DIY: Walbro fuel pump install

[jimmyjames]

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?br...ocation_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]

Nice write up. I will be using this soon to install mine.

[jeenyusss]

miller chills! barrrfff



nice write up:yo:

[japarossa]

Do I need to do anything to regulate fuel pressure? Or just drop this in and thats it?

[jimmyjames]

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.

[05 hatch]

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]

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...

[02_epdriver]

sweet right up man. What size injectors would you use for an n/a setup

[jimmyjames]

sweet right up man. What size injectors would you use for an n/a setup

stock 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]

How many mods are you thinking before you kick it to at least 310

[jimmyjames]

How many mods are you thinking before you kick it to at least 310

I 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]

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

[japarossa]

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]

the 3/8 hose number is H206

[jimmyjames]

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.