BOSCH 67791 Original Equipment Fuel Pump Module Assembly

Introduction

This manual provides detailed instructions for the installation, operation, and maintenance of your BOSCH 67791 Original Equipment Fuel Pump Module Assembly. Designed for select Hummer H3 and H3T models, this fuel pump ensures perfect fit and superior performance, utilizing innovative Turbine Pump technology to virtually eliminate fuel pulsation, noise, and hot-start problems. Each unit is factory-tested to guarantee the highest quality and reliable performance.

• Original Equipment: Engineered to match the fuel pumps vehicles were built with, ensuring perfect fit and superb performance.
• Innovative Technology: Features patented Turbine Pump technology for reduced fuel pulsation, noise, and hot-start issues.
• Optimal Performance: Designed for reliable operation in extreme temperatures and low fuel conditions, extending service life.
• Factory Tested: Every unit undergoes end-of-line function testing for maximum customer satisfaction.
• Ready to Install: Includes instructions and a fuel strainer to prevent premature pump failure from dirt and debris.

Safety First

Always prioritize safety when working with fuel systems. Fuel vapors are highly flammable and can cause serious injury or death.

• Ensure a fire extinguisher is readily available.
• Never smoke or work near open flames, sparks, or anything that could ignite fuel.
• Always wear appropriate personal protective equipment, including safety glasses and gloves.
• Work in a well-ventilated area to prevent the buildup of fuel vapors.
• Keep clean-up materials on hand and immediately clean any fuel spills.
• Always relieve fuel system pressure before opening any fuel lines or components.
• Store fuel in an approved, sealed container.
• Disconnect the vehicle's battery negative terminal before starting any work to prevent electrical short circuits.

Installation Guide

This section outlines the general steps for replacing the fuel pump module assembly. Specific vehicle procedures may vary. Refer to your vehicle's service manual for precise instructions.

1. Pre-Installation Steps

1. Ensure the vehicle is parked on a level surface and the engine is cool.
2. Disconnect the negative terminal of the vehicle's battery.
3. Relieve fuel system pressure. Consult your vehicle's service manual for the correct procedure.
4. Access the fuel pump module. This typically involves removing the rear seat to expose the fuel tank access panel.

2. Removal of Old Fuel Pump Assembly

1. Carefully remove any covers or bolts securing the fuel tank access panel.
2. Disconnect the electrical connector and fuel lines from the old fuel pump module. Be prepared for residual fuel.
3. Use a specialized tool to loosen and remove the retaining ring that secures the fuel pump module to the fuel tank.
4. Carefully lift the old fuel pump module out of the fuel tank, ensuring the float arm does not get snagged.

3. Installation of New BOSCH 67791 Fuel Pump Assembly

Before installing, compare the new BOSCH 67791 unit with the old one to ensure they match OEM specifications.

Image: The BOSCH 67791 Original Equipment Fuel Pump Module Assembly, ready for installation.

1. Carefully insert the new BOSCH 67791 fuel pump module into the fuel tank, aligning it with the fuel tank slot. Ensure the float arm moves freely.
2. Install the new sealing gasket (if provided) and then the retaining ring. Tighten the retaining ring by hand first, then use the specialized tool to secure it, but do not overtighten.
3. Reconnect the fuel lines and the electrical connector to the new fuel pump module. Ensure all connections are secure and make good contact.
4. Replace the fuel tank access panel and secure it with its bolts.

4. Post-Installation Check

1. Reconnect the negative battery terminal.
2. Turn the ignition key to the 'ON' position (without starting the engine) for a few seconds to allow the fuel pump to prime the system. Repeat this a few times.
3. Check for any fuel leaks at the connectors and around the fuel pump module. Inspect all seals.
4. Start the engine and observe its operation. Listen for any abnormal noises and check the fuel gauge reading.

Installation Videos

Operating Instructions

The BOSCH 67791 Fuel Pump Module Assembly operates automatically as part of your vehicle's fuel system. Once correctly installed, it will deliver fuel from the tank to the engine at the required pressure. No specific user interaction is needed beyond ensuring adequate fuel levels in the tank.

• Ensure your fuel tank always has sufficient fuel to prevent the pump from running dry, which can cause damage.
• Monitor your vehicle's fuel gauge for accurate readings, indicating proper function of the fuel sending unit.

Maintenance

The BOSCH 67791 Fuel Pump Module Assembly is designed for long-term reliability with minimal maintenance. The integrated fuel strainer helps protect the pump from contaminants.

• Regularly check your vehicle's fuel filter (if separate) and replace it according to your vehicle manufacturer's recommendations.
• Avoid consistently running your fuel tank to empty, as this can put additional strain on the fuel pump and reduce its lifespan.
• If you notice any changes in engine performance, fuel efficiency, or unusual noises from the fuel tank area, have your fuel system inspected by a qualified technician.

Troubleshooting

If you experience issues after installation or during normal operation, consider the following common troubleshooting steps:

• Engine Cranks but Won't Start: Check for proper electrical connection to the fuel pump. Verify fuel pressure at the engine. Ensure there is fuel in the tank.
• Engine Misfires or Stalls: This could indicate inconsistent fuel delivery. Check for proper fuel pressure and flow.
• Whining Noise from Fuel Tank: A loud whining noise may indicate a failing fuel pump or a clogged fuel strainer/filter.
• Inaccurate Fuel Gauge: This suggests an issue with the fuel sending unit. Ensure the float arm is correctly installed and moves freely.
• Fuel Leaks: Immediately address any fuel leaks. Recheck all connections and the retaining ring for proper sealing.

If these steps do not resolve the issue, consult a certified automotive technician.

Specifications

What's in the Box:

• Fuel Pump Module Assembly

Warranty Information

BOSCH products are manufactured to high-quality standards. For specific warranty details regarding your BOSCH 67791 Fuel Pump Module Assembly, please refer to the warranty documentation included with your purchase or visit the official Bosch Automotive website. Keep your proof of purchase for any warranty claims.

Customer Support

For further assistance, technical support, or to inquire about other Bosch products, please visit the official Bosch store or contact Bosch customer service.

Bosch Store: Visit the BOSCH Store on Amazon

Always ensure you have your product model number (67791) and purchase details ready when contacting support.