing get the best of me. I'll report back when the job is complete.
 

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Discussion Starter #7
Saaber99 said:
I have replaced the fuel pump on my 91' 9000. I was not a very challenging job if you are patient with the process. You can avoid the high cost of buying a whole unit if you take apart the assembly and just replace the pump. This is what I did and it only cost about $150. The only tricky part of the job is removing the two connections at the top of the pump assembly. Use some type of lubricant and spray it into these two connections before attempting to wiggle them back and forth and up at the same time. I had to access mine by removing the trunk floor ( CD model) and would think a hatchback would make this all the more accessible. I was unlucky enough to break one of these connections by rushing and was able to purchase a replacement check valve for $13.
Where did you get your replacement pump? And which one...part #? How about a direct link. Thanks.
 

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Discussion Starter #8
The Saga Continues...

Well, went out & bought some bar stock steel to make a ring removal tool. NO LUCK!!! The ring just won't budge. Any ideas??? I'm really at my wits end. I've even tried criss crossing 2 pry bars, and wedging it in there in an attempt to loosen the ring. Still no go. It's like the friggin' thing is fused in there.

I doubt that even if I had the factory ring removal tool that it would work to loosen the ring.

Once again, any ideas? Thanks.
 

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Discussion Starter #9
Finally!!!!!!!!!!!!

After fighting with the ring for the last 5 hours, I FINALLY got the sucker off:evil: by continually using 2 pry bars in unison. Managed to the get the pump housing up & out of the tank without breaking anything. Took the pump housing apart to gain access to the old pump. After having the pump in hand I was curious so I hooked up a 12v source to it...DEAD as can be.

Off to the parts store in the morning to pick up the replacement WALBRO pump they have in stock...which is an exact match to the one I took out....a WALBRO as well.

I'll report back after the new one is in, but for now "I'm beat!!" Time for a cold one, or four!;)
 

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If you want to buy just the Walbro pump, note that it is model 5CA606. Available here:

http://www.eeuroparts.com/productdetail.aspx?searchResults=1&code=4664


For more info, here's something I posted to another list recently:


The hardest thing about pump replacement seems to be not breaking the right-angled plastic fuel line fittings when pulling them out of the top of the pump. Also, not breaking the plastic retainer piece (yellow piece in the following pictures).

http://bellsouthpwp.net/d/a/davidprantl/saab/pump/fitting_remove1a.jpg

http://bellsouthpwp.net/d/a/davidprantl/saab/pump/fitting_remove2a.jpg

http://bellsouthpwp.net/d/a/davidprantl/saab/pump/fitting_remove3a.jpg

Saab sells a cheap metal bracket. Here's a nice Saabnet writeup on it:

[url="http://www.saabnet.com/tsn/members/gallery.html?memberID=473&do=show&id=7712"]http://www.saabnet.com/tsn/members/gallery.html?memberID=473&do=show&id=7712[/url]

"bobc" also has a nice writeup on the 9-5 climate control "code 08" fix.

For those of you banned from Saabnet, here are two relevant pictures I "borrowed":

http://bellsouthpwp.net/d/a/davidprantl/saab/pump/line_bracket_1a.jpg

http://bellsouthpwp.net/d/a/davidprantl/saab/pump/line_bracket_2.jpg

Replacement fittings are available, even though some sites (e.g. thesaabsite) still claim that the return fitting is not available separately.

Feed line:

http://www.eeuroparts.com/productdetail.aspx?searchResults=1&code=7992

Return line (must reuse the snap-in valve seat and peg from the old fitting):

http://www.eeuroparts.com/productdetail.aspx?searchResults=1&code=8489

New fittings can be spliced to your old fuel lines with short pieces of 8mm rubber fuel hose, provided the barbed part of the old fitting remains inside the plastic fuel line to keep it from collapsing:

http://bellsouthpwp.net/d/a/davidprantl/saab/pump/fitting_splice_a.jpg

Otherwise, Saab has a special tool to jam a new fitting into the end of the hard plastic fuel line in your car:

Version used with slip-joint pliers:

http://saab.spx.com/detail.asp?id=145

Version with attached press fixture:

http://saab.spx.com/detail.asp?id=689

The second hardest thing is unscrewing the plastic collar that holds the pump assembly in the tank.

Saab has special tool for this:

http://saab.spx.com/detail.asp?id=142

Homemade version:

http://bellsouthpwp.net/d/a/davidprantl/saab/pump/pumptool1.jpg

http://bellsouthpwp.net/d/a/davidprantl/saab/pump/pumptool2.jpg
 

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Discussion Starter #12
Thanks guys. It's already done. I purchased the Walbro pump locally and had it installed in about an hour. Hooked up the battery, turned on the ignition and let the system prime itself. After hearing the system was done priming itself, I crossed my fingers and turned the key. Fired right up. Took her out for a little test drive, and all is GOOD!!!
 

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Admin. If this is the wrong thing to do let me know. I am sure my fuel pump is a big failure, 93, 9000 CSI, 372,000km. Car started to "miss" "surge", slowed to a stop. When I jump the fuses to get the pump to run it sounds like a "road roller" my tow home car, a 93 9000 has this "quiet whine", 190,000km just a bit more noise than my 92 900 vert, 100,000km.

I can get a new one locally for just over NZ $300.00.
But simple question, how does the rear boot wooden cover come out!
Should be simple, cant see any screws holding it in, I have taken off the trim at the front edge.

I know it is a dumb question.
I should be able to see the answer in front of my eyes!

Robin
 

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Thank you.

Maybe I am about blind.
Perhaps there are two screws I have not seen.
 

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Found them. Was very dark in the shed where I am working, with a light, yes.

Too easy.

Now to get it out. Presently soaking in a bit of WD 40.
 

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Many thanks. I would do that if I had experience, and if I could get the old one out without cutting the plastic retaining threaded ring.

I am considering doing what you suggest for my 93 9000 griffin, 192,000km, it has a slight whine.
My 92 900 vert has just a very quiet whirr 100,000km.

So for this car, I have ordered a full replacement pump, which comes with the retaining ring, from PFS, cost to me NZ$280.00.

So I have some time to let the ring "soak" to see if I can get it out with the ring intact, minus a couple of lugs I have broken off!
 

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The only hard part is soldering the wires going to the pump. Some of the Walbro OE refit kits include fuel-safe shrink tubing for rewiring. They all include tubing and clamps to replace the feed line in the OE module.

You can't pop the ring loose with a screwdriver and hammer without snapping off the tabs. You really need a tool to grab at least 4 of the tabs across from each other to give even pressure. I've seen tools made from 4" PVC.
 

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Thank you. The PVC Tube sounds like a great idea.
 
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