I have a Zex dry kit on the way, so I figured I'd better upgrade my fuel and ignition systems. I have a Mallory 685 ready to go on, but I still need to order the harness which is probably backordered. I also snagged a Bosch pump part #580 254 938 from work(It's nice to work at Bosch). I did some research yesterday and apparently this same pump is sold by Accel and a couple other companies. I need to know how you guys and gals installed an inline pump on your cars. What fittings did you need, where did you mount it? Any and all advice will be greatly appreciated.

 

I ran a TRex in-line pump before I upgraded my in-tank pump. The pump mounted under the car, on the sheet metal right behind the back seat (up in the well where the differential rides). Go to a good hardware store and pick-up some metal clamps that have the rubber "liners". Use these to secure the pump to the floor board. They will help to reduce the vibration noise generated by your new pump. There's a connector mounted there that supplies the power to the stock fuel pump. This power is used to trigger a relay to turn on your new in-line pump. A separate power feed line in run to the relay from the battery (be sure to add a fuse to the power line). Run the negative side of the fuel pump to the relay. The last electrical connector is the ground for the relay; clean off the paint on the sheet metal and use a sheet metal screw for the ground wire. As far as the fuel line goes, use rubber fuel line rated for a fuel injected system. The stock fuel line has a plastic feed from the fuel tank to the fuel filter. This line can be cut, add a metal barb fitting to the output of the fuel tank that can be melted into place (heat it to 400 degrees in a toaster oven for 20 minutes), add new rubber line to the new pump, then send the output of the fuel pump back to the stock line that goes to the fuel filter with another barb connector.

 

If you got the complete Zex kit, it includes a Walbro in-line pump. Why pay extra $ for a Mallory pump? The installation of the Zex pump is straight forward. Just follow the instructions in the kit. Very simple. Even the wiring. Did mine in less than 1 hour.
Good luck.

 

I am getting the Zex kit used and it doesn't come with the inline pump. Even if it did I would probably use this Bosch pump because it's a bad ******. Thanks for the info OBE1 95Z28, I really appreciate it. Did you just heat the barb fitting in the oven and then slide it into the plastic line? That's a pretty neat trick. I need to find a barb fitting for one end of this pump(it uses a sealing washer so I'm sure it'll be a pain to find), but it shouldn't be too hard to install. Do you leave your pump on all the time, or do you have it on a switch? Any cooling issues? Thanks.

 

My local Pep Boys has the brass barb fittings which include the instructions on heating. Yes the heated barb fitting is just fitted into the end of the stock plastic line...be sure to wear a glove!

The pump is on whenever the stock pump is on, remember you wire the relay to the stock power line (acts as the relay trigger).