DIY Walbro 255Lph Fuel Pump Install

[EZ Boy]

** Install of Walbro 255lph in-tank fuel pump **

Performed on a TJ AWD, but the assembly appears to be identical to other 3rd gen models - not sure about 2.4L thou.

1st step is to open the inspection cover. Disconnect the fuel pump electrics plug (white). Turn on motor and idle until car stutters. Shut off as stuttering starts. This is to purge the fuel line pressure so you don't get a face full of petrol when you disconnect the line. Disconnect the negative battery terminal lead. Install walbro. Reconnect battery lead. Reconnect fuel pump elec plug. Turn over motor until car starts. Check for leaks etc. When satisfied replace the inspection cover. Unless racing later that day, put you back seat back in and your cardigan on the parcel shelf.

Expect the large black plastic lid to be super tight. I used a bolt and a hammer to GENTLY tap the lid counterclockwise to loosen it. Turns out I had to tap it nearly all the thread way it was so tight. Turns out the thread on mine was dodgy and took flipping ages to get the thread to start when I reinstalled. I thought I'd retightened my lid enough but with a full tank of fuel later that day I was bleeding juice all over the road. With the help of the previous bolt and hammer I retightened the rotten thing. I did lube the thread with a dash of oil after placing the plastic lid in a container of boiling water - to get the thing to expand and thread easier, which it did thankfully as the light was fading and my car was reaking of petrol.

The next biggest time waster was the connection with the olive inside it. To get the rotten thing off (because you cant lift the fuel pump out without it disconnected in the AWD). I used a stanley blade to slice the plastic of the outside connector so that the inside olive (?) style section would have enough play for the larger plug to separate and come off the line.

Yes it has a distinct whine to it hence the "whine-bro" nickname. Thought my phone was doing something stupid before I realised what the source of the noise was. Nothing some more dynamat can't fix/aid.

Good luck hope this helps.

[MAD35L]

so is this guy 500hp yet?

if so im owed a drive!

[EZ Boy]

- someone's already read the fine-print! Got some plumbing to do next wk. Then it's action stations.

[zero]

Excellent,like the pics and titles.....you better do a whole workshop manual like that.

[Levinitup]

Just incase anyone is intending to use this guide in the future:
I noticed a few differences in my TJ2 vrx when i just installed one
The lid wasn't a screw top - it had about 6 x 8mm nuts holding it on,
There was only one annoying hose to get off on the top, not 3,
And i didn't have a removable bracket to modify, it was all one piece so i had to bend the bottom to get it in.
Cheers

[PeteW]

seems TF are different mine was the same as levinitup, one hose and wire clip the bracket i have is one peace, 8mm nuts holding it down. the 255lph walbro i got was about 1cm longer than the origional so with some mods it went in

for the hose these are way east its a squeeze release typeclip, ignore the cut this lug bit in the photo with long nose pliers sqeese the sides and push it on then off, yes on before pulling it off

[Tevo]

Btw don't go doing this with a full tank off fuel