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Walbro Fuel pump #12250
22/12/2005 00:50
22/12/2005 00:50

A
Anonymous
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Anonymous
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Has anyone fitted one of these themselves to their 20VT?

I've got one being delivered tomorrow and wondered how hard it would be to fit myself?

cheers

Re: Walbro Fuel pump #12251
22/12/2005 00:52
22/12/2005 00:52

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Anonymous
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quite alot of the guys have fitted these, im sure one one of them will be on later to explain better!

Re: Walbro Fuel pump #12252
22/12/2005 01:16
22/12/2005 01:16

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Anonymous
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Anonymous
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Mine was fairly straight forward to fit, the guide and Rog shouting instructions helped immensely. Im not sure where the guide is. You dont have to drop the fuel tank as per the guide you can get access from the little hatch inside the boot.

Re: Walbro Fuel pump #12253
22/12/2005 01:26
22/12/2005 01:26

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Hannys original fuel pump fitting guide. No pictures though sorry. I fitted mine too, not very hard, but I was constantly bricking it thinking I was gonna go up in flames...

Quote:

Right here is the Welbro up-rated fuel pump, it is slightly larger than the standard pump and does need some modification to fit. Below is the fitment guide and I will stress that it is not a straightforward fit but not that difficult.

I am posting this guide now as to explain what is involved so that you can make the decision on ordering, you have two choices of either fitting your self or getting the fuel pump and getting a garage/specialist to fit for you.

WARNING – please note that if you choose to fit your self that there will be fuel vapours present and all necessary safety precaution should be taken in working on the fuel tank to avoid any risk of accidents.

I have been running the up-rated fuel regulator and up-rated fuel pump now for a week and have not seen any indications with relation to over fuelling, this pump is a 190 litres per hour specification as opposed to the OE Welbro pump of 120 litres per hour.

On reading this fitment guide and you wish to proceed with the group purchase please PM me with your: Name, Address, Contact Number and just post below a YES/NO to indicate confirmation or order so that I can work out what the final price will be in relation to order number.

The cost is £100, which includes vat, and P+P to all UK based buyers, for all people living elsewhere I shall get confirmation of postage costs and adjust price accordingly. This price is for a min of 10 orders, if less then the price will go up, I will post final once I see final requirements

I shall provide a link for payment via Paypal or you can send me a cheque (if cheque is sent I shall wait for 5 working days to clear before postage).

Fitment Guide

This is the packaging that you shall receive for the up-rated pump, it includes all parts necessary for fitment (not tools).

The only part that you need to purchase to aide fitment is a jubilee clip that will fit around the pump and modified pump bracket. See step 15.

OPEN FUEL FILLER CAP TO UNPRESSURISE FUEL TANK.
DISCONET THE MAIN BATTERY
ENSURE THAT YOU HAVE MIN AMOUNT OF FUEL IN THE TANK




1) This access panel to the top of the fuel tank is via the boot area of the Coupe, you need to lift the carpet on the floor of the boot to see. There are three cross screws fixing the access panel.


2) DISCONECT MAIN BATTERY before continuing – you need to remove all electrical connections, they are standard bayonet type connectors. (the brown wire to the left is my extra earth splice – not standard)

3) Note the inlet and outlet pipes, be very careful most parts are plastic and will be brittle due to constant fuel wash, these pipes have a bayonet type fitment and should NOT be either loosened by side to side movement or forced upwards. The pipes have a clip on the side that needs to be pressed in with pliers and then pull gently upwards – any resistance then stop and ensure that you are squeezing the clips correctly.

4) Once all the electrical and pipes have been disconnected you shall note that there is a white plastic ring that seals/attaches the swirl pot into the fuel tank. Fiat have a special tool for removal but not available to the public. When attempting to unscrew (anticlockwise) beware that again this is brittle, make sure that what ever you use (piece of wood against ring and rubber hammer) that you try to make as much material contact as possible – i.e. don’t just try using a corner of the fin mould.

Note that this is a picture with the fuel tank lower under the car with a trolley jack, you may wish to attempt to remove straight up through the inspection hatch in the boot – up to you but it is a very tight fit.



5) This is another picture of the ring – but removed.

6) Once the ring above has been removed note that there is also a rubber seal that the ring fits over, it is at this point of trying to remove the swirl pot that space becomes a premium so it is up to you if you wish to drop the tank or attempt to remove the swirl pot up through the inspection hatch in the boot.

7) This pic shows the swirl pot top being pull upwards, picture taken from in the boot, also note that to give more room the fuel tank has been lowered onto a trolley jack.

8) This is the swirl pot complete (please ignore the fuel pipe still attached, as this swirl pot is from a diff car and if you should of removed the pipes earlier within this guide).

9) The swirl pot splits into two pieces, you have to remove the fuel return pipe (black pipe dangling) form the base of the pot and pull upward to separate.

10) Inside the base of the swirl pot you will see the OE fuel pump, this is held with in a plastic bracket that has three runner which attach inside – lever upwards to remove. (note bag filter attached to bottom of pump)

11) Separate the components as seen in this picture.

12) The pump bracket ( centre item in picture above) needs to be moded to allow fitment of the larger length of the up-rated fuel pump – first you need to cut off the bottom section – see next two pictures.

13) You have to now cut the side of the pump bracket to allow for the larger diameter of the pump

14) Empty the up-rated pump bag and extract the pump, bag filter, jubilee clips and wire.

15) Fit the up-rated fuel pump in the modified pump bracket and use a jubilee clip to hold into place (note jubilee clip needs to be purchased separately)

16) You need to fit the new filter bag onto the end of the pump and adjust so that it will fit into the base of the swirl pot. Reinsert modified pump bracket with up-rated fuel pump back into the base of the swirl pot.

17) Reassemble top and bottom of the swirl pot and use existing corrugated fuel pipe, you will also have to connect the electrical wires by either soldering or connectors – ensure you use heat shrink or similar suitable electrical sealing, tape will loose its adhesive with the fuel.

18) The swirl pot should not be assembled and ready for re-fitment back into the fuel tank. Key points to check are:

- Electrical connections are secure and insulated.
- The jubilee clips hold all pipes securely.
- All associated filters are in place.
- All parts are assembled correctly and spring function of the top and lower parts of the swirl pot do not put any strain on either the pipes or electrical wires.

Now you need to fit the swirl pot back into the fuel tank in reverse of your removal.

Make sure that when you refit the swirl pot-retaining ring that fits over the rubber seal is screwed securely as this may lead to fuel leaking.

Once reconnection complete go for a test drive and check for leaks, engine may not fire on first turn over due to pressure being relieved when fuel pipes were connected.

Note: my fitment was done by Barbz and I assisted with the minor aspects, should you not be confident in fitment then I would advise to seek professional advise from your nearest garage/specialist.




Re: Walbro Fuel pump #12254
22/12/2005 02:19
22/12/2005 02:19

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Anonymous
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Anonymous
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Cheers for the guide, any idea how much it would cost to have fitted? just an average as I know everywhere would be different.

Re: Walbro Fuel pump #12255
22/12/2005 02:49
22/12/2005 02:49

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Anonymous
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Anonymous
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i have the picture of the fitting,whom do i send it to to load it????
email please!!!

Re: Walbro Fuel pump #12256
22/12/2005 02:52
22/12/2005 02:52

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Anonymous
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Anonymous
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I have now been emailed the guide with pictures, thanks.

I think I'll see how much it will be to have it fitted first. Probably safer!

Re: Walbro Fuel pump #12257
22/12/2005 02:52
22/12/2005 02:52
Joined: Dec 2005
Posts: 12,293
Sandhurst
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Ex El Presidente
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I AM a Coop

Joined: Dec 2005
Posts: 12,293
Sandhurst
Chris, register yourself an account on www.photobucket.com (its free) and you can upload 25mb of photo's there. Then you can post them in the forum without the need to send them to someone else to fo


Originally Posted by Jonny - After being taken out at Spa
Your car is Usain Bolt with wellies
Re: Walbro Fuel pump #12258
22/12/2005 06:47
22/12/2005 06:47

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Anonymous
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Anonymous
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Gaz - do you know any mechanics in Warrington who will do this job?

Re: Walbro Fuel pump #12259
22/12/2005 07:13
22/12/2005 07:13

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Anonymous
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Anonymous
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I reckon Camco88 should, they are turbo and fuel injection specialist (thats what they advertise anyway). I used to take my RS Turbo there a bit.

Re: Walbro Fuel pump #12260
22/12/2005 16:06
22/12/2005 16:06

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Anonymous
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You could try Bob at JRT Motor Services 01925 604505 - next door to the petrol station on Knutsford Rd near the Springbrook pub. He does the servicing/repair work for Car Planet (Jap import garage) so regularly works on perforance Skylines/Subarus/Mitsis/etc. He also runs his own Subaru rally car - top bloke!

Last edited by Munchkin; 23/12/2005 18:23.
Re: Walbro Fuel pump #12261
22/12/2005 17:12
22/12/2005 17:12

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Anonymous
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Anonymous
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ok thanks, I'll try both places, and see how much. I don't imagine its much more than an hours work for pros.

Re: Walbro Fuel pump [Re: ] #1513257
27/10/2014 17:17
27/10/2014 17:17

M
MiZe
Unregistered
MiZe
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M



Has someone the DIY pictures?

Thank you, best regards

Re: Walbro Fuel pump [Re: Anonymous] #1664436
03/04/2023 17:52
03/04/2023 17:52
Joined: Aug 2022
Posts: 20
Derby uk
F
Fly2 Offline
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Joined: Aug 2022
Posts: 20
Derby uk
Hi not fitted pump just fuel sending unit got replacement sender but having trouble refitting the ring won't tighten up tried always 20v none turbo


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