(234-2641 utg.2) Replacing the fuel pump
Symptom: Noise from the fuel pump
The fuel pump does not work
Misleading fuel gauge
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MODIFICATION INSTRUCTION
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Bulletin Nbr:
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234-2641 utg.2
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Date:
...........
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Juni 2007
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Market:
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enl. separat lista
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Customer Satisfaction Program 154 50
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Cars in stock must be rectified before delivery.
A personal communication must be sent to the owners of cars already delivered requesting them to get in touch with the nearest Saab garage as soon as possible to have the fault rectified.
Saab 9-5 within Vehicle Identification Number range 53532761 - 63523755 with engine alternative B205E in the BioPower version
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Note
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Some cars within the Vehicle Identification Number range are not affected. See separate information for the Vehicle Identification Numbers affected.
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The fuel pump's brush can, in certain driving conditions, be worn out prematurely which results in noise or the pump not working.
Due to process problems the fuel pump connector may be damaged by water. This could result in corrosion in the connector as well as a misleading fuel gauge.
Symptom description
Noise from the fuel pump
The fuel pump does not work
Misleading fuel gauge
12 775 809 Fuel pump
22 672 293 Seal
Contact Protect CRC (www.crcindustries.com) or Contact 61 or similar
12 800 301 Foam block
11 900 515 Cable tie (3 per car)
Insulating tape
In the event of corrosion in the fuel pump connector (estimated defective production issue 1%):
12 762 664 Wiring harness
For fitting the modification identity plate:
12 785 148 Modification identity plate
93 160 907 Cleaning agent Motip Dupli, aerosol 400 ml (sufficient for 50-100 cars)
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Checking the modification identity plate
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Before proceeding, check box A4 of the modification identity plate. From and including M04 the car's Warranty and Service Book contains the "Table of Modifications". A modification identity plate must be fitted in accordance with the section "Fitting the modification identity plate" where local directives require the marking of the car. If the box is not marked, continue as follows.
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1.
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Remove the fuel pump in accordance with WIS - 9-5 - Engine - Fuel system, petrol - Adjustment/Replacement - Fuel pump, US (also E85).
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2.
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Cut off and remove the 3 cable ties. Note down how the cable ties are positioned on the wiring harness.
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3.
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Fit new cable ties in the same positions (A), (B) on the wiring harness.
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4.
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Fit cable tie (C) in the same position as the original one but turn it 180 degrees. The harness must be positioned under all fixing points.
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5.
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Tape the excess wiring harness (D) in along the wiring harness, start taping from the right-hand side of the front cable tie (A) and continue to tape the whole way to the attachment (E) of the wiring harness to the floor.
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Note
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Do not tape the pin into the cable tie (B).
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6.
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Clean the surface where the foam block (F) shall be fitted.
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7.
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Fit the wiring harness cable ties (A), (B) and (C) to the mountings in the body.
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8.
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Fit the foam block (F) along the cavity and align the block against the wiring harness at the top edge.
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9.
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Fit the fuel pump in accordance with WIS - 9-5 - Engine - Fuel system, petrol - Adjustment/Replacement - Fuel pump, US (also E85).
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Note
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To prevent the fuel gauge from sticking and showing incorrect values:
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-
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Ensure that the bleed hose (A) in the tank is connected to connection (B) on the fuel pump.
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-
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Ensure that the pump is in the right position according to the following.
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•
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retainers (C) are in the right position in relation to the cut-out (D).
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•
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the fuel pump's connector (E) is in line with the rear long side of the tank.
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Marking the modification identity plate
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After carrying out the procedure, mark box A4 on the modification identity plate. From and including M04 the car's Warranty and Service Book contains the "Table of Modifications". Mark the box with the number "7" if the procedure was carried out by the importer or with the number "8" if carried out by the dealer.
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Fitting the modification identity plate
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Note
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A modification identity plate must only be fitted where local directives require the marking of the car.
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Fit the modification identity plate in accordance with WIS
9-5 M04 - General - General - Technical data - Plates and labels
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Warranty/Time Information
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See separate information.
