HOW TO: S13 Walbro Fuel Pump Install

[ZiG]

So, I noticed that the tech articles were severely lacking in one area: Fuel pump installs on an s13. I just bought a Walbro last week and read the s14 writeup hoping it would be the same, it's slightly different. I figure I may as well document it just for the sake of it.

WHAT YOU NEED-Phillips screwdriver-10mm socket-8mm socket-ratchet (of course)-rags/paper towel-wire strippers-crimping tool or soldering iron w/ solder-heat gun-heat shrink tubing

-maybe a crescent wrench-maybe penetrating oil (it's always nice)

PROCEDURE

1. Disconnect the fuel pump fuse (or if you are like me, just flip your hidden kill switch off)

2. open the gas cap

3. start the car and let it run till it dies

4. start it again and wait till it dies again

5. disconnect battery

6. use the phillips screwdriver to remove the cover over the wiring connection

7. use either a phillips screwdriver or a 10mm socket to remove the fuel pump access door and unplug the wiring connector that was under the first cover

Then you will see this:



You will notice that the screw hole closest to the camera is all torn to hell. That's because the screws are just held in by nuts on the bottom and three of the four had come loose, so I couldn't get the screw out. I had to cut one with a hacksaw, bend the cover over a bit, then hold the nut from underneath with a crescent wrench while I used the socket on the top side.

8. Clean it all up real well, and spray penetrating oil on the bolts

9. wipe it off as best you can

10. mark the two hoses connecting to the middle, and remove them. Have the rags ready for the gas that will come out of the one on the right.

11. remove the 8mm bolts from the perimeter

12. lift the thing straight up, careful not to damage the float assembly

13. Cut the rubber hose connecting the fuel pump to the L shaped bracket and remove the pump

14. cut the wires right in the middle, careful to only cut the two leading to the pump!

15. cut the wires on the new pigtail to the same length as the wires coming off the old pump



16. crimp or solder the wires together and be sure to use heat shrink. Go very far away from the car if you are using a lighter

17. install the sock on the new pump just as the instructions tell you to. Don't worry, it only goes on one way.

18. install the new isolator per the instructions

19. cut about half an inch off the supplied bit of hose

20. shove the hose onto the fuel pump and onto the connection on the L bracket and set the fuel pump in place.

21. plug the pigtail in

22. gently lower the assembly back into the tank. Check the o-ring to make sure it hasn't deteriorated.

23. screw it back in, careful not to over tighten the bolts, and connect the hoses

24. plug the harness back in, reinstall the fuel pump fuse, and reconnect the battery

25. turn the ignition on but do not start the engine

26. listen for the fuel pump. hear it? Good.

27. turn the key off, then back on, wait 5 seconds, then off again. Maybe do this a few times to make sure the thing is primed properly.

28. Go check for leaks

29. start the car and make sure all is well. If it is, reinstall the fuel pump access panel and the wiring connector cover, put the trunk back together and go crack open a beer. Oh and change your clothes before smoking.

That should be about it. Usual disclaimer stuff, i may have forgotten something so beware, if you blow yourself up it isn't my fault, i did not have sexual relations with that woman, yada yada.

Now to make this easy to find in a search, 240sx s13 walbro fuel pump installation instructions how to mad jdm tyte ka-t sr20det bowling ball pink panther.

Modified by ZiG at 1:56 PM 8/17/2007
Modified by ZiG at 1:57 PM 8/17/2007

[JchavezJ]

Hey good thread i recently installed one this would have helped alot if i would have known about it earlier lol Thanks anyways

Chavez

[94_240sx]

For #15, I just took the old wires out and soldered new one in, so there was no crimping or cutting involved. It was more clean that way too. Just my .002.

[onosqv]

good work... but we aren't lacking install threads for these...

Here's one: zerothread?id=257071

Next time, search b4 u post

[wetwilly8690]

Nice thread helped out alot

[tripleJs15]

Has anyone eliminated the old wiring and ran new wiring/relay etc to the pump ? If so can you give me a run down on how it was done ?

Thanks.