[s-cars] Bosch 091G Fuel pump install results.

[Dave Forgie]

Good news - bad news - kind of good news

The good news:  The Bosch 091 G (OEM spec) pump is in.  What a "Chinese"
puzzle to get all the hoses and the fuel sender oriented so that the
wire float arm won't get hung up! I didn't pay enough attention to
exactly how the the high pressure hose was oriented on the bottom of the
fuel pressure sender when I disassembed it. As a result, I had to "dry"
fit the sender and figure out where the hoses had to go a couple of
times before I actually attached the hoses to the bottom of the sender
plate. Even then it was fun keeping the top hoses out of the way while
pushing the internal hose to the "north" side of the plastic sender arm
AND lowering and jostling the sender assembly down onto the magic O-ring
landing spot.  I am guessing that the reason people have problems with
their fuel level senders after replacing their fuel pumps is the hose
from the pump to the sender plate is on the "south" side of the plastice
sender arm rather than the "north" side (which keeps it away from the
wire float arm).  I can truely see why I was charged 5 hours labour when
the original pump failed 2 years ago (on a road trip) and I had to have
the work done at a stealership.  The job is a pain in the @ss.
Hopefully, I won't have to repeat it anytime soon.

The BAD news:  On a short test drive, I still got some pinging
(Grrrrrr...) on initial WOT (I was in third gear, in  the left lane up
against some "No Post" concrete barriers, with the window down, so I
could hear pretty good.).  Seemed not as bad as before but it was still
there.  I am not going to admit defeat quite yet.  I will give the ECU a
bit of time to adapt.  If there is no improvement,  I don't know exactly
what I will do.  The quick (easy) answer is less aggressive software.
The hard work answers include looking for kinks in the fuel line as a
result of the original fuel line replacement work and/or adding a Bosch
044 in-line between the 091G and the fuel rail.  I ain't goin' back in
that fuel tank again any time soon if I can help it.

Kind of good news:  Because the trunk was empty and I am down to about
18 L in the tank, the car was rather quick.  I couple of times I had to
get on the brakes real quick (BIRA System 1) because I either came up on
traffic or there was a red light.  I actually got the ABS to come on on
dry pavement - mind you I still have my snow tires (Pirelli Wintersport
210s) on.  Since there is little or no chance that Vancouver is going to
get any snow and the snow at Whistler isn't worth the drive, the winter
tires are coming off in the next hour.  I just wanted to post this and
let the rotors (and wheels) cool off first.

Dave F.