Replacing The Fuel Sending Unit In Your 2007 Saab Aero

Replacing the fuel sending unit on a 2007 Saab Aero is a complex task that requires a good understanding of car mechanics and the Saab Aero model. The fuel sending unit is part of the fuel pump assembly, and while it can be purchased separately, the whole assembly may need to be replaced depending on the car's mileage. The process involves removing the exhaust, supporting the converter, disconnecting electrical plugs and fuel lines, and lowering the fuel tank. It is important to ensure the fuel level is as low as possible to reduce the weight of the tank. Some people have also cut an access hole in the car body to avoid dropping the tank. This is a hazardous procedure and should only be attempted with extreme caution.

Remove the fuel tank

To remove the fuel tank from a 2007 Saab Aero, you will need to first remove the exhaust. Some cars have an access plate so you can get to the pump without dropping the tank, but this car is not one of them.

Make sure to support the converter so the flex pipe doesn’t break. If you live in the northeast, you’ll need a smoke wrench to separate the front pipe from the back.

There is one main electrical plug and three fuel lines to disconnect from underneath. Disconnect the main feed and return lines along with the electrical plug, and then the vapor line to the right of the canister.

Now, you can remove the fuel tank straps and lower the tank.

Disconnect the fuel pump and three fuel lines

Disconnecting the fuel pump and three fuel lines is a crucial step in changing the fuel sending unit of a 2007 Saab Aero. Here is a detailed, step-by-step guide to help you through the process:

Step 1: Before you begin, it is important to ensure your safety. Fuel and fuel vapors are highly flammable, so exercise extreme caution throughout the process. Work in a well-ventilated area and avoid any sources of ignition, such as lit cigarettes or open flames. It is also recommended to wear safety goggles and gloves for eye and hand protection.

Step 2: Locate the fuel pump and three fuel lines. They are positioned underneath the vehicle, towards the rear. You will need to raise the car and lie on a creeper to access this area comfortably.

Step 3: Identify the fuel lines. There should be one main feed line, one return line, and a vapor line. The vapor line is usually found to the right of the canister.

Step 4: Start by disconnecting the main electrical plug. This will power down the fuel pump and reduce the risk of sparks or unexpected activation.

Step 5: Proceed to disconnect the main feed and return lines. These are the larger fuel lines that supply fuel to and from the engine. Use appropriate tools, such as line disconnectors or wrenches, to carefully detach the lines without damaging them. Place a container or rag underneath to catch any residual fuel.

Step 6: Now, focus on the vapor line. This line is typically smaller in diameter and connects to the charcoal canister or EVAP system. Again, use the correct tool to detach the line securely.

Step 7: Once all three fuel lines and the electrical plug are disconnected, carefully move them out of the way. Ensure they are not resting on any hot surfaces or in areas where they might sustain damage.

Step 8: At this point, the fuel pump and sending unit should be isolated. You can now proceed with the next steps in the fuel sending unit replacement process, such as removing the fuel tank straps and lowering the tank. Remember to refer to the repair manual or seek professional guidance if you are unsure about any steps.

Safety is paramount when working with fuel systems, so take your time and double-check each step.

Remove the exhaust

To remove the exhaust, follow these steps:

• Remove the right rear wheel and inner liner.
• Remove the chassis subframe braces.
• Lower the exhaust system and hang it with a support.
• Remove the fuel line and vent connections to the carbon canister.
• Remove the connector from the Evap canister.
• Take off the hose from the tank to the filler pipe and vent.

Note: Some of these steps may require an extra set of hands, so it is recommended to have an assistant to help with the process.

Support the converter to prevent the flex pipe from breaking

To support the converter and prevent the flex pipe from breaking, you will need to remove the exhaust. Here is a step-by-step guide:

Step 1: Remove the exhaust

First, you will need to remove the exhaust from your 2007 Saab Aero. This will give you access to the fuel sending unit. Be sure to have a suitable workspace and all the necessary tools before beginning this process.

Step 2: Support the converter

With the exhaust removed, you can now focus on supporting the converter. This is a crucial step to prevent the flex pipe from breaking. Place a jack or a support stand under the converter to hold it securely in place. Ensure that the support is stable and can bear the weight of the converter.

Step 3: Secure the flex pipe

Once the converter is supported, you can now focus on the flex pipe. Inspect the flex pipe for any signs of damage or wear. If the pipe is damaged or brittle, it may be advisable to replace it to prevent breakage. Use suitable clamps or supports to secure the flex pipe and ensure it is firmly attached to the converter and other exhaust components.

Step 4: Reattach the exhaust

With the converter supported and the flex pipe secured, you can now reattach the exhaust to the vehicle. Ensure that all connections are securely fastened and that there are no leaks or gaps in the exhaust system.

By following these steps, you will help prevent the flex pipe from breaking and ensure the stability of the converter in your 2007 Saab Aero.

Disconnect the main electrical plug

Disconnecting the main electrical plug is a crucial step in changing the fuel sending unit of a 2007 Saab Aero. Here is a detailed, step-by-step guide on how to do this safely and effectively:

Step 1: Remove the Fuse

Before beginning any work on your Saab Aero, it is important to reduce the fuel pressure by removing fuse 2 from the engine compartment while the engine is still running. This is a crucial safety precaution and will make the subsequent steps safer and more manageable.

Step 2: Drain the Fuel Tank

The next step is to drain the fuel tank as much as possible. This will make the tank lighter and easier to work with when you need to remove it. Use an extra jack to help lower the tank and place it on a piece of cardboard to avoid any damage to the EVAP canister. Remember to seal off the filler hole to prevent any fuel spillage.

Step 3: Disconnect the Main Electrical Plug

Now, locate the main electrical plug. This can be found underneath the vehicle, connected to the fuel tank. Carefully disconnect the plug, putting it somewhere safe and out of the way. Ensure that you do not force the connection, as this may damage the plug or the surrounding components.

Step 4: Lower the Fuel Tank

With the electrical plug disconnected, you can now focus on lowering the fuel tank. This will grant you better access to the fuel sending unit and other components. Remember to support the weight of the tank and lower it carefully to avoid any damage to the EVAP canister or other nearby parts.

Step 5: Remove the Fuel Sending Unit

With the tank lowered, you can now access the fuel sending unit. Remember to clean any dirt or dust from the tank before proceeding. Carefully remove the fuel sending unit, being mindful of any remaining fuel in the tank and the fuel pump. Have some rags on hand to soak up any spilled fuel.

Step 6: Reinstall the New Fuel Sending Unit

Once the old fuel sending unit is removed, you can now install the new one. Ensure that the wires are connected correctly, with the solid wire and the wire with writing on it properly placed. Secure the new fuel sending unit in place, and you can now start reassembling your Saab Aero, reversing the steps you took to gain access to the fuel sending unit.

Remember to take your time and work carefully, especially when dealing with fuel and electrical components. Safety should always be your top priority when performing any maintenance or repairs on your vehicle.

Frequently asked questions