Draining Fuel: Removal & Installation Saab 9-2X I

Removal

Set the vehicle on a lift.

Release the fuel pressure.

Drain the fuel from the fuel tank.

Remove the rear seat.

Disconnect the connector (A) of fuel tank cord to the rear harness.

Push the grommet (B) which holds the fuel tank cord on floor panel into under the body.

Scheme 145

Remove the rear crossmember.

Remove the canister.

Disconnect the connector from pressure control solenoid valve.

Loosen the clamp and disconnect the fuel filler hose (A) and evaporation hose (B) from the fuel filler pipe.

Scheme 146

Scheme 147

Move the clips, and disconnect the quick connector.

Disconnect the fuel hoses.

Scheme 148

Support the fuel tank with a transmission jack, remove the bolts from bands and dismount the fuel tank from the vehicle.

Scheme 149

Installation

Support the fuel tank with a transmission jack and push the fuel tank harness into the access hole with the grommet.

Set the fuel tank and temporarily tighten the bolts of fuel tank bands.

Scheme 150

Insert the fuel filler hose (A) approx. 35 to 40 mm (1.38 to 1.57 in) over the lower end of fuel filler pipe, and tighten the clamp.

Insert the evaporation hose (B) to the lower end of evaporation pipe, and hold the clamp and clip.

Scheme 151

Scheme 152

Connect the fuel hoses, and hold them with clips and quick connector.

Scheme 153

Connect the connector to the pressure control solenoid valve.

Install the canister.

Tighten the band mounting bolts.

Tightening torque

33 Nm (3.4 kgf-m, 25 ft-lb)

Scheme 154

Install the rear crossmember.

Connect the connectors (A) to the fuel tank cord and plug the service hole with grommet (B).

Scheme 155

Set the rear seat and floor mat.

Connect the connector to the fuel pump relay.

Scheme 156

Release the fuel pressure.

Open the fuel filler flap lid and remove the filler cap.

Disconnect the ground cable from battery.

Scheme 157

Remove the screws holding packing in place.

Scheme 158

Lift up the vehicle.

Remove the rear right side wheel nuts.

Remove the rear right side wheel.

Scheme 159

Drain the fuel from the fuel tank.

Remove the fuel filler pipe protector.

Scheme 160

Separate the evaporation hoses from the clip of fuel filler pipe.

Scheme 161

Disconnect the evaporation hoses from fuel pipes.

Scheme 162

Remove the bolts which hold the fuel filler pipe bracket on the body.

Scheme 163

Loosen the clamp and separate the fuel filler hose (A) from the fuel filler pipe.

Move the clip and separate the evaporation hose (B).

Scheme 164

Remove the fuel filler pipe to under side of the vehicle.

Remove the evaporation pipe together with clip from the body.

Scheme 165

Open the fuel filler flap lid.

Set the fuel saucer (A) with rubber packing (C) and insert the fuel filler pipe into hole from the inner side of apron.

Align the holes in fuel filler pipe neck and set the cup (B), and tighten the screws.

Note. If the edges of rubber packing are folded toward the inside, straighten it with a screwdriver.

Scheme 166

Install the evaporation pipe.

Scheme 167

Connect the evaporation hoses to fuel pipes.

Scheme 168

Insert the fuel filler hose (A) approximately 35 to 40 mm (1.38 to 1.57 in) over the lower end of fuel filler pipe and tighten the clamp.

Insert the evaporation hose (B) approximately 25 to 30 mm (0.98 to 1.18 in) into the lower end of evaporation pipe and hold the clip.

Scheme 169

L = 27.5+/-2.5 mm (1.083+/-0.098 in)

Scheme 170

1. Hose
2. Clip
3. Pipe

Tighten the bolt which holds the fuel filler pipe bracket on the body.

Tightening torque

7.5 Nm (0.75 kgf-m, 5.4 ft-lb)

Scheme 171

Secure the evaporation hose to clip of fuel filler pipe.

Scheme 172

Install the fuel filler pipe protector.

Scheme 173

Install the rear right wheel.

Scheme 174

Lower the vehicle.

Tighten the wheel nuts.

Connect the connector to the fuel pump relay.

Scheme 175

Connect the battery ground cable to battery.

Scheme 176

Note. The fuel pump assembly consists of a fuel pump and a fuel level sensor.

Release the fuel pressure.

Open the fuel filler flap lid and remove the fuel filler cap.

Disconnect the ground cable from battery.

Lift up the vehicle.

Drain the fuel from the fuel tank.

Raise the rear seat and turn the floor mat up.

Remove the access hole cover.

Scheme 177

Disconnect the connector from fuel pump.

Scheme 178

Disconnect the quick connector and then disconnect the fuel delivery hose and return hose.

Move the clip and then disconnect the jet pump hose (A).

Scheme 179

Remove the nuts which install the fuel pump assembly onto the fuel tank.

Scheme 180

Take off the fuel pump assembly from the fuel tank.

Install in the reverse order of removal. Do the following

Note. Replace the gaskets with new ones.

1. Ensure the sealing portion is free from fuel or foreign particles before installation.
2. Tighten the nuts in alphabetical sequence shown in figure to specified torque.

Tightening torque

4.4 Nm (0.45 kgf-m, 3.3 ft-lb)

Scheme 181

Note. Fuel level sensor is built in fuel pump assembly.

Remove the fuel pump assembly.

Disconnect the connector from the fuel pump bracket.

Scheme 182

Remove the fuel temperature sensor.

Scheme 183

Remove the bolt which installs the fuel level sensor on mounting bracket.

Scheme 184

Install in the reverse order of removal.

Disconnect the ground cable from battery.

Scheme 185

Lift up the vehicle.

Drain the fuel from the fuel tank.

Remove the rear seat.

Remove the service hole cover.

Scheme 186

Disconnect the connector from the fuel sub level sensor.

Disconnect the fuel jet pump hose.

Scheme 187

Remove the bolts which install the fuel sub level sensor on the fuel tank.

Scheme 188

Remove the fuel sub level sensor.

Scheme 189

Install in the reverse order of removal.

Note. Use a new gasket.

Scheme 190

1. Ensure the sealing portion is free from fuel or foreign particles before installation.
2. Tighten the nuts and bolts to specified torque in the order as shown in the figure. Tightening torque: 4.4 Nm (0.45 kgf-m, 3.3 ft-lb)

Note. Fuel filter is built into the fuel pump assembly.

Release the fuel pressure.

Remove the fuel pump assembly.

Remove the fuel pump.

Separate the fuel filter from fuel pump.

Scheme 191

1. Fuel filter
2. Fuel pump

Turn the filter holder around to the arrow direction, and then remove the filter.

Scheme 192

Install in the reverse order of removal.

Remove the fuel tank.

Remove the protect cover.

Scheme 193

Move the clip and disconnect the evaporation hose from fuel cut valve.

Scheme 194

Remove the bolts which install the fuel cut valve.

Install in the reverse order of removal.

Tightening torque

4.4 Nm (0.45 kgf-m, 3.3 ft-lb)

Scheme 195

Release the fuel pressure.

Remove the fuel damper valve from the fuel delivery line and fuel return line.

Scheme 196

Install in the reverse order of removal.

Tightening torque

1.25 Nm (0.13 kgf-m, 0.94 ft-lb)

Set the vehicle on a lift.

Release the fuel pressure.

Open the fuel filler flap lid and remove the fuel filler cap.

Remove the floor mat.

Remove the fuel delivery pipes and hoses, fuel return pipes and hoses, evaporation pipes and hoses.

Scheme 197

In engine compartment, detach the fuel delivery hoses, return hoses and evaporation hose.

Separate the quick connectors of fuel delivery line and return line by pushing the ST to the direction of arrow.

ST 32005086 CONNECTOR REMOVER

Remove the clip, and separate the evaporation hose from pipe.

Scheme 198

Lift up the vehicle.

Separate the quick connector on fuel line.

Clean the pipe and connector, if they are covered with dust.

To prevent from damaging or entering foreign matter, wrap the pipes and connectors with plastic bag, etc.

Scheme 199

Hold the connector (A) and push retainer (B) down.

Pull out the connector (A) from retainer (B).

Scheme 200

1. Connector
2. Retainer
3. Pipe

Connect the quick connector on fuel line.

Scheme 201

Set the new retainer (B) to connector (A).

Push the pipe into the connector completely.

Note. At this time, two clicking sounds are heard.

Scheme 202

1. Connector
2. Retainer
3. Pipe

Scheme 203

1. Connector
2. Retainer
3. Pipe

Connect the fuel delivery hose to the pipe with an overlap of 20 to 25 mm (0.79 to 0.98 in).

Type A: When the fitting length is specified.

Type B: When the fitting length is not specified.

liters: 2.5+/-1.5 mm (0.098+/-0.059 in)

L: 22.5+/-2.5 mm (0.886+/-0.098 in)

Scheme 204

1. Type A
2. Type B
3. Pipe
4. Clamp
5. Hose

Connect the return hose and evaporation hose to pipe by approx. 15 mm (0.59 in) from the hose end.

Fuel return hose

L = 22.5+/-2.5 mm (0.885+/-0.098 in)

Fuel evaporation hose

L = 17.5+/-2.5 mm (0.689+/-0.098 in)

Scheme 205

1. Hose
2. Clip
3. Pipe