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Replacing Bosch main fuel pump 900

Some notes on replacing the Bosch main fuel pump on a -93 945 B230-FD.
It left me stranded on the road after +480000 km of service.

- If the fuel injection relay, the wite realy with a date code, engages when igniton is turned on but you hear no sound for 1-2 seconds from the fuel pump it's a good sign of pump failure. You can feel the relay engage with your finger on the plastic casing.
- The connectors to the pump are colour coded, can be hard to see if there are lots of undercoating.
- If you replace the short fuel line between the pump and the filter make a note of how it's positioned and tighten the conical connection on your workbench before mounting. Takes two 17mm spanners.
- If you don't replace it the lock nut should turn relative to both the fuel line and the pump but may be corroded and make you have to also loosen the banjo fitting on the filter. Have two gaskets ready for that.
- Have something ready to plug the low pressure side hose when you undo it. It will otherwise siphon the tank empty. New hose clamp most likely needed.
- Consider replacing the FI relay at the same time.


HTH
mila







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