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Saab: 1992 Saab 900, non-turbo, 5 spd, plastic soda bottle, tank c


Question
QUESTION: The system asked for a new ? So, how do I fix my Saab. I ck'd the fuel at the tank, the pump outlet. But, I haven't ck'd the filter. Where is it?

ANSWER: Hugh:
 Sorry, but I goofed...there is no external filter on your model. However, you can check fuel delivery AT the injector manifold as follows:

a. Remove the hose [coming out the bottom]from the pressure regulator. Be CAREFUL inasmuch some fuel under pressure may come out.
b. Connect a length of fuel line to the regulator and lead it into a secure container such as a plastic soda bottle.[The regulator is a cylindrical canister mounted to the driver side of the head, opposite the lifting eye. It has 3 hose connections, one to the intake manifold for vacuum, one to the fuel manifold, and one going out the bottom for excess fuel return; this last one is the one to connect to.]

c. Energize the pump for exactly 10 seconds

d. The fuel collected should be a minimum of 10 ounces.

  If NOT, then a. Check system pressure (35 psi)
         
         b. Possible clogged filter (within the fuel tank)

         c. Worn out pump

  If YES, then you'll need to check that the fuel injectors are firing...that's a whole new 'ball game' so let's go step by step.

---------- FOLLOW-UP ----------

QUESTION: Took a break. previously, got the pump to run but no gas pressure. yesterday I reviewed my jumper setup,think I had the pins reversed(I'm old, what can I say). So, went to start the car and...wait, wait.. the ignition tumbler gives out. Got the tumbler out. The flange that reaches into the tumbler sheared off. Can the thing(what's it called?) between the tumbler and the switch(swivels in the shift housing), be replaced? I've already got disassembly down to needing special tool 87 90 370 to remv shift housing. Should I make this tool or can I buy it? Or do you have a different idea?

ANSWER: Hugh:
  No problem; I have seen this before and have an easy remedy! First, to remove the switch housing, you can easily make a tool to loosen the three-cornered nuts by hacksawing slots in a piece of pipe OR a disposible (cheap, so the metal is not hardened) socket such that you have a three cornered  castle (as in a chesspiece) that fits around the nuts in question.
  Second, if the broken piece is, as I suspect, a shaft with the  flange broken off, which itself is attached to a  quadrant of gear teeth, then I have several such and can readily send you one if you wish. It comes out easily.
  Hope this helps,
         Jerry

---------- FOLLOW-UP ----------

QUESTION: I got the shift housing out of the car. Your description of the "quadrant" sounds accurate. I do need one. But, I don't see how to get it out of the housing. To be clear, this is the device that the key tumbler turns.

Answer
Hugh:
 To get the broken part out, you will need to remove another geared arm that in turn controls the reverse lock out lever. I simply hit its shaft with a hammer and the circular clip holding it falls away. You can then rotate the broken part clear of the housing overhang and remove it. I never re-install the reverse lockout mechanism since its failure-prone and with an older car.....who is going to steal?????
 Chances are that the little tab at the end of the "gear quadrant shaft" has broken off. I have braze welded new tabs on sucessfully.

         Making progress........

         Jerry