1. Introduction
This manual provides essential information for the installation, operation, and maintenance of the Bosch 67166 Fuel Pump Module Assembly. This state-of-the-art turbine fuel pump is designed to offer reliable performance, near silent operation, and improved drivability for your vehicle. Its core components are engineered to significantly reduce wear, contributing to a longer service life. The Bosch 67166 is designed for a precise fit, being nearly identical in dimension and appearance to the original units it replaces.
Figure 1: Bosch 67166 Fuel Pump Module Assembly, side view.
2. Important Safety Information
Always observe the following safety precautions when working on your vehicle's fuel system:
- Disconnect the vehicle's battery before beginning any work to prevent electrical hazards.
- Wear appropriate personal protective equipment, including safety glasses and gloves.
- Ensure adequate ventilation in your work area. Fuel vapors are flammable and hazardous.
- Keep open flames, sparks, and other ignition sources away from the work area.
- Relieve fuel system pressure before disconnecting any fuel lines. Refer to your vehicle's service manual for specific procedures.
- Handle fuel with extreme care. Clean up any spills immediately.
- Dispose of old fuel and components according to local environmental regulations.
3. Package Contents
Verify that all components are present and undamaged before proceeding with installation:
- Bosch 67166 Fuel Pump Module Assembly
- Fuel Strainer (pre-installed or included separately)
- Application-specific installation instructions (may be included with the product or available online)
4. Specifications
Key specifications for the Bosch 67166 Fuel Pump Module Assembly:
| Feature | Specification |
|---|---|
| Brand | Bosch |
| Model Number | 67166 |
| Product Dimensions (L x W x H) | 50.29 x 20.57 x 15.49 cm (19.8 x 8.1 x 6.1 inches) |
| Item Weight | 1.27 kg (2.8 lbs) |
| Material | Alloy Steel (Body) |
| Fit Type | Vehicle Specific Fit (2000-03 Ford Taurus) |
| Lift Type | Electric |
| OEM Part Number | YF1Z9H307EG |
| Specification Met | OE (Original Equipment) |
Figure 2: Superior Turbine Pump Design - Internal components for optimal performance and durability.
Figure 3: OE Product Specification requirements for Bosch Premium Fuel Pumps.
5. Installation Instructions
5.1 Pre-Installation Checklist
Before starting the installation, ensure you have the following:
- Appropriate tools for fuel tank removal and fuel line disconnection.
- New fuel tank gasket/seal (recommended for replacement).
- Clean rags and a suitable container for draining fuel.
- Fire extinguisher nearby.
- Access to your vehicle's specific service manual for detailed steps.
5.2 General Installation Guidance
Replacing a fuel pump module assembly is a complex procedure that typically requires specialized tools and automotive knowledge. It is highly recommended that installation be performed by a qualified automotive technician. If you choose to perform the installation yourself, carefully follow the vehicle-specific, illustrated step-by-step instructions provided with the Bosch fuel pump or refer to your vehicle's official service manual.
The Bosch 67166 Fuel Pump Module Assembly is designed as a direct, plug-and-play replacement, ensuring an exact fit and simplifying the installation process when compared to universal alternatives.
Figure 4: Bosch 67166 Fuel Pump Module Assembly, ready for installation.
6. Operation
The Bosch 67166 Fuel Pump Module Assembly utilizes advanced turbine pump technology. This design offers several operational advantages:
- Near Silent Operation: The turbine design virtually eliminates the fuel pulsation and noise often associated with older roller-cell and inner-gear pump designs, contributing to a quieter driving experience.
- Improved Drivability: Consistent fuel delivery and pressure contribute to smoother engine performance and enhanced vehicle response.
- Optimal Performance: Engineered to operate reliably in extreme temperatures and under low fuel conditions, ensuring consistent fuel supply when needed most.
- Extended Service Life: The robust design and quality materials significantly reduce wear on internal components, leading to a longer operational lifespan for the pump.
7. Maintenance
The Bosch 67166 Fuel Pump Module Assembly is designed for long-term reliability with minimal maintenance. However, proper fuel system hygiene is crucial for its longevity:
- Fuel Strainer: The included fuel strainer is critical for preventing contaminants from entering the pump, which is a primary cause of pump failure. Ensure the strainer is properly installed and consider inspecting it during major fuel system service.
- Fuel Quality: Always use high-quality, clean fuel. Contaminated fuel can clog the strainer and damage the pump.
- Fuel Filter: Regularly replace your vehicle's in-line fuel filter (if applicable) according to the manufacturer's recommendations to protect the entire fuel system, including the pump.
- Avoid Running on Low Fuel: While the pump is designed to operate under low fuel conditions, consistently running the fuel tank near empty can expose the pump to higher temperatures and potentially shorten its lifespan.
8. Troubleshooting
If you experience issues after installation or during vehicle operation, consider the following common troubleshooting steps. For complex issues, consult a qualified automotive technician.
| Symptom | Possible Cause | Action |
|---|---|---|
| Engine cranks but won't start | No fuel pressure, electrical issue, clogged fuel filter | Check fuel pump fuse/relay. Verify electrical connections to the pump. Check fuel pressure at the rail. Inspect fuel filter. |
| Engine misfires or runs rough | Inconsistent fuel pressure, contaminated fuel, clogged injectors | Check fuel pressure. Inspect fuel for contaminants. Consider fuel system cleaner or injector service. |
| Whining noise from fuel tank | Fuel pump working harder than usual, low fuel level, clogged strainer | Ensure adequate fuel level. Inspect fuel strainer for clogs. |
| Fuel gauge inaccurate | Fuel level sender issue (part of module assembly) | Verify electrical connection to the sender. If new pump, ensure float arm moves freely. |
9. Warranty Information
Bosch Fuel Pumps are backed by a Limited Lifetime Warranty. This warranty covers defects in materials and workmanship under normal use and service. For specific terms, conditions, and claim procedures, please refer to the official Bosch warranty documentation provided with your product or visit the official Bosch Automotive Aftermarket website.
10. Customer Support
For further assistance, technical support, or inquiries regarding the Bosch 67166 Fuel Pump Module Assembly, please contact Bosch customer service. You can typically find contact information on the official Bosch website or through the retailer where the product was purchased.
Online Resources: Visit the official Bosch Automotive Aftermarket website for product information, technical bulletins, and frequently asked questions.
