That sucks man, at least you have the parts on the way and know what you're in for. Rain is not a fun thing to work in, even if you do have the roof over you in this case.

 

I did the exact same thing last year in the snow in front of my house, car died right in the middle of the street, I just put it in reverse and cranked the engine over to move it back into its spot. Before you even THINK of pulling the fuel lines off the top of the pump just remember they are VERY fragile and if you break one you will be kicking yourself cause it will delay you again, IF you break one here is the link for the Return Line eEuroparts - Fuel Pump Return Valve Kit - # 4161766RV and the Supply Line eEuroparts - Fuel Pump Check Valve Kit (Feed Valve) - # 4161766A

Just be careful when you pull them out, dont rush it and it should be ok, oh and FWIW go buy a can of expanding house foam and spray around the tank between the tank and steel from inside to seal the hole that you have cut from the outside, I didnt want to take any chances with water getting in somehow. Also if you break a fitting you cant just push the new one over the old hose, its very hard pvc stuff and wont budge, I went out and bought a small length of aluminum tubing that was slightly smaller than the line and a bit of rubber hose to go from the check valve to the rubber line to aluminum line to PVC line, just check for leaks very well, had to tighten mine alot on the pvc side.

 

I would go ahead and buy one of these ... (Fuel line return clip). I think the clips will almost always break and I didn't have any tools to make my own, so I used an soda can. It worked to move the car around but was obviously not a permanent solution.

 

I'll trade you a set of turbo x wheels for your broken viggen.

 

So the Viggen is going to have a large hole in the floor.... nice. *

It's not hard to remove the tank you realize - then again this is a rust belt car, so it could prove more challenging then I'd expect. I still doubt it would take you much longer to do correctly compared to cutting a hole in your car..... Good Luck!

 

That is the same exact reason I didnt drop my tank, one look at my straps and one attempt at loosening the nut, watching the strap itself twist with a horrific crunching sound made me rethink that approach. For me cutting a hole in my floor took all of about 20 mins, the hardest part was trimming and refitting the carpet.

 

Am I missing something? My Viggen already has an access port for the fuel pump under the back seat.

 

Port hole - it's for looking through and un-plugging wires - that's all.

 

No it doesn't.

 

Yep I stand corrected. A magnificent hole it is. While the pump is right next to it, they may as well have port-holed that as well.

 

The hole has been cut... I did a pretty good job at making it a pretty looking hole at least! haha. I just bought the flat stock steel tonight to make the special tool. I have all of the little parts and pieces so I should be set to go on Wednesday when the pump comes in.

The funny thing though, after cutting the hole, I decided to try turning the key for shits and giggles to see if I could hear the pump kick on... Sure enough, my jarring around while cutting the hole must have shocked the fuel pump back into life temporarily because it primed and started right up. Either way, doing it before Carlisle as I don't feel like getting stranded in PA. Hopefully nothing breaks in the process of the swap. Wish me luck!

Also, as for the hole cutting vs tank dropping... I just did what Saab should have done from the factory. Every other Saab had an access hole for the fuel pump, what's the difference of who put it there? It'll save a lot of hassle in the future if I ever have problems again, and I don't really plan on selling the car anytime soon. It's not a visible hole and my seats have only been lifted up ONCE in my ownership prior to this, and that was to install my wiring harness for my sub. I'd much rather do this from the top than struggle with straps, exhaust, and a tank full of gasoline all while working on my back on the ground in the pouring rain. Yep, much rather take the hole in the floor route.

 

I did this on my '96. Didn't really care how it looked because when is your back seat ever up? Nothing ever came in either. And saved a bunch of time. I also had about 3/4 of a tank of gas in there and did not want to deal with lowering that and getting it back up.

 

I agree with Just cutting the hole. I replaced my fuel pump with a used one I had about 10k ago and it shit the bed last week. I bought a new one and had it installed in about 30min. Would've taken way longer to drop the tank. Might not of had to if I didn't put in a used one but I was in a jam and had it so it worked at the time.

 

Got the pump out tonight after work. Took it all apart, pushed in the brass fitting into the plastic line, attached the submersible hose to that, and am now just waiting for UPS to deliver the pump and pigtail (tomorrow). This has to be the closest deadline for anyone prior to Carlisle. I have to be on the road Thursday morning for 8am. I work tomorrow til 5p. Hopefully everything goes back together without a hitch.

And I FOUGHT with the damn retainer ring that holds the pump into the tank. I made the special tool out of flat stock and was bending the shit out of it. I ended up using a flat head screw driver, a hammer and vise grips lol. Took a good 30 minutes to remove the damn thing in one piece. And getting the pump out of the tank is a damn puzzle of twisting around without bending the float arm.

 

And yes, the brass is in there, but I used 5/16" fuel line unions from the parts store, cut them and then pushed it into the plastic hose with a heat gun and boiling water in a cup... The submersible hose did not fit snug over the unions, so I actually pushed the hose over the middle part of the union (larger than the hose), and then pushed the hose over the plastic line and used a fuel injection clamp on it... It'll actually have a better seal I think than than if the hose was on the barbs.

 

Nice - I've seen this job hacked up so many times before. I still don't understand why the 9-3 did not have this from the facotory, nor do I understand why the 2006-2009 9-5's have the hole and they re-fitted a more expensive pump and tank which made it like the OG9-3 car's - a hole to nothing...

Nice choice on the clamp btw - those seem to hold much nicer over time. I still like doing these the old fashion way w/out any fuel hose - just the OEM plastic line to the new pump (which would have a barb on it).

So I assume it's all back together and running then?

 

Waiting for the pump to arrive still. It will be here today after work.

 

Nice - hope it shows up - otherwise you may have to drive the Sonett to Carlisle

 

It's ALIVE!!!!!