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Fuel pump replacement a DIY project?

1766 Views 7 Replies 5 Participants Last post by  4th_Saab
The fuel pump on my 1992 US Spec 9000S recently died stranding my darling wife and daughter on the other side of town...

I had the car towed to a local garage that fixes everything (I suppose). They want about $150 more for the fuel pump than the local foreign car parts place charges, $80 for a $10 - $15 fuel filter and $240 in diagnostic/labor charges. The nearest Saab dealer with $120/hr labor rate wants 1.5 hrs, but the pump is even more money.

How difficult is it to replace the fuel pump? Can a relatively mechanically inclined person (me) with little auto repair experience (I just did the brakes and have done a number of lock motor changes and used to change the fuel filter in my C900) do this without killing himself, burning down neighborhood, etc.? I've never messed with fuel tanks, etc. other than repairing a leak in an old car 20+ years ago.

Fortunately this is our third car so I can take my time (AFAIK)...
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Yah, very easy. I swapped pumps in my '94 in the parking lot in front of my girlfriend's apartment in about half an hour. I used a big channel-lock wrench to undo the sealing ring. Other than that, a Torx screwdriver to take off the hatch floor and maybe a flathead to pry out the checkvalves are the only tools you need.

Speaking of check valves, be careful with them. I managed to put a tiny crack in one and had gas spraying around for about two weeks before I noticed. I was able to get replacements off a parts car, but they are VERY VERY VERY hard to push back in to the nylon fuel lines.
 

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No, the tank doesn't have to come down. The hatch floor comes out (held in by a pair of Torx screws), then there's a silver-color cover over the pump that is held in by a pair of hex retainers. The pump fits into a hole in the top of the tank.

Looking at my shop manual, it's a different procedure for the LH-Jetronic models, but you still get at it from the trunk. You don't have to worry about those nasty plastic check valves. If you like, I can PM the removal and refitting instructions to you or something.
 
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