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  1. #1
    UKDM > JDM jimmyjames's Avatar
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    DIY: Walbro fuel pump install

    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!!
    Last edited by jimmyjames; 11-18-2017 at 12:05 PM. Reason: revised hose section

  2. #2
    Registered User civictype_r04's Avatar
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    Nice write up. I will be using this soon to install mine.

  3. #3
    * jeenyusss's Avatar
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    miller chills! barrrfff



    nice write up:yo:

  4. #4
    ephatch member 02_epdriver's Avatar
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    sweet right up man. What size injectors would you use for an n/a setup

  5. #5
    UKDM > JDM jimmyjames's Avatar
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    Quote Originally Posted by 02_epdriver View Post
    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.

  6. #6
    ephatch member 02_epdriver's Avatar
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    How many mods are you thinking before you kick it to at least 310

  7. #7
    UKDM > JDM jimmyjames's Avatar
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    Quote Originally Posted by 02_epdriver View Post
    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.

  8. #8
    ephatch member 02_epdriver's Avatar
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    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

  9. #9
    UKDM > JDM jimmyjames's Avatar
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    Quote Originally Posted by 02_epdriver View Post
    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.

  10. #10
    ephatch member 02_epdriver's Avatar
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    Cool thanks for the info Jimmy

  11. #11
    Registered User k20z3ep!!!'s Avatar
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    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??

  12. #12
    ΜΟΛΩΝ ΛΑΒΕ talonXracer's Avatar
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    Quote Originally Posted by k20z3ep!!! View Post
    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.
    ALL advice issued with this "Disclaimer"
    Tim "the Toolman" Taylor is my HERO ! ! !

    "Labor Unions are Domestic Terrorist orgainizations"

  13. #13
    jan 05 stepintoliquid's Avatar
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    this write up is the shit!

  14. #14
    Site Sponsor MadLorEP3's Avatar
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    good shit right here
    tnx
    Quote Originally Posted by nmysiismyn View Post
    Ecclesiastes 1:9
    "What has been will be again,
    what has been done will be done again;
    there is nothing new under the sun."

    -King Solomon



  15. #15
    Registered User
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    very informative.....

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