Parts: Walbro 255lph fuel pump
Tools: Multi Tip Screwdriver
Ratchet with 10mm and 8mm sockets
Shrinkwrap
Soldering Iron
Flux W/Lead(lead is for electronics)
Zip ties(optional, but nice to have)
Rubber gloves(optional, nice to not have gas hands for 2 days)
Time:1 hour
SAFETY: OPEN ALL WINDOWS AND LEAVE TRUNK OPEN WHEN WORKING ON THIS, OR ELSE SUFFER A HUGE HEADACHE AND MAYBE WORSE. Also start with less than 1/4 tank of gas to keep you from having you put your hands directly into gas.
First you wanna depressurize your gas lines by unplugging the fuse from under the hood for the fuel pump, taking your fuel cap off, and running the car until it stalls.
Pic of where the fuse is for the fuel pump, you can see where it should be on the lid to the left.
Now you wanna remove the negative battery cable(so you don’t get a spark and blow yourself up). The fuel pump is easily accessed in the trunk closest to the side where the fill spout is. You’ll need to use the ratchet w/ 10mm socket for these 4 bolts that hold the gas tank cover on, and a screwdriver for the 2 screws for the harness cover. Unplug the harness once you have access.
Okay, once the first cover is off, the access to the gas tank has 6, 8mm bolts holding it on. There are 2 hoses, the one on the left should be the return and the right hose should be the feed. Either way make sure you mark or remember which side goes where. Take the hoses off, and take the 6 bolts off.
Getting the fuel pump assembly out is pretty tricky, make sure not to bend anything, especially the rod and float for the fuel gauge. The S13 fuel pump doesn’t clip on to a bracket on the side of the tank, it just goes straight down into a bowl looking device, you’ll see when you get to this part. This is what the fuel pump assembly looks like.
See the brownish plastic tank to the bottom center (upper picture), that is the float for the fuel gauge. I cut the Red and Black wires really close to the terminals on the old fuel pump and removed the old fuel pump(this is straight forward). I soldered and shrinkwrapped the red and black wires together(for anyone who wants to ask it was Red to Red and Black to Black, lol) from the walbro clip and the stock wiring.
YOU WANNA SHRINKWRAP WHATEVER YOU DO HERE, UNLESS YOU WANNA CHANCE A SPARK IN YOUR GAS TANK!!!
I proceeded to get the walbro unit ready to install, you wanna take this lock washer from the bottom of the stock fuel pump filter, and put it on your walbro unit, it holds the filter tight.
Then you wanna put the rubber insulator on top of that, it has grooves that make this a no brainer.
This is what the unit will look like when you are ready to put it back on, you’ll wanna cut a little bit of the hose off, whatever you need to accomodate.
Now you are ready to put the pump back onto the assembly, it is a little tricky to do it with the rubber insulator on the bottom of the pump. I preferred to have the hose attached to the pump first then slide it onto the assembly. Tighten your clamps, put the power/ground clip into the walbro units socket. I also put a few zip ties around the unit to secure it and have piece of mind.
Now you should be ready to put it back into the tank. Install from this point is exact same as removal. Make sure you get the fuel hoses into the correct pipe. Take the car out for a rip, watch your fuel gauge to make sure you didn’t mess the sender, float or rod up. Should be easy as that.
If anybody has anything to add, then please feel free to post. Can someone please sticky this.