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DIY Walbro Intank Fuel Pump Install

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Old Jan 19, 2009 | 11:53 PM
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Default DIY Walbro Intank Fuel Pump Install

Crayola already made a post, but I figured I would write my own so future installers can reference both. I didn't have time to take any pics, so I'll try and be as descriptive as I can.

1.) Disconnect negative on battery.
2.) Pull the rear seat cushion out - it just takes a firm pull straight up on both sides.
3.) Using a flat-head screw driver, gently and carefully pull the metal plate covering the fuel pump. You'll identify this as a circular plate with a few wires running into it.
4.) Disconnect the two plugs and set the cover aside.
5.) Remove the yellow plastic c-clip holding the fuel line.
6.) Before removing the fuel line, prepare the area with rags because fuel will be coming out.
7.) After removing the line, wrap it in a bag and zip-tie it out of the way.
8.) Using an 8mm socket, remove all the bolts to the black plate - there's another bolt under a bracket that's holding a wire harness.
9.) Gently remove the fuel pump by sliding it straight up. You may need to tilt it here and there to get it out.
10.) Looking at the fuel pump housing, you'll notice it's three pieces. A top piece which has the port for the fuel line, the middle which houses the fuel pump, and the bottom piece which holds the pump and the fuel filter.
11.) Remove the bottom piece by taking a flat-head screw driver and gently lifting and turning so the tab releases. Do this all the way around until the lower piece is removed. (Set this aside - we'll be modifying it soon.)
12.) Remove the top piece in the same fashion - unclipping the tabs. Pull apart from the middle piece - no worries it may seem hard to do... but it's just a rubber o-ring that's sealing the pump to the top portion.
13.) Unclip the harness to the fuel pump from the top piece. (Set aside - top piece will be modified)
14.) Now the stock fuel pump is out. Take the plastic sleeve, o-ring, and plastic cap that's on the stock pump, and transfer it to the new Walbro.
15.) On the bottom of the Walbro, you'll see 4 legs, tabs, whatever you want to call it. These will need to be ground down with a dremel. Do NOT ground the middle stub.
16.) Now insert the modified Walbro into the middle housing. It will slide right in - remember to have the plastic sleeve, o-ring, and plastic cap on the new Walbro.
17.) Now take the bottom piece of the pump housing and trim out the area where it looks like it was designed to cover the plastic part of the fuel filter. It looks like a U. Trim this out but don't trim up to the middle hole.
18.) Take a round file or a drill and open that hole on the bottom piece just enough so the Walbro's bottom knub can fit.
19.) Install the new filter on the fuel pump and secure it with the supplied clip from the install kit.
20.) Snap the lower piece onto the middle section with the Walbro in. It should be secured now.
21.) Take the top piece of the fuel pump and snip off the factory connector but leave some room just in case you may ever need it in the future. Solder the supplied connector to the wires from the top piece. Blue wire goes with connector's Red wire - and Black goes to Black of course. I would also use heat-shrink tubing over the solder joints.
22.) Plug the new connector onto the Walbro, and snap the top piece to the rest of the housing. It should snap in place with no issues.
23.) Reinstall fuel pump in the tank, and do steps 1-8 in reverse order.

So there's my install that I did today. After doing it and seeing what it takes, there's no reason I shouldn't be able to do this again in less than one hour. The most time was used during the sanding down and the soldering.

This DIY will make less cutting to the lower piece, and keeps it more secure. Only a small portion is needed to be trimmed off the lower piece - just enough to clear the new filter. The hole in the middle needs to be make just a tad bigger - but not much. The rest of the trimming is on the Walbro itself.
Old Jan 20, 2009 | 12:13 AM
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woot, nice write up....

yeah for me teh cutting was trial and error...i cut too much but hey what can ya do.
Old Jan 20, 2009 | 04:08 PM
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Are you guys running a ton of boost to have to change out the fuel pump?
Old Jan 20, 2009 | 04:24 PM
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change out the fuel pump lol i wish it was that easy i run a return set up with a garden hose for plumbing lol
Old Jan 20, 2009 | 04:30 PM
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Originally Posted by REVOSOLDIER
Are you guys running a ton of boost to have to change out the fuel pump?
No - I installed it as a security blanket.
Old Jan 20, 2009 | 05:05 PM
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Boost!!!!!
Old Jan 20, 2009 | 06:58 PM
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watching! blah the only thing that holds me off from getting one is that i have to redo my fuel map again and im gonna be abusing the car again! lol
Old Jan 20, 2009 | 10:01 PM
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nice b, the more info we get the better off the community is
Old Jan 20, 2009 | 10:03 PM
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nice
Old Jan 20, 2009 | 10:29 PM
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Originally Posted by Ace83
watching! blah the only thing that holds me off from getting one is that i have to redo my fuel map again and im gonna be abusing the car again! lol
I don't think you need to Ace. This install didn't affect the Unichip tune at all. It ran just like it did before.
Old Jan 20, 2009 | 10:32 PM
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thats good news.. i thought its gonna make it really rich.. and i think i know an easier way not to change the entire map when if it make the tune richer
Old Jan 21, 2009 | 04:00 PM
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Nice write up. Add some pics and you an excellent DIY
Old Jan 23, 2009 | 06:29 PM
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yea add pics and i'll sticky this too. lol.
Old Jan 23, 2009 | 08:24 PM
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Hmm.. How can I add pics after-the-fact?

Maybe Crayola can give me his pics - and I'll edit them in Adobe to fit here?
Old Jan 23, 2009 | 10:41 PM
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I'll take lots of pics when i get one lol but thats prolly gonna be forever lol we'll see
Old Jan 24, 2009 | 07:29 PM
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Originally Posted by B_Real45
Originally Posted by Ace83
watching! blah the only thing that holds me off from getting one is that i have to redo my fuel map again and im gonna be abusing the car again! lol
I don't think you need to Ace. This install didn't affect the Unichip tune at all. It ran just like it did before.
I'm running the FIC, didn't notice much of a change in the AFR's with the walbro upgrade. Probably get retuned when it gets warm as it is tuned for winter temps.
Old Jan 24, 2009 | 07:57 PM
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i love DIY write ups
Old Jan 26, 2009 | 04:55 PM
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Here you can see the four tabs at the bottom of the fuel pump that need to be trimmed.

P/N for Walbro pump and install kit: GSS342, 400-762. It is basically a Supra pump kit.

Old Jan 26, 2009 | 04:58 PM
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There you go! Yes those 4 tabs should be ground down smooth.
Old Jan 26, 2009 | 07:38 PM
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those are exacly the tabs grind those down thatll bolt up just fine...or you can open up the bottom of the housing lol
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