intake pump installation of the Bosch 040

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kid nismo
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intake pump installation of the Bosch 040

Post by kid nismo » Wed Oct 21, 2009 9:57 pm

What you will need:

*phillips screw driver
*2x ring terminals = 6.3mm and 5.3mm
*m5 and m6 bolts
*solder iron

First thing, disconnect the battery.

unplug the fuel pump connection, which is located near the fuel pump.
fuelpumpconnection.jpg
then proceed with removal of all the nuts you can see. There should be a total of 2 lids to remove. Once this is done, it should look like this. note to take extreme care when taking out the fuel pump. all you need to do is jiggle it out. hard force may lead to a spark, and it's anyones guess as to what can happen. :shock:
originalfuelpump.jpg
remove the pump and 2 lids (do not dismantle) to a different location away from the petrol fumes.
Last edited by kid nismo on Wed Oct 21, 2009 10:06 pm, edited 2 times in total.

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kid nismo
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Joined: Wed Apr 11, 2007 8:58 pm
Location: Sydney

Post by kid nismo » Wed Oct 21, 2009 10:02 pm

now remove the bracket by removing the bolts and also remove the fuel hose.
bracketbolts.jpg
you will need to change the standard ring terminal to 6.3mm and 5.3mm. M5 and M6 bolts are required to secure the terminals.

I choose to solder the new terminal on. (remeber i am as far as possible from the car so that i wont ignite the petrol fumes).

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kid nismo
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Joined: Wed Apr 11, 2007 8:58 pm
Location: Sydney

Post by kid nismo » Wed Oct 21, 2009 10:13 pm

Then fit the Bosch 040 pump into the craddle.

Please note I have used both the original rubber supports. this will aid in a quiter operation as it will absorb some of the harsh vibration from the pump operation and also add extra support.

also when installing the pump, be sure to push it down as far possible, so that the pump sit under the support as circled in the pic. lower the pump sits, the better the fuel pick up is when the fuel is running low. I have disregarded the stock fuel filter as it would not fit.

(pic is of the fuel pump that needs to be pushed down lower) :wink:
fuelpumpunderbracket1.jpg

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kid nismo
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Location: Sydney

Post by kid nismo » Wed Oct 21, 2009 10:19 pm

more pics and guide to come. :D

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Callumgw
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Joined: Fri Aug 11, 2006 12:55 pm
Location: Melbourne, Australia

Post by Callumgw » Thu Oct 22, 2009 6:03 am

so far

8)

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