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View Full Version : DIY: Walbro fuel pump install



jimmyjames
04-21-2008, 08:25 AM
The reason I am posting this up is because although there are a handful of DIYs, there is a major step wrong with them and we all want this info on ephatch, not crsx or something. So here we go.
NOTE: it is a good idea to replace the fuel filter when doing this.
Photobucket changed their hosting policies and all photos down. Send me a PM (and be patient) and I can send o you or post on facebook or something.

Fuel system part numbers (Majestic numbers and Honda):
26488 - Gasket, Base - 17574-S1A-E01
368416 - Holder, fuel pump - 17049-S5A-930
368409 - Housing, fuel pump - 17042-S5A-930
1093205 - reservoir (denso) - 17043-S5A-941
368411 - cap, reservoir - 17044-S5A-930
399254 - filter set, fuel - 16010-S5A-932
1077164 - Regulator Assy. - 16015-S6M-930
368406 - Wire, lead - 16016-S5A-930
1077176 - Pump Set, fuel - 17040-S6M-930

Parts list
Gates submersible fuel line - MUST BE SAE 30R10 RATED!!!!
If you do not get the right hose, it will melt/disintegrate in the gas. Purchased from NAPA.
All the DIYs skip this step and call for a braided or regular line.
http://www.gates.com/brochure.cfm?brochure=5091&location_id=541
[IMG]http://www.gates.com/common/images/Gates/ezlit/header_indexed.gif

[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3830.jpg

Some long zip ties
Some small stainless steel hose clamps
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3835.jpg

Walbro fuel pump number GSS342
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3831.jpg
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3834.jpg

Various tools like screwdrivers and a dremel or good utility knife.
Prep the car by removing the back seat, unscrewing the cover plate over the gas tank, and disconnecting the fuel line and wire harness...have plenty of rags handy.
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3823.jpg

Next, the easiest way to get the big collar off is using a big ass wrench but they don't make one aside from the special tool. First time I took it off, I used a coping saw arm. This time, I used a bent piece of 1" steel bent in a U
shape. This is bought from Home depot for like $5. Keep in mind this is needed to remove AND reinstall the collar.
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3822.jpg

Take off the collar and pull out the fuel pump/filter assembly. Since I am not able to run the car down to empty, I will have to drain the gas. I pulled it out just a bit.
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3824.jpg

Siphoning out gas
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3825.jpg

Fuel pump assembly out
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3826.jpg

Disassemble the the assembly. Be careful! Look to see how it is all put together so you don't break anything during this step.
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3827.jpg

Here is why I am doing this, the bracket cracked from a rock hitting the precise point where my pump was and then after fixing it, it cracked again...I know, I should have replaced the bracket but I was not smart.
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3828.jpg

You will have to cut the stock pump bracket for the hose to connect. I was fortunate enough to have that piece cracked off mostly, so i just finished the job. Once you see it back together, you will know how much extra may
need to be cut to install zip ties.

Next, start the reconstruction subbing in the walbro for the stock fuel pump.
The Walbro will be longer than the stock but don't worry, it will fit.
You will need to attach the hose after adding the bracket, front, and back pieces.
Use a hose clamp for the pump connection.
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3838.jpg

Add the zip ties as shown or as you see fit. Keep in mind there is not unlimited clearance in the stock assembly
housing so trim the ties according and rotate them around to not prevent closing it back up.
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3842.jpg

Next, the housing itself needs to be cut for the hose. Proceed as shown, keep in mind that the one tab there still needs to lock closed so only cut what you need.
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3843.jpg
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3844.jpg

Put everything back together.
Connect all the harnesses and plug the other end of the fuel line to the filter.
NOTE: The submersible fuel line you need to use is only 5/16" and the connection to the filter is very tough, you
may want to try connecting this end first before hooking up the pump since that is easier. I could not get it on all the way but I got it on mostly. The SAE30R10 3/8" hose is definitely the way to go, I do not have the NAPA part number at the moment. Just ask for it. (cheaper than 5/16" anyway)
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3845.jpg
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3846.jpg
[IMG]http://i30.photobucket.com/albums/c335/jjgarris7/car%20stuff/IMG_3847.jpg

After this, you will have to maneuver the more obtrusive pump assembly back in. You are supposed to replace the large rubber O-ring and I did. I don't have the part number on me but in retrospect, I don't think it is
essential.
Honda technician secret....use some white lithium grease so everything slides back together easier.
Use the special tool you made before to tighten the collar back down.
Hook everything back up and cycle the key to accessory II a few times to get the pressure back up and then start
it!!

civictype_r04
04-21-2008, 01:41 PM
Nice write up. I will be using this soon to install mine.

jeenyusss
04-21-2008, 01:54 PM
miller chills! barrrfff :meek:



nice write up:yo:

02_epdriver
04-21-2008, 02:35 PM
sweet right up man. What size injectors would you use for an n/a setup

jimmyjames
04-21-2008, 03:35 PM
sweet right up man. What size injectors would you use for an n/a setupstock injectors are fine. If you have a lot of mods requiring more fuel, kick it up to 310cc. A built N/A car could probably have 310 or max 440.

02_epdriver
04-21-2008, 03:39 PM
How many mods are you thinking before you kick it to at least 310

jimmyjames
04-21-2008, 03:41 PM
How many mods are you thinking before you kick it to at least 310I look at it this way...a stock RSX has 310cc injectors. Therefore anything above and beyond basic I/H/E (i.e. cam or head swaps) would warrant bigger injectors.

02_epdriver
04-21-2008, 03:48 PM
Thats what I thought. I'll get the pump for now and wait till the k24 comes through all the way until I get the bigger ones

jimmyjames
04-21-2008, 03:50 PM
Thats what I thought. I'll get the pump for now and wait till the k24 comes through all the way until I get the bigger ones..and I should add that according to Hondata, the stock pump is good enough up to about 300hp. :juggle:

02_epdriver
04-21-2008, 03:57 PM
Cool thanks for the info Jimmy

k20z3ep!!!
06-03-2008, 10:23 AM
hey what about the new si 07 up do u think a stock ep3 fuel pump is strong and good enough for those engines?? for should i replace it for the walbro??

talonXracer
06-03-2008, 10:27 AM
hey what about the new si 07 up do u think a stock ep3 fuel pump is strong and good enough for those engines?? for should i replace it for the walbro??

I ran a stock EP3 fuel pump with the cammed A2/Z3 and had no issues untill the filter started to get full of crap. One thing I did notice when the filter started to degrade the fuel pressure was that at below about about a 1/4 tank the pump would become uncovered by fuel and heat up and loose pressure. The fuel pump is liquid cooled by the fuel.

stepintoliquid
07-17-2008, 07:35 PM
this write up is the shit!

MadLorEP3
01-14-2011, 12:53 AM
good shit right here
tnx

dnrprojectsvp
01-17-2011, 11:53 PM
very informative.....

rolldogK20
01-23-2011, 08:53 PM
Good info bro !!! man i did mine and danm it was a bitch. i wish i wouldve saw this thread.

japarossa
02-17-2011, 10:46 PM
Do I need to do anything to regulate fuel pressure? Or just drop this in and thats it?

jimmyjames
02-18-2011, 04:49 AM
Do I need to do anything to regulate fuel pressure? Or just drop this in and thats it?
The stock assembly has a fuel pressure regulator, any excess just squirts back in the tank.
In the last picture on the first page, it's the little metal thing sticking up above my thumb.

japarossa
02-18-2011, 10:09 AM
Thanks, great DIY. I take it that the wiring is pretty straight forward since you didn't mention it, Black to black and red to red?

AKEP
02-18-2011, 05:20 PM
the 3/8 hose number is H206

k20power
02-18-2011, 08:09 PM
Im glad the made this cause I might replace my pump soon

jimmyjames
02-21-2011, 04:56 AM
Thanks, great DIY. I take it that the wiring is pretty straight forward since you didn't mention it, Black to black and red to red?

Even more simple than that. All wiring remains unchanged. No cutting or splicing of anything needed. Stock plugs go back into same places. Fuel pump harness is standard.

firmk20
04-26-2011, 12:39 PM
very great write up

the1986
05-13-2011, 04:27 PM
Is that new fuel line you add the important part? does it flow more than the stock lines or something?

Canuck Civic
05-14-2011, 06:17 PM
Is that new fuel line you add the important part? does it flow more than the stock lines or something?

You cut the old one off and you need a line that can be put in gasoline and not be eaten up.

the1986
05-14-2011, 06:37 PM
You cut the old one off and you need a line that can be put in gasoline and not be eaten up.

I get that, I just don't quite understand why you have to cut the old one off and replace it... its never really explained on why these changes are made -other than the broken fitting

japarossa
05-17-2011, 04:14 PM
Just did this DIY, great write up. With these instructions I did it start to finish in about an hour. The reason you need to cut off that piece and use the hose is because the new pump doesnt have the same fitting as the stock pump and it is alot longer so even if it did fit the quick release fitting they don't really line up. Thanks again for the write up

neoamd
05-18-2011, 02:11 PM
Just did this DIY, great write up. With these instructions I did it start to finish in about an hour. The reason you need to cut off that piece and use the hose is because the new pump doesnt have the same fitting as the stock pump and it is alot longer so even if it did fit the quick release fitting they don't really line up. Thanks again for the write up

What did you use to get the big collar off and back on? Same as the OP?

japarossa
05-18-2011, 02:48 PM
I used a big flat head screw driver and a hammer to tap the ring loose and then I could just loosen it by hand.

neoamd
05-18-2011, 05:08 PM
I used a big flat head screw driver and a hammer to tap the ring loose and then I could just loosen it by hand.

Awesome thanks. So I just need the new pump, submersible fuel line, OEM fuel filter and I'm ready to go? Or should I also pick up the install kit for walbro as well?

japarossa
05-18-2011, 09:10 PM
No there is nothing in the install kit you need.

neoamd
05-19-2011, 02:45 PM
No there is nothing in the install kit you need.

Word! Thanks man. So the pump and the line is all thats needed.

05 hatch
05-25-2011, 05:49 PM
Ya, nice write up. I'll be doin this real soon. So where is the fuel filter? Is it in the assembly you pull out of the tank or is it that canister just outside of the tank? I have 85,000 miles and want to replace the filter also.
Is there any difference between the walbro 255 fuel pumps? The number for it is diiferent than the one on clubep3.

jimmyjames
05-26-2011, 02:39 PM
Sorry for the absence. Looks like it's all been discussed.
Submersible hose is to prevent the line from degrading in the gas. Normal vacuum line will melt and rupture...also, the existing stock line is a special heat shrunk tube that is plastic or something, it has to be cut off the old pump and can't be reused.
Getting the collar off requires some creative thought, just don't buy the honda tool...it'll work great but cost you extra money.
The filter is contained within the white housing you pull out of the tank. I THINK you may not be able to buy the filter as a separate unit anymore. I could be wrong...
Part number on the walbro may be different because these pumps do have a purpose. It just so happens we are custom fitting these so the pump internals are the most important part, not necessarily the shape of the housing. I got mine from clubrsx which is the same as clubep essentially...at the time, I think there were several ones to choose. I used the one from a write up I saw.
Sorry about spelling errors, on my phone...

USAF EP3
05-26-2011, 11:14 PM
I just did mine last week. Few differences in my install though:

1. I used an 06 RSX-S fuel pump assembly, difference is that the lines run differently and the fuel level buoy is on the opposite side. For some reason our tanks are somewhat differently shaped than the RSX so the buoy will get stuck and not read correctly, To remedy this I turned the pump assembly 45 degrees counter clockwise so it position the buoy where the EP3 buoy would be.

2. I installed an aftermarket return, so I capped off the part that squirts fuel back into the tank from the stock assembly and modded the top of the assembly for a return feed with a #6 AN bulkhead.

TakeNotes
02-20-2012, 06:19 PM
Followed a DIY to switch out to a Walbro. Was having some issues mentioned such as random cut off at idle. Loss of power when full throttle nears, rough idle (did IACV DIY and cleaned, high idle 2kish but dosent bounce from 1k to 3k anymore)

When I removed the fuel pump assembly, A bracket was broken and wires were rubbing up against something. The red one snapped in half and a black thin wire was disconnected. I stripped the tip of the black wire and reconnected to port and retied the red ends after stripping a piece of wire.

I was afraid to put anything around it that would dissolve in the gasoline so I just put a fat ziptie over the connection. Oh. had a hard time siphoning out the gas as local auto"SHOP" has no siphon pump and I tasted some gas a few times trying to get it to go so I quit.

Put the damn pump in and now the car wont start. Cranks, new battery "new" alternator 3 weeks ago. Started up for a sec twice but died even when i tried to pump the gas.

ep32424
02-20-2012, 07:06 PM
nice DIY.

freeme62410
03-14-2012, 10:05 AM
How is one supposed to replace the filter if you can't buy it? Buy a whole fuel pump assembly! ?

differentK
03-15-2012, 06:47 AM
How is one supposed to replace the filter if you can't buy it? Buy a whole fuel pump assembly! ?

yea basically- they dont sell them separately. BTW guys i installed the new Deatchwerks 265 drop in pump last weekend and it was a breeze. no need for cutting or new fuel hose or anything- fit perfectly and works great- getting tuned this weekend on the new setup

Ba82Ep3
03-15-2012, 06:51 AM
BTW guys i installed the new Deatchwerks 265 drop in pump last weekend and it was a breeze. no need for cutting or new fuel hose or anything- fit perfectly and works great- getting tuned this weekend on the new setup

Link?

differentK
03-15-2012, 08:12 AM
http://www.deatschwerks.com/products/fuel-pumps/dw65c-compact-in-tank-fuel-pump

i dont have any pics but if you follow the install for the walbro 255 it should be self explanatory- it fits like the stock pump

freeme62410
03-16-2012, 11:14 AM
If you purchase the walbro install kit, there is a filter that comes with the pump. If you are like me and need to change the filter in addition to the pump, and do not want to buy an oem pump just for the oem filter fitment, then you can do as follows:

1) Pry the metal stud off the filter side of the pump:

http://s1271.photobucket.com/albums/jj627/freeme62410/?action=view&current=20120316_120529.jpg#!oZZ4QQcurrentZZhttp%3 A%2F%2Fs1271.photobucket.com%2Falbums%2Fjj627%2Ffr eeme62410%2F%3Faction%3Dview%26current%3D20120316_ 120529.jpg

2) Pull off the oem filter
http://s1271.photobucket.com/albums/jj627/freeme62410/?action=view&current=20120316_120529.jpg#!oZZ3QQcurrentZZhttp%3 A%2F%2Fs1271.photobucket.com%2Falbums%2Fjj627%2Ffr eeme62410%2F%3Faction%3Dview%26current%3D20120316_ 120545.jpg

3) VERY carefully, take a utility knife or dremel, and cut out the inner circle of the rubber fitting on the oem filter side as pictured:
http://s1271.photobucket.com/albums/jj627/freeme62410/?action=view&current=20120316_120529.jpg#!oZZ2QQcurrentZZhttp%3 A%2F%2Fs1271.photobucket.com%2Falbums%2Fjj627%2Ffr eeme62410%2F%3Faction%3Dview%26current%3D20120316_ 122301.jpg

4) Cut the other side of the bracket (where the submersible hose goes) off so the walbro pump fits in the bracket as the beginning of his DIY explains.

5)Fit together the orange fittings, and then install the pump into the bracket, and then install the walbro filter. I used pvc glue to make sure it stays on. When you are done, complete all the other steps of this DIY:
http://s1271.photobucket.com/albums/jj627/freeme62410/?action=view&current=20120316_120529.jpg#!oZZ1QQcurrentZZhttp%3 A%2F%2Fs1271.photobucket.com%2Falbums%2Fjj627%2Ffr eeme62410%2F%3Faction%3Dview%26current%3D20120316_ 122807.jpg

Thank you for this DIY!!

EP3Lov3
03-29-2012, 11:46 AM
Never knew so much went into fuel pump install

Eddie Murphy
04-03-2016, 08:44 PM
Is this the fuel filter everyone is talking about?
Has anyone changed out this Denso 9520020 Fuel Pre-Pump Filter?
http://www.autohausaz.com/<wbr>pn/9520020 (http://www.autohausaz.com/pn/9520020)
http://www.autohausaz.com/images/9520020.jpg