HOW TO: Change the fuel pump (Walbro install)

Discussion in 'How-To/Tech Database' started by master_1011, Aug 12, 2008.

  1. master_1011

    master_1011 The Man.

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    1.run gas out untill light has been on for a few miles!

    2.remove fuel pump relay(under hood fuse box)and remove gas cap to relieve pressure...now turn key to the on position....wait....turn engine over may start and die a few times but continue untill all lines are fuel free!

    3.remove negative battery terminal.

    4.jack up rear passenger side of the car(please use jackstands)

    5.look at gas tank....there are two straps..first loosen driverside strap a little then loosen passenger strap all most all the way make sure it is still threaded in though or tank will drop!(NOT NESCESSARY)

    6.you will see a big round white canister in the pass. side of the tank...remove the fuel line,and two clips from the canister,tuck out of way.then get screw driver,chisel,etc. and rubber mallet, use those to loosen up platic ring holdin canister in tank.

    7.ok put ring to the side...know its time to jimmy the canister out of the tank....dont be too aggressive the floater on can. could get damaged...

    8.once removed remove clip from top of can. should cotain red& black wire,remove those to(remember what color went where in the clip)there should only be two small blue wires left in clip.

    9.ok now time for little tool use this to pry open the can. where it is clipped together be carefull ...dont break it.... seperate,ok now pull fuel pump from canister install walbro 255 the same way stock was installed but use stock bushing on bottom of stock pump.

    10.pull red&black wires through top,replace all all seals bushings that are needed,put cap back on canister correctly.

    11.unclip pick-up sock from bottom of canister, while off look through bottom to see if blue bushing and pump set correctly....ok then replace filter sock,use new seal/small black o-ring

    12.put red&black wires back in the the clip...the right way (have good memory)......clip back together.If you look at the bottom of clip it has #'s(1234 Black goes in 4 red in 1 with new pump)

    13.install can. back in tank with new seal....just like it was removed...there is a little tab on can and slot in tank to make sure the two line up correctly, once it is flush with tank..reinstall the big white ring(dont cross thread it)hit with mallet and chisel,etc. to tighten up.

    14.reinstall two clips and fuel line two correct locations on can, tighten up tank straps....make sure you did everything right...lol,put battery terminal back on,put relay back in.

    15.ok you should be done know get a gas can,go get gas(put in car),turn key to on position and back off a few times untill you think line has enough pressure back in it... now try and start....Ok you should be done just be sure to turn the key to the on pos. everytime and wait for fuel to pump(little red light on dash shuts off)sometimes you may even need to prime the system by turning over for slight second,turn off then turn over to start car....its not too hard to figure out....well hopefully i didnt leave anything out, just follow your steps and good luck!!!!
     
  2. 2muchpsi

    2muchpsi Gold Supporting Members

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    what no pictures? lol