As my signature says, I am in process of lots of rust repair, coming along well. While replacing the rusty tank that was also starting to leak, I am also replacing the rusty but perfectly functional Bosch fuel pump assembly. 180k on it, probably original. In preparation, last year I bought a cheap pump/sending unit assembly by US Motor Works, basically just to get a rust free sending unit. Rock Auto ranked it as Daily Driver, not Economy. Regardless, I want to replace the pump with a Bosch or other reliable brand before installing it in the vehicle.

After reading through some of the 96 fuel pump threads, my question is, is there anything else that I shouldn’t use on the US Motor Works sending unit? Like the OBD2 feedback portion of the sender, is that going to stop it from running if it quits? Or anything else?

I primarily only go 9 miles to work and back in the sticks. So if it runs screwy I can deal with it. Just don’t need it strand me in the winter.

 

Because of the '96 being a changeover year, I would get a fuel pump assembly specifically made for the '96. Like the Crowne fuel pump assembly. I've had better luck this way than an assembly made for a year range. The problem is, the fuel pump assembly setup is different from the 95 and older AND 97 and newer.

 

if you scroll down a few posts you will see I have commenced a write up on '96 fuel pump assemblies, with links (to be completed)

You do not say whether you have purchased a "unique" '96 assembly/module, or some other year ?.

I believe a Carter brand '96 assembly is said to be good quality

In short, what I did is;

Dismantle and clean the original assembly skeleton
clean and polish the circuit card
replace the fuel pump itself with a new Bosch
clean the original regulator

It all seems to be working well

 

Thanks for tips. I did get a 1996 specific fuel pump assembly. It has the special 5 pin connector and the dual float level circuits.

My plan is to replace the pump itself with a new Bosch.

 

I have done this using the Bosch pump suits 94-96 (possibly earlier as well I believe)

The 97 onwards pumps are advertised as different

Do not lose any tiny parts, fasteners etc, as you do not always get new ones in the kit

 

The setup is different. On 95 and older, fuel pressure regulator is at the fuel rail in the engine bay. On the 96, the fuel pressure regulator is integrated into the fuel pump assembly that's mounted on the side of the gas tank. On 97 and newer, the fuel pump assembly changed as it's mounted on the top of the gas tank.

While the fuel pump itself might work, I haven't had good results with trying to use a fuel pressure regulator from a different year. Hence, why I say to buy a 96 only fuel pump assembly.

 

I cant comment on the 97 on,

but for 94-5, the regulator is apparently the same Crown part number according to the NAXJA thread as the '96 reg

On the '96, it is in the tank, and has no vacuum connected to it, runs at 49psi

on the pre 96, when it is fitted externally, it runs at 31 psi, and it was stated this is due to having vacuum applied

That is what the author stated anyway

I can testify it is easy to replace the pump itself, remove and clean the circuit board, and the regulator appears to be replaceable if needed, te part is available on Amazon and elswhere

 

That's good to know. Thanks for the information! Maybe I just got a hold of a bad part.