Replacing The Fuel Pump In Your 2007 Saab: Step-By-Step Guide

Replacing the fuel pump in a 2007 Saab can be a challenging task, and there are a few different approaches you can take. One option is to cut a hole underneath the back seat of the car to access the fuel pump, but this method can be tricky and may require cutting multiple holes to access the necessary components. Another approach is to drop the fuel tank from underneath the car, which provides better access but can be more complex and time-consuming. It is important to carefully consider the pros and cons of each method before proceeding, as well as taking the necessary safety precautions when working with fuel lines and electrical connections.

Disconnect the battery and take precautions when working near fuel lines

Disconnecting the battery and taking precautions when working near fuel lines is crucial for safety and preventing accidents. Here are some detailed instructions to ensure a safe working environment when replacing the fuel pump in a 2007 Saab:

Disconnect the Battery:

• Locate the battery in your Saab. It is usually found in the engine bay or the trunk.
• Identify the negative (-) and positive (+) terminals on the battery.
• Disconnect the negative terminal first, followed by the positive terminal.
• Ensure that you have removed any ignition sources, such as spark plugs or glow plugs, to prevent accidental activation during the fuel pump replacement process.

Precautions when Working Near Fuel Lines:

• Use Personal Protective Equipment (PPE): Wear safety goggles, gloves, and fire-resistant clothing to protect yourself from fuel spills and vapors.
• No Smoking or Open Flames: Ensure there is no smoking or any sources of ignition, such as flames, sparks, or hot surfaces, near the fuel lines or the vehicle. Gasoline vapors are highly flammable and can easily ignite.
• Ventilation: Work in a well-ventilated area or outdoors to prevent the buildup of gasoline vapors, which can be harmful if inhaled.
• Spill Response: Have spill response kits readily available in case of fuel spills or leaks. Absorbent materials, such as sand or commercial absorbents, can be used to contain and clean up spills quickly.
• Avoid Skin Contact: Avoid prolonged or repeated skin contact with fuel. Wash your skin thoroughly with soap and water if you come into contact with fuel.
• Fuel Handling: Use only approved containers and equipment for handling and transferring fuel. Do not use your mouth to siphon gasoline, as it is harmful and may cause serious health issues if swallowed.
• Static Electricity: Use grounding equipment to prevent static electricity buildup, especially when working with fuel lines and during fueling.
• Fire Safety: Keep a fire extinguisher nearby and know how to operate it. In case of a fire, immediately evacuate the area, alert others, and call the fire department.
• Fuel Storage: Store gasoline in approved containers, in a cool, dry, and well-ventilated area, away from sources of heat or ignition. Only store the minimum amount of gasoline needed.

Remember to carefully read and follow the safety guidelines provided by the vehicle manufacturer, fuel suppliers, and equipment manufacturers. These precautions will help ensure your safety and prevent accidents when working near fuel lines and during the fuel pump replacement process.

Remove the back seat

To remove the back seat of a 2007 Saab, you will first need to disconnect the battery and take all the necessary precautions when working around fuel lines.

The first step is to remove the seat backs. There are bolts at the bottom of the seat backs that need to be accessed from either the boot side or the car side. There is also a springy metal clip on the backrest hinge that needs to be released with a screwdriver. Once the clip is released, the backrest can be lifted out vertically.

Next, the seat bases can be removed. There are red plastic retaining clips on the hinge that need to be removed, and then the hinge pin can be slid out. The base will then lift off.

Finally, the electrical connector for the heater, if the car is equipped with one, needs to be disconnected.

It is recommended to start by removing the 40% "half" of the seat first, and to be careful not to undo the seat belt bracket connector to the floor—only the plastic clip should be removed.

Cut a hole in the floor to access the fuel pump

To cut a hole in the floor of your 2007 Saab to access the fuel pump, you will first need to remove the back seat of the car. You will then need to locate the fuel pump by lifting up the seat.

Once you have located the fuel pump, you can begin to cut the hole. Take the necessary precautions when working around fuel lines, and disconnect the battery. You can cut the hole using a nibbler, sheet metal shears, or a Dremel with a cutoff wheel. Make sure to cut a hole that is large enough to access the fuel pump comfortably.

After cutting the hole, you will need to remove the fuel pump. The pump is secured to the tank with a metal ring, which can be removed using a screwdriver and a hammer. Be careful not to damage the plastic tank when removing the ring.

With the fuel pump exposed, you can now begin the process of replacing it. This may involve fishing new fuel lines through the hole and connecting them back. Make sure to follow the appropriate safety procedures when working with fuel lines.

Remove the fuel pump retaining ring

Removing the fuel pump retaining ring can be a challenging task, but with the right tools and techniques, it can be accomplished successfully. Here are some detailed instructions to guide you through the process:

Step 1: Prepare the Work Area

Before beginning, ensure you are working in a well-ventilated area and take the necessary safety precautions when working with fuel systems. Disconnect the battery and ensure there is no risk of sparks or open flames. Place a suitable container underneath the vehicle to catch any spilled fuel.

Step 2: Accessing the Fuel Pump

To access the fuel pump retaining ring, you will need to either drop the fuel tank or create an access hole. Some Saab models have an access port under the rear seat, but for others, you may need to carefully cut an opening in the floor or rear seat area to reach the fuel pump. If you choose to drop the fuel tank, follow the steps outlined in the resources provided. If you decide to create an access hole, use a suitable cutting tool to carefully cut an opening just large enough to access the fuel pump and its retaining ring.

Step 3: Loosening the Retaining Ring

The fuel pump retaining ring is typically locked in place with a locking ring or a metal ring with tabs. To remove it, you will need a specialized tool or a creative DIY solution. You can purchase a fuel pump removal tool or create your own tool by modifying a PVC pipe or a steel bar to fit the retaining ring. Some people have reported success using a screwdriver and a hammer to carefully tap or hit the retaining ring in a counter-clockwise direction to loosen it. However, this method may require significant force and carries a risk of damaging the plastic tabs on the ring.

Step 4: Removing the Retaining Ring

Once the retaining ring is loosened, you will need to continue turning it counter-clockwise to unscrew it completely. This step may require some force and patience. Use your tool of choice to carefully turn the ring, being mindful not to damage the plastic tabs or the fuel tank itself. If the ring is particularly tight, you may need to apply some penetrating oil or WD-40 to help loosen it.

Step 5: Final Removal

After unscrewing the retaining ring, you should be able to lift the fuel pump out. Be careful when removing the pump, as there may still be fuel lines and electrical connections attached. Detach these carefully, and your fuel pump retaining ring removal is complete!

Tips and Troubleshooting:

• When creating a DIY tool, consider using PVC pipe or a steel bar that can be modified to fit securely into the notches or tabs of the retaining ring.
• Applying some force or using a hammer may be necessary when loosening and turning the retaining ring.
• If the plastic tabs on the retaining ring break, you may need to fabricate a new tool that engages multiple tabs simultaneously for more even force distribution.
• Penetrating oil or WD-40 can help loosen a stubborn retaining ring.
• When turning the retaining ring, ensure you are turning it in the counter-clockwise direction.
• Be cautious when working with fuel lines and electrical connections to avoid spills or damage.

Remove and replace the fuel pump

To remove and replace the fuel pump in a 2007 Saab, you can opt to cut a hole underneath the back seat of the car or drop the fuel tank.

If you choose to cut a hole, you will need to be very careful when working around the fuel lines. Disconnect the battery and take all the necessary precautions. You will need to cut a flap in the floor, then cut through another layer of metal to reveal the pump. You will then need to loosen the tank and drop it down to make room to pull the pump out.

If you choose to drop the tank, you will need to jack up the car and use jack stands. You will then need to remove the exhaust, the fuel tank straps, and the fuel lines.

To replace the pump, you will need to remove the locking ring that holds the pump in place. This can be done with a custom tool, or with a hammer and screwdriver. Be careful not to puncture the fuel tank.

Once the old pump is removed, you can install the new pump and reconnect the fuel lines and electrical connectors. Be sure to torque the bolts to the correct specifications.

Frequently asked questions