Mod: WRX Performance (Walbro 255lph fuel pump install)

subedude · 04-09-2005, 02:23 PM

FUEL PUMP INSTALL

This is fairly easy and an important mod if you are building up your "PONIES". The Walbro pump fits into the stock mounting assembly with little modification.
By doing this mod, there is not a lot that can go wrong, but should your project turn to S---, I am not responsible for your demise!! You will notice in the pics that my car is gutted. Just imagine my carpet and all the other stuff is still there and you should have no problem locating the bolts you need to access.

REMOVAL OF REAR SEAT

Locate and remove the 2- 12mm bolts holding the bottom section of your rear seat in place. Once it is loose, remove from car and set aside. Now look along the top of the remaining piece of seat and locate two more bolts. Remove them, lift up on the seat and remove from car.

subedude · 04-09-2005, 02:31 PM

LOCATING THE ACCESS COVER

Looking toward the rear of the car, the access cover will be on the left side of the car just before it goes into the trunk. It is under the carpet, so carefully peel back what you need to until you can see the cover. You will see 4 screws that are holding the cover in place. Remove them.

subedude · 04-09-2005, 02:46 PM

DE-PRESSURIZING OEM FUEL PUMP

With the cover removed you should be looking at a white electrical plug. Start your engine and remove the white plug. Let your car run until it dies out. Your system is now relieved of pressure. Turn off your ignition switch and remove your "Negative" battery cable.

subedude · 04-09-2005, 03:07 PM

REMOVAL OF FUEL PUMP BRACKET AND ASSEMBLY

Start this step by removing the three remaining hoses from the top of the plate that you are looking at. The fuel lines might still have some gas in them, so put on your goggles and place a rag under the hose to catch any leaking fuel. Once the hoses are off, remove the eight nuts holding down the pump assembly. BE EXTRA CAREFUL NOT TO DROP THEM AS IT WILL BE A REAL B---- TRYING TO RETRIEVE THEM FROM THE CRACKS AROUND THE GAS TANK!!!!!

At this point, I removed the whole assembly and took it over to my bench. When pulling out the unit, be careful not to bend up the float or any other part of the pump unit. I also laid the cover over the hole after I removed the pump to keep any dirt or debris from falling into the tank.

subedude · 04-09-2005, 03:38 PM

REMOVING OEM PUMP FROM BRACKET

Start by disconnecting the electrical plug. Next loosen the hose clamps and remove the hose and pump. Take the OEM pump, hose, clamps & isolator (rubber piece the pump sits on) and put them to the side as they are no longer needed!!

subedude · 04-09-2005, 03:56 PM

CUTTING THE SUPPLY TUBE

This next step is the modifying part of the install. Because the Walbro pump mounts upside down compared to the OEM pump, the filter and hoses won't line up like the stock ones.

To remedy this problem, I cut 3" off of the supply tubing and replaced the piece of hose that comes with the pump with a 6" piece of hose from the auto parts store.
This allows the filter to mount in the isolator properly and creates a lazy "S" in the hose allowing both ends to fit on the barbs. (Filter mounts on top side of pump)

subedude · 04-09-2005, 04:24 PM

MOUNTING THE NEW PUMP

Start this by placing your new isolator into the oem bracket as shown in pic. The next thing is to place the filter on the end of the pump. Now insert the pump tabs into the isolator slots, with the filter mounted on the top side of the pump.

To help level and stabilize the pump in the bracket, I used the small piece of hose that came with the pump and cut it in half, placing it under the new pump. I also chose to anchor it down with a couple of tie-wraps to prevent any pump slippage.

Now take the 6" piece of hose and insert it on the barbs of the pump and supply tubing. Hold it in place with the clamps supplied with your pump. The last thing to do is hook up the wiring. With the Walbro pump, it is a direct plug-in. You should now have a completely assembled pump and bracket unit ready to re-install into the gas tank of your car.

subedude · 04-09-2005, 04:30 PM

RE-INSTALL OF PUMP INTO CAR

Now just reverse the steps to re-install your new pump. Once again be careful not to bend the float when inserting into the tank. Take extra care not to pinch the rubber tank seal and tighten all 8 nuts evenly to prevent any leaks!!

Enjoy,
Subedude

04-09-2005, 03:38 PM	#5
subedude Registered User Join Date: Jun 2004 Location: Bullhead City, Arizona Posts: 2,225 Threads: 41 Thanks: 135 Thanked 104 Times in 78 Posts Groans: 2 Groaned at 0 Times in 0 Posts Award-Showcase Awards Showcase Total Awards: 6 Total Points: 0	Mod: WRX Performance (Walbro 255lph Fuel Pump Install) REMOVING OEM PUMP FROM BRACKET Start by disconnecting the electrical plug. Next loosen the hose clamps and remove the hose and pump. Take the OEM pump, hose, clamps & isolator (rubber piece the pump sits on) and put them to the side as they are no longer needed!!

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