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SolaraGuy.com • View topic - Walbro Fuel Pump Installation DIY
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Walbro Fuel Pump Installation DIY

Walbro Fuel Pump Installation DIY

Postby ASG14 » Wed Jul 22, 2009 10:43 am

Big thanks to Vik (Dawgz) for helping with the install and the DIY here. J

1: Unscrew gas cap to relieve pressure in the fuel system.

2: Remove the rear seat bottom. Simply pull the seat up. It’s just held down by 2 grip tabs.

3: Pull up the metal shield. It’s just attached with sticky stuff. Make sure not to get any on the carpet or seats.

4: Unplug the electrical connector.

5: Unscrew the 2 8mm screws that hold the shield over the fuel line.

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6: Remove the fuel line by holding in the 2 clips and gently pulling the line.

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7: Pull out the fuel pump assembly and have a bucket to put it in, so that gas doesn’t leak all over the interior.

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8: Take off the bottom white cap holding the fuel pump in.

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9: Remove the white rectangle piece with the wires and metal rod.

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10: Remove the main black fuel pump and housing, and unclip the harness.

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11: Cut the OEM connector off, then crimp the connector that came with the aftermarket fuel pump back on.

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12: Remove the 4 outside tabs on the fuel pump.

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13: Assemble the fuel pump. Put on the filter and attach the metal O-ring to secure it. Then put o-rings (need to get at the hardware store) over the fuel pump outlet, and place the OEM O-ring on the top.

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14: Slide the fuel pump into the main black housing, then plug in the connector. Next, slide in the fuel pump onto the assembly, and push back on the black housing.

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15: Cut out the top center of the bottom white cap that holts the fuel pump on.

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16: Put back on the white rectangle piece with the wires and metal rod.

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17: Put back in the fuel pump assembly into the car. It is a SLIGHT bit longer then the OEM one was, so it is a bit tricky to screw down. This is normal, so don’t be worried. It takes a while to get it screwed down the 1st time.
17A: Place the round black bracket over the fuel pump assembly.
17B: Connect the fuel hose by simply sliding it onto the clips. Do NOT force it on. If it doesn’t go right on, the clip is in the wrong position.
17C: Place the smaller black cover back on.
17D: Screw the 8mm bolts back on in a criss cross pattern and torque to 35 in/lbs.

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18: Plug the connector back in and put back on the cover.

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19: Put back in seat.
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Postby Ilovemylara » Wed Jul 22, 2009 11:10 am

Nice tutorial Adam! Thanks, I was actually looking for this, to install mine.
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Postby Dawgz » Wed Jul 22, 2009 11:13 am

the pics came out nice.


If anything, the way to "modify" the fuel pump itself is the key to this whole install.
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Postby SdeA » Wed Jul 22, 2009 11:24 am

Nice tutorial. Thanks for taking the pics step by step.
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Postby SleeperSolara » Wed Jul 22, 2009 11:58 am

Nice tutorial man. 8)
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Postby carstenmeiner » Wed Jul 22, 2009 1:23 pm

Nice DIY :D
Did you buy the pump on Ebay ? Is it a 190 L/Hr Walbro ?
Do you remember the size on the O-rings ?
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Postby lilm » Wed Jul 22, 2009 1:27 pm

sweet write up thanks
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Postby Solarizona » Wed Jul 22, 2009 2:36 pm

Wow, nice write up. Very clear.
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Postby ndeguzma » Wed Jul 22, 2009 3:01 pm

Funny you guys did this at the show!
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Postby akora12 » Wed Jul 22, 2009 3:12 pm

It's about time someone finally wrote this up. Nice work!
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Postby Pogs » Thu Jul 23, 2009 3:36 am

nice ima need this real soon
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Postby 1gSE » Sat Jul 25, 2009 6:46 am

carstenmeiner wrote:Nice DIY :D
Do you remember the size on the O-rings ?


^^^ Yeah that. How long did it take? I might put the 255 in soon
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Postby Dawgz » Sat Jul 25, 2009 8:47 am

I'd say less than 30 mins?
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Postby ArizonaEagle07 » Sat Jul 25, 2009 9:11 am

May I ask what benefits do you get with this Fuel Pump if any?
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Postby Dawgz » Sat Jul 25, 2009 9:20 am

ArizonaEagle07 wrote:May I ask what benefits do you get with this Fuel Pump if any?




on a N/A setup, its not needed.


but if ur sc'd, that 90lph oem pump isn't going to cut it, so you need this setup or a 255lph walbro.
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