Saab 9-3ss Fuel Tank R&amp R

2. Engine\Fuel system Adjustment/Replacement - Fuel ...
Fuel tank
Warning
Removal of the fuel tank involves partial dismantling

of the car's fuel system. The following points must
therefore be observed in connection with this work.
• Have a class BE fire extinguisher on hand! Be
aware of the risk of sparks, i.e. in connection with
electric circuits, short-circuiting, etc.
• Absolutely No Smoking!
• Ensure good ventilation! If there is approved

ventilation for evacuating fuel fumes then this must
be used.
• Wear protective gloves! Prolonged exposure of the

hands to fuel can cause irritation to the skin.
• Wear protective goggles.
Important
Be particulary observant regardning cleanliness when

working on the fuel system. Loss of function may occur
due to very small particles. Prevent dirt and grime from
entering the fuel system by cleaning the connections and
plugging pipes and lines during disassembly. Use 82 92
948 Plugs, A/C system assembly. Keep components free
from contaminants during storage.
To remove
1.
Reduce the fuel pressure by removing fuse 2 when the engine is running (fuse 2 is in
the electrical box in front of the battery). When the engine has stopped, turn the
ignition key to LOCK and refit the fuse.
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2. Drain the fuel tank. See Emptying the fuel tank. Remove the tank cap.
3. Place the car on a lift.
4. Raise the car.
5. Remove the right rear wheel.
6.
Remove the bolts and nuts to the wing liner.
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7. Release the wing liner from the stud bolts.
8.
Release the wing liner from the liner edge starting at the back. Then release the
entire liner edge. Remove the wing liner.
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9. Release the rear spoiler shield. CV: Remove Chassis reinforcement, centre tunnel,
CV and Chassis reinforcement, rear support frame, CV, right side.
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10. Remove the rubber mounts and carefully lower the exhaust system, fasten with 83
95 212 Strap .
11.
Separate the fuel connections and vent connections at the carbon canister. Catch
any spilt fuel.
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12. Seal the connections to the outlet line from the fuel pump.
13. Separate and remove the connector at the evaporative emission canister.
14.
Detach the hose between the filler pipe and tank, and separate the fast coupling on
the vent.
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15. Place a single-support lift under the tank, remove the tank straps and fuel tank. Be
careful when removing the tank, ensure that no components or connections are
damaged.
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To fit
1. Remove the filler pipe and change the connection hose between the tank and the
filler pipe.
2. Use Vaseline to lubricate the filler pipe connection to the filler cap opening.
3. Fit the filler pipe and tighten the bolts. Check the rubber seal in the filler cap
opening, and adjust if necessary.
4. Raise the tank and refit the tank straps.
Tightening torque 25 Nm (18 lbf ft).

5.
Connect the fuel filler pipe hose and tighten the clamp.
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Tightening torque 4 Nm (3 lbf ft)

6. Tighten the bolt on the fuel filler tube.
Tightening torque 25 Nm (18 lbf ft).

7. Connect vent hose.
8.
Attach the connector to the evaporative emission canister.
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9. Connect the vent and fuel lines.
10.
Fold in the wing liner. Press the lower liner edge against the wheelarch. Guide the
liner onto the upper stud bolts. Then fit onto the other stud bolts.
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11. Fit the wing liner to the liner edge and bumper cavity. The wing liner should lie
behind the bumper cavity.
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12. Check the fit of the wing liner.
13. Attach the rear spoiler shield.
14.
Refit all bolts and nuts.
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15. Fit Wheel.
16.
Fit the rubber mounts and exhaust system. CV: Fit Chassis reinforcement, rear
support frame, CV right side and Chassis reinforcement, centre tunnel, CV, .
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17. Lower the car.
18. Fill with petrol of the correct octane rating, and fit the filler cap.
19. Connect and exhaust extractor and start the engine for function test.
9-3 (9440) 4 2004 14

Saab 9-3ss Fuel Tank R&amp R

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2. Engine\Fuel system Adjustment/Replacement - Fuel ...

Removal of the fuel tank involves partial dismantling

• Ensure good ventilation! If there is approved

• Wear protective gloves! Prolonged exposure of the

• Wear protective goggles.

Be particulary observant regardning cleanliness when

9-3 (9440) 4 2004 1

3. Place the car on a lift.

4. Raise the car.

5. Remove the right rear wheel.

Remove the bolts and nuts to the wing liner.

9-3 (9440) 4 2004 2

7. Release the wing liner from the stud bolts.

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4. Raise the tank and refit the tank straps.

Tightening torque 25 Nm (18 lbf ft).

9-3 (9440) 4 2004 8

Tightening torque 4 Nm (3 lbf ft)

Tightening torque 25 Nm (18 lbf ft).

Attach the connector to the evaporative emission canister.

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9. Connect the vent and fuel lines.

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12. Check the fit of the wing liner.

13. Attach the rear spoiler shield.

Refit all bolts and nuts.

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15. Fit Wheel.

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17. Lower the car.

9-3 (9440) 4 2004 14

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