The fuel pump for the Zetec motor is not driven by a shaft in the motor as was the case with the old single overhead cam motor. The pump for the Zetec motor is away from the motor and is powered by electricity. Further, because it has to provide fuel at a higher rate to a fuel injection system, the fuel pump required for the Zetec motor installation must be more powerful. Pegasus recommends the Bosch 979 pump for the Zetec. The cost is $299.99. The part number is 1124-101.
So the question then became…where to put it? The more current applications utilizing such a higher pressure Bosch pump mount it inside the fuel cell. I was dealing with an older chassis that had a fuel cell designed around an external fuel pump. Placing the Bosch 979 Fuel Pump outside the fuel cell was, however (according to the Pegasus web site), recommended by Bosch.
There was a small and yet sufficient space in the forward left portion of the engine bay. I needed to find a way to, at least temporarily, mount the fuel pump in that location. Pegasus sells brackets that can be clamped to tubing of various sizes. They had one that would fit a 1 inch diameter tube. These brackets are called Floating Saddle Mounts. Fortuitously, there was a 1 inch in diameter engine bay brace tube in that forward left side engine bay space. I ordered two of the saddle mounts from Pegasus. They were $32.99 each. The part number is 1825-100-1.000.
Spotted an immediate complication once the saddle mounts arrived. The mounts clamped perfectly to the selected brace, but the attachment tabs, which the large cushioned hose clamps (holding the fuel pump) would bolt to, were 90 degrees off. The tabs were oriented perpendicular to the centerline of the brace. I needed them to be in line with that centerline. So back to the Norman Racing Group in Berkeley so that Dennis could perform another re-orientation. The tabs were cut from their perpendicular position, rotated 90 degrees so as to align with the centerline of the mount and then re-welded into their new position.
This cut and re-weld task was another of the 30 minute variety.
The Bosch 979 fuel pump is 2 3/8 inches in diameter so large diameter cushioned hose clamps were going to be needed to secure the fuel pump to the re-oriented saddle mount tabs. McMaster-Carr in Southern California can provide such clamps. They call them Snug-Fit Vibration Damping Loop Clamps. They’re made out of stainless steel with a neoprene rubber cushion. And they have them in a 2 ½ ID. They cost $2.74 each. Their part number is 3177T62.
The mounts for the fuel pump will probably be welded into position once I’m satisfied that this location is the best location for the pump.
The next task, once the Bosch 979 pump was clamped into place, was selecting fittings. Pegasus can provide the metric to AN adapters needed to use this pump with AN fittings.
The inlet side adapter is a 14 mm to 6 AN. The part number is 3276-027. The cost was $12.99. The outlet side adapter is a 12mm to 6 AN. That part number is 3275-003. The cost was $5.49. Both adaptors thread into the pump with 1.5 mm threads.
As appearing in the photo above, the pump is situated on an angle that approaches 45 degrees. So to go vertical, either into or out of the pump, was going to require a 45 degree fitting.
I decided to use a 45 degree, female, 6AN push-on fitting for the intake side of the pump. The fittings already on the line from the fuel cell were already of the push-on type so I just stayed in genre. Pegasus supplied the fitting. The part number is 3288-06-045. The cost was $16.99.
Then I needed to add a fuel filter on the intake side.
Pegasus was, once again, my source. The in-line filter is a Setrab product. 150 micron with -6 AN male fittings. The part number is SET-IF0606D. The cost was $59.00.
Two female, 90 degree, -6 AN push-on fittings were needed to connect to the existing line coming out from the fuel cell (on the “IN” side of the filter) and then to connect from the “OUT” side to a short 3/8 ID line descending from that 45 degree fitting attached to the inlet side of the fuel pump. The part number for the 90 degree fittings is 3288-06-090. Each cost $16.99. The 3/8 inch ID hose is $5.49 a foot. That part number is 3290-06.
I decided to use bent tube swivel hose ends for all of the outlet side hoses. Something about the classic blue and red anodized fittings and stainless steel braided hose seemed appropriate for this application.
The initial fitting for the outlet side of the Bosch pump was a female, 45 degree, -6 AN swivel hose end. This allowed the line to go straight vertical because, yes, the pump was roughly aligned at a 45 degree slant. The cost was $16.49. The part number is 3271-06-045.
This 45 degree fitting was inserted into a 0.34 inch ID stainless steel braided hose intended for such -6 AN fittings. This length of hose would gently loop through the upper front portion of the engine bay. The part number for the hose is 3270-06. The cost was $6.59 per foot. The loop required 22 inches of hose.
As seen in the above photo, the loop ended where I’d previously placed another in-line filter on the forward intake side of the fuel rail. This had been done during the initial building-of-the-engine phase (as documented in the Junk Yard Zetec Project report). Connecting to this fuel filter required a straight, -6 AN swivel hose end. The cost was $6.99. The part number is 3271-06-000.
The Bosch fuel pump can deliver more fuel through the fuel rail to the injectors than they need. So there is a fuel pressure regulator situated towards the rearward end of the fuel rail to control that fuel flow. It is then necessary to provide a pathway for that excessive fuel to flow back into the fuel cell. Two 90 degree, -6 AN, swivel end fittings, coupled with about 17 inches of the 0.34 inch braided hose, provided that pathway. I’m not certain why, but for this application I used the Forged “Cutter” style swivel hose ends. The two fittings cost $19.99 each. The part number is 3274-06-090.
The fuel filler neck into the fuel cell did not provide a way for that excess fuel flow path to actually reach the fuel cell. So back to Berkeley to have Dennis modify the filler neck.
Dennis drilled into the neck and then welded a male -6 AN fitting to the new access hole. This task took about an hour, including contemplation and design time. Pathway completed.
Zetec Conversion 