91 HO Fuel Delivery Issue

[HOrnbrod]

Yes, I've seen the non-Mopar refurbed fuel pumps too, and never considered them. But you would think before Mopar put their name on something it would be reliable. They have been selling refurbed water pumps, starters, alternators, even computers for years and I haven't heard any negatives. That's probably what you mostly get when you bring your Mopar vehicle to the dealership for repair.

[kryptronic]

The fuel pump install was definitely interesting.  I expected the part to drop in.  I'd hate to see what a shop would do during the install.  For reference, this is what I pulled from my 91 MJ:

 

 

The fuel pump, which I believe to be OE (and lasted 231k miles) is labeled as follows:

 

BOSCH 9580810019

12V 927 068-18 Made in USA 31

8935003591 0H18

 

Notice the alignment tab on the sending unit in which the top retaining bracket is placed.  Sorry for the blurry picture.  The socket is right above the notch.  This fit is the ultimate goal:

 

 

This is how the Bosch fits together as delivered:

 

 

And a shot showing the retaining bracket and mounting adapter don't fit quite right:

 

 

Adding a notch helped:

 

 

But then fitment was an issue.  The unit was sitting 0.20" higher. 

 

 

I could have notched the sender at that point, but I refuse to mutilate a factory part like this to install something that's not.  Plus I had already modded the adapter.  So, the final cutting on the top plastic adapter was  0.20" off the top, 0.20" off the top of the fins on the sides, 0.30" wide x 0.15" deep notches cut on either side of the opening.  

 

Perfect fit achieved:

 

 

I guess a lot of us have the same pump.  There is a noticeable difference (audibly) in both the charging and running of this pump.  It sounds like a gun shooting fuel up prior to start, and runs very quietly.  And I know it's in there in a solid fashion.  I hope this helps somebody else.

[HOrnbrod]

Excellent writeup and pics. Thanks for taking the time to do it. 

[jeep.kevin]

Looks like a pretty good adapting job you did there.  Good thing you replaced the pump.  I had one whining in my older XJ and I ignored it right up until it failed about 15 miles out in the desert. Good thing I had cell service and friends. 

 

[kryptronic]

8 hours ago, HOrnbrod said:

Excellent writeup and pics. Thanks for taking the time to do it. 

No problem.  I had actually taken all the pics to do a DIY writeup, but with the mods needed, and me not being sure on differences between HO and Renix sending units, it didn't happen that way.