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Walbro Fuel Pump Install

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krazy86t

Member
Joined
Jun 21, 2009
Messages
388
Finally dropped the fuel tank to swap the fuel pump, pretty easy job until I started putting the Walbro pump into the fuel pump bracket. A few observations:

1) The Walbro is about 1/2" shorter than the AC pump
2) The turbo regal fuel pump assembly uses a "pulsator"
3) Instructions say to re-install the pump with the pulsator to "snug" fit

Snug fit is impossible with the pulsator due to the 1/2" shorter Walbro pump. :confused:

I could make it work if I dump the pulsator and use a length of fuel line to connect the fuel pump outlet with the exit tube out of the fuel tank.

Also, the electrical connector that came with the kit plugs into the fuel pump perfectly, but the wire lead connector on the other end does not mate to the car fuel pump wires. The de-structions indicate that the car wire connections should be cut off and then crimp connected to the kit connector, but there is no crimp-type connector in the kit. 2x:confused:

Any help very appreciated - new chip from TT is also ready to go in the car:biggrin:
 
Take the "pulsator" and toss it in the trash. Run one peice of fuel line from the pump to the sending unit .
 
Thats what most will do get rid of pulsator, longer hose, with the wire connections use a paper clip on the inside of the connection and it will pop out then just slide it in the correct location
 
Couple more things....

When using a piece of hose in place of the pulsator, get the hose thats rated for in-tank use, SAE J30R10. Regular hose..even high pressure fuel injection hose...will fall apart from the fuel eating it away and you'll be dropping your tank sooner than expected.

Also most people cut off the "neck down" portion of the nipple on the sending unit before installing the hose and pump. It's supposed to be a restriction but I didn't really notice a difference doing it. Its just one of those "every little bit helps" kinda things I guess.
 
Great advice - as always. Thx!

What about the foam rubber pump cozy that is around the AC fuel pump. Do you put that around the Walbro or NOT?
 
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