Regan Brown
Removing the fuel tank from a 2008 Saab 9-3 can be a tricky task. Before beginning, it is important to note that fuel is highly flammable and may cause skin irritation, so proceed with caution. The first step is to drain the tank, which can be done using a siphon. Next, you'll need to remove the middle pipe or the entire middle muffler section, depending on your exhaust type. After that, the fuel filter must be removed, and then the challenging part of disconnecting the EVAP purge line from the fuel filler neck begins. You'll need a fuel disconnect tool for this step. Following this, you can remove the filler neck from the gas tank and then the fuel pump. Finally, you can remove the fuel line check valves and the fuel tank itself.
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What You'll Learn
Drain the tank
To drain the tank of your 2008 Saab 93, you must first ensure you are working in a well-ventilated area, as fuel is extremely flammable and may cause skin irritation. You should also wear safety goggles and gloves.
The first step is to remove the fuel filler neck rubber hose. This can be done by loosening the hose with a flat screwdriver and sliding it off the tank. Place a catch pan underneath the hose to collect the fuel. You can then use a siphon to drain the fuel from the tank.
Alternatively, you can drive the car until the tank is almost empty of fuel. This will make removing the tank easier.
Once the tank is drained, you can move on to disconnecting the EVAP purge line from the fuel filler neck. This requires a fuel disconnect tool. Insert the tool and push the blue ring outward to release the latch on the valve.
The next step is to remove the filler neck from the gas tank. This will require removing the two gas tank straps, as well as the exhaust. For the V6 model, there is only one exhaust clamp that needs to be loosened.
Finally, you can proceed to remove the fuel line check valves, being careful to take your time and use the appropriate tools to avoid damage.
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Remove the exhaust
To remove the exhaust from your 2008 Saab 9-3, you will need to follow these steps:
First, ensure that your gas tank is almost empty. This will make the process of removing the exhaust and fuel tank much easier.
Next, you will need to remove the cat converter. If you have a V6 Dual exhaust, the cat converter is on the way, so it must be removed to access the fuel tank.
Now, you can start removing the exhaust components. Loosen the single exhaust clamp on the V6 cars using a 15mm wrench or deep socket. You will also need a flat screwdriver to remove the hanger donut clip. All other hanger donuts should simply slide off.
After that, remove the middle pipe just after the first muffler that goes to the rear muffler. If you have an aftermarket exhaust, you may only need to remove this pipe. However, if you have the stock exhaust, you will need to remove the entire middle muffler section.
At this point, you will also need to remove the heat shield. There are two 10mm nuts holding the heat shield in place. One is located ahead of the bend before going over the axle, and the other is right after the axle. This step is mandatory as there will not be enough room to wiggle the fuel tank out without removing the heat shield.
Once you have removed the heat shield and the middle pipe or muffler section, you will have cleared the exhaust out of the way, and you can continue with removing the fuel tank.
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Disconnect the EVAP purge line
Disconnecting the EVAP purge line from the fuel filler neck can be a tricky step. You will need a fuel disconnect tool to do this. Insert the tool to push the blue ring outward, which will release the latch on the valve.
It is recommended to avoid using a tool with both size "e" and "f" on it and a pivot piece in the middle. This is due to insufficient room between the housing collar of the valve and the lip when using the two-sided tool.
You can also use a flat screwdriver to loosen the fuel filler hose and slide it off the tank.
Before disconnecting the EVAP purge line, you will need to remove the middle pipe just aft of the first muffler going to the rear muffler (if you have an aftermarket exhaust) or the entire middle muffler section for a stock exhaust. You will also need to remove the heat shield and the fuel filter.
Additionally, it is important to note that the fill tube vent is a quick disconnect, but it is not intuitive how to detach it. You need to squeeze it, but be careful not to pry it and ruin it as you may need to cut it off and replace it with a short section of the fuel line.
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Remove the filler neck
To remove the filler neck of a 2008 Saab 9-3, you will first need to remove the rear backseat and cut an access door with tinsnips. You can refer to the following steps for guidance:
- Begin by removing the rear backseat.
- Using tinsnips, cut an access door into the floor of the car.
- Next, you will need to disconnect the EVAP purge line from the filler neck. This requires a fuel disconnect tool to push the blue ring outward, releasing the valve latch.
- It is recommended to avoid using a tool with both size "e" and "f" and a pivot piece in the middle, as there may be insufficient room.
- Now, you can remove the filler neck from the gas tank.
It is important to note that some users have reported challenges with removing the fuel filler neck, particularly the collar at the fuel cap. If you encounter similar difficulties, you may need to apply gentle force with a screwdriver blade to pry the retainer free.
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Remove the fuel line check valves
Removing the fuel tank from a 2008 Saab 9-3 involves several steps, and it is important to be careful throughout the process.
One of the steps in removing the fuel tank is to remove the fuel line check valves. Before attempting this, it is important to ensure that you have freed up your supply line check valve. The white valve can be freed by spraying the opening with PB Blaster and carefully wiggling it back and forth. This must be done carefully, as the valve or the yellow plastic tab can break.
Once the supply line check valve is freed, you can remove the fuel line check valves. This process should be done slowly and carefully. Mechanics gloves can be used as a buffer between the body of the valve and a pair of vice grips. The vice grips should be clamped onto the body of the valve, and the adjuster closed right until they clamp on. The grips can then be removed, and the gloves placed in between the two.
After the fuel line check valves have been removed, the next step is to cut back the fuel line. This should be done carefully, cutting back about half an inch, just to the start of the last "tang" on the check valve. Be prepared for some fuel to pour out when you pull away the check valve.
A new check valve can then be secured in place using a Dorman fuel line tool, with the fuel line secured to the other end of the tool. Pressure can then be applied with the tool, repositioning the check valve if necessary.
It is worth noting that the Dorman fuel line tool is sold by itself or as part of a kit, but only the fuel line and some brass connectors are likely to be useful for Saab vehicles.
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