bc3tech
September 16th, 2010, 8:28pm
Original author: PistoNHeaD @ redlineforums.com
As we know the Walbro fuel pump is a bit longer than the stock pump and some slight modification of the fuel sending unit is required. Here is a comparison of the 2, the stock one being on the right...
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo2.jpg
The fuel sending unit has an opening where the electrical plug fits on the pump.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo1.jpg
The housing on the stock pump fits inside this opening like so.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo3.jpg
The housing on the new pump doesn't fit in the opening....
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo5.jpg
So some plastic needs to be removed to make some room. A Dremel works great for this.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo6.jpg
Also the fitting that the output side of the pump gos into.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo4.jpg
needs to be trimmed down a little. Gently remove this from the top of the sending unit to gain better access for ease of trimming, once again a Dremel works great for this. Be sure to remove the rubber seal that fits into the fitting. There is plenty of room to fit it back in so trimming of the seal is not needed. It should look something like this when done.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo7.jpg
Be sure not to trim too much off at first, trim a little and test fit, trim a little and test fit and so on till you get it right. When its all done the top of the sending unit should look like this with the housing of the new pump protruding from the top of the sending unit.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo8.jpg
Then reconnect the power connector to the pump and the sending unit is ready to be reinstalled into the fuel tank.
NOTE: IF YOU ARE CONVERTING TO A RETURN STYLE FUEL SYSTEM THE
IN-TANK FUEL PRESSURE REGULATOR MUST BE REMOVED PRIOR TO
REASSEMBLY OF FUEL SENDING UNIT.
To do this you must first gain access to the regulator by cutting the zip tie holding the regulator housing together and remove the regulator cover.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/1015-1.jpg
There is a ball bearing and spring loaded metal tab inside.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/1015-2.jpg
Remove these so it looks like this.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/1015-3.jpg
Reinstall cover (no zip tie needed) and reassemble fuel sending unit.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/1015-4.jpg
More... (http://www.redlineforums.com/forums/howto-section/46411-walbro-fuel-pump-install-pictures.html)
As we know the Walbro fuel pump is a bit longer than the stock pump and some slight modification of the fuel sending unit is required. Here is a comparison of the 2, the stock one being on the right...
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo2.jpg
The fuel sending unit has an opening where the electrical plug fits on the pump.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo1.jpg
The housing on the stock pump fits inside this opening like so.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo3.jpg
The housing on the new pump doesn't fit in the opening....
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo5.jpg
So some plastic needs to be removed to make some room. A Dremel works great for this.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo6.jpg
Also the fitting that the output side of the pump gos into.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo4.jpg
needs to be trimmed down a little. Gently remove this from the top of the sending unit to gain better access for ease of trimming, once again a Dremel works great for this. Be sure to remove the rubber seal that fits into the fitting. There is plenty of room to fit it back in so trimming of the seal is not needed. It should look something like this when done.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo7.jpg
Be sure not to trim too much off at first, trim a little and test fit, trim a little and test fit and so on till you get it right. When its all done the top of the sending unit should look like this with the housing of the new pump protruding from the top of the sending unit.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/photo8.jpg
Then reconnect the power connector to the pump and the sending unit is ready to be reinstalled into the fuel tank.
NOTE: IF YOU ARE CONVERTING TO A RETURN STYLE FUEL SYSTEM THE
IN-TANK FUEL PRESSURE REGULATOR MUST BE REMOVED PRIOR TO
REASSEMBLY OF FUEL SENDING UNIT.
To do this you must first gain access to the regulator by cutting the zip tie holding the regulator housing together and remove the regulator cover.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/1015-1.jpg
There is a ball bearing and spring loaded metal tab inside.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/1015-2.jpg
Remove these so it looks like this.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/1015-3.jpg
Reinstall cover (no zip tie needed) and reassemble fuel sending unit.
http://i892.photobucket.com/albums/ac122/redline06/Car%20Project/1015-4.jpg
More... (http://www.redlineforums.com/forums/howto-section/46411-walbro-fuel-pump-install-pictures.html)