BOSCH 67799 Original Equipment Fuel Pump Module Assembly Instruction Manual

1. Product Overview

The Bosch 67799 Original Equipment Fuel Pump Module Assembly is designed to provide precise fuel delivery and reliable performance for compatible Chevrolet Express and GMC Savana vehicles. This assembly ensures a perfect fit and superior performance, mirroring the quality of the original components your vehicle was built with.

Key Features:

• Original Equipment Quality: Engineered to meet the exact specifications of the original fuel pump, ensuring optimal fit and performance.
• Innovative Turbine Pump Technology: Utilizes patented turbine pump technology to minimize fuel pulsation, reduce noise, and prevent hot-start issues.
• Durable Performance: Constructed to operate reliably in extreme temperatures and low fuel conditions, extending service life.
• Factory Tested: Each unit undergoes end-of-line function testing to guarantee high quality and performance.
• Ready for Installation: Designed for straightforward installation, including a fuel strainer to protect against debris and prevent premature pump failure.

Image: The Bosch 67799 Fuel Pump Module Assembly, showcasing its complete structure with electrical connectors and fuel lines.

2. Specifications

3. Setup & Installation

Installation of a fuel pump module assembly requires careful attention to detail and adherence to safety protocols. It is recommended that this procedure be performed by a qualified mechanic or an individual with sufficient automotive repair experience. Always consult your vehicle's specific service manual for detailed instructions.

Safety First:

• Have a fire extinguisher nearby.
• Never smoke or work near anything that could cause a spark or ignite fuel, such as pilot lights and incandescent light bulbs.
• Always wear safety glasses, and gloves are recommended.
• Work in a well-ventilated area. Keep clean-up materials on hand, and clean up any spills immediately.
• Always relieve fuel pressure prior to opening fuel systems. Releasing fuel under pressure can cause fire and injury.
• Store fuel in an approved container like a gas caddy or gas can.

General Installation Guidance:

1. Preparation: Ensure the vehicle is parked on a level surface, the engine is off and cool, and the battery is disconnected. Relieve fuel system pressure as per your vehicle's service manual.
2. Access the Fuel Tank: Depending on your vehicle model, access to the fuel pump may be from under the rear seat, through an access panel in the trunk, or by dropping the fuel tank.
3. Disconnect Components: Carefully disconnect electrical connectors, fuel lines, and any other components attached to the old fuel pump assembly. Be prepared for residual fuel spills.
4. Remove Old Assembly: Remove the retaining ring or bolts securing the old fuel pump assembly to the fuel tank. Carefully lift the assembly out of the tank.
5. Inspect and Clean: Inspect the fuel tank for any debris or contamination. Clean the fuel tank opening and surrounding area.
6. Assemble New Unit (if necessary): Some fuel pump module assemblies, like the Bosch 67799, may have the float arm packaged separately to prevent damage during shipping. Attach the float arm to the sending unit as shown in the video below.
7. Install New Assembly: Carefully insert the new Bosch 67799 fuel pump module assembly into the fuel tank, ensuring the fuel strainer is properly positioned and not bent. Secure it with the retaining ring or bolts.
8. Reconnect Components: Reconnect all electrical connectors and fuel lines. Ensure all connections are secure and leak-free.
9. Final Checks: Reconnect the battery. Turn the ignition to the 'ON' position (without starting the engine) several times to prime the fuel system and check for leaks. Start the engine and verify proper operation.

Image: Side view of the Bosch 67799 Fuel Pump Module Assembly, showing the fuel level float arm and electrical connections.

Image: A different perspective of the Bosch 67799 Fuel Pump Module Assembly, highlighting the internal components and wiring.

Image: Top view of the Bosch 67799 Fuel Pump Module Assembly, showing the fuel outlet and return lines, and electrical connectors.

Instructional Videos:

4. Operating Principles

The Bosch 67799 Fuel Pump Module Assembly is a critical component of your vehicle's fuel delivery system. It is responsible for drawing fuel from the fuel tank and delivering it under precise pressure to the engine's fuel injectors. The integrated fuel level sending unit accurately measures the amount of fuel in the tank, providing data to your vehicle's fuel gauge.

The turbine pump technology ensures a consistent and quiet fuel flow, which is essential for optimal engine performance and fuel efficiency. The design also helps to prevent common issues like fuel starvation during aggressive driving or low fuel conditions.

5. Maintenance

Fuel pump module assemblies are generally designed for long-term, maintenance-free operation. However, certain practices can help ensure the longevity and optimal performance of your fuel system:

• Keep Fuel Tank Full: Avoid consistently running your vehicle on a very low fuel level. The fuel helps cool and lubricate the fuel pump, and running dry can lead to premature wear.
• Use Quality Fuel: Using high-quality, clean fuel helps prevent contaminants from entering the fuel system and clogging the fuel strainer or pump.
• Regular Fuel Filter Replacement: While the fuel pump assembly includes a strainer, a separate inline fuel filter (if present in your vehicle) should be replaced according to your vehicle manufacturer's recommendations to ensure clean fuel delivery to the engine.
• Address Warning Lights Promptly: If your check engine light illuminates or you notice any issues with fuel delivery or the fuel gauge, have your vehicle inspected by a qualified technician.

6. Troubleshooting

If you experience issues with your vehicle's fuel system, the following common symptoms may indicate a problem with the fuel pump module assembly:

• Engine Cranks but Won't Start: This could indicate a lack of fuel pressure from the pump.
• Engine Stalling: The engine may stall, especially under acceleration or when the fuel level is low, if the pump is failing to deliver adequate fuel.
• Loss of Power/Hesitation: Reduced fuel pressure can lead to the engine not receiving enough fuel, resulting in poor acceleration or hesitation.
• Whining Noise from Fuel Tank: A loud whining or humming noise coming from the fuel tank area may indicate a failing fuel pump.
• Inaccurate Fuel Gauge Readings: If the fuel level sending unit is faulty, your fuel gauge may display incorrect readings.

If you encounter any of these symptoms, it is recommended to have your vehicle diagnosed by a professional mechanic. Attempting repairs without proper knowledge and tools can be dangerous and may cause further damage.

7. Warranty & Support

Bosch Original Equipment Fuel Pumps are backed by a Limited Lifetime Warranty. For specific warranty details, claims, or technical support, please refer to the documentation included with your product or contact Bosch Automotive customer service directly. Always retain your proof of purchase for warranty purposes.