Walbro 255 install on a 760(21gal tank)

[ovlov760]

This project has been a major pain in the ass and it's not even done yet. The pump is in the tank and works but I'm still chasing minor leaks and my fuel gauge is dead. This pumps pressure is no joke. Anyways here are some pics..
http://www.cramptonstation.com/walbro1.jpg
http://www.cramptonstation.com/walbro2.jpg
stock pump and assembly out. dirty filter sock was also sorta crumbly.
http://www.cramptonstation.com/walbro3.jpg
walbro mounted. I added more hose clamps later because the pump would fall off when I installed it in the tank.
http://www.cramptonstation.com/walbro4.jpg
Two more hose clamps to hold the metal thing and everything goes in without getting messed up.
http://www.cramptonstation.com/walbro5.jpg

[Addicted242Boost]

stop breaking your car

[ovlov760]

got the fuel gauge working again and fixed the big leak. still have minor vaporish leak out of the little electrical caps on the tank cap.

[240T man]

anybody done a walbro for the main pump and have pics? this is what I want to do..

[ovlov760]

anybody done a walbro for the main pump and have pics? this is what I want to do..
I've never seen what those Walbro pumps look like but I *assume* it would be pretty straightforward and you could leave the in-tank pump alone.

[740Turbo92Wagon]

anybody done a walbro for the main pump and have pics? this is what I want to do..

not that hard, you should have the mid-car basket, just drop it, install the new bracket/pump on the cage, modify the lines to accept barb fittings or see if the banjo bolt will thread onto the pump, put the wires onto the terminals of the pump... re-assemble... really easy.

got the fuel gauge working again and fixed the big leak. still have minor vaporish leak out of the little electrical caps on the tank cap.

what was wrong w/ the gauge?

[Boosted2003]

Did your replace the seal and the ring when you changed the pump? It really helps

[ovlov760]

I reused the old seal since it looked ok. I guess the gauge stopped working because one of the sender wires was messed up. After getting rid of the little vaporish leak the 2" long 1/2" hose under the car that comes before the fuel filter literally burst on a slogging run.

[240T man]

not that hard, you should have the mid-car basket, just drop it, install the new bracket/pump on the cage, modify the lines to accept barb fittings or see if the banjo bolt will thread onto the pump, put the wires onto the terminals of the pump... re-assemble... really easy.

I figured such. My prepump seems to be fine, so you know what they say, if it ain't broke...besides, the prepump is just supposed to be a feeder for the main anyway. the main pump is worn out and is now quite loud. the prepump is fine, I can hear it humming when I put my ear up to the filler neck.

[ovlov760]

You can measure how many amps either one is drawing from the fuse box. Gives you some indication of the pumps health.

[BoxDriver2]

I might end up doing a conversion to the main or intank.

The 91 has the intank conversion, but i am not sure if i like it that much, seems to leak at full fill up at the tank.

[ovlov760]

I intend to make this into an article of sorts since the current one doesn't cover the 21 gal tank to my knowledge. More info... My experience so far is that the 1/2" or 7/16" that goes from the metal line to the pump underneath the car DOES NOT CUT IT. I blew it open twice so far. That line needs to be replaced with something high pressure. This is what I found at the local hydraulic shop I like. I will probably replace the piece of hose in the trunk with this stuff even though it's not currently giving me any problems. I imagine it's in better shape because it's not as exposed to the elements.
http://www.cramptonstation.com/walbrohose.jpg
Steel belted inside and rated at 1250psi. Safe for any type of common fuel. I'll be damned if the walbro can blow this sucker up. It survived its maiden run. I wish I hadn't have had to destroy the old hose to get it off because the section that the walbro literally blew up would make a nice pic.

[ovlov760]

I might end up doing a conversion to the main or intank.

The 91 has the intank conversion, but i am not sure if i like it that much, seems to leak at full fill up at the tank.
maybe they didn't tighten down the hoses enough? Maybe one of the hoses is leaking? Possible that the hose outlets need to be brazed welded as they could be leaking from corrosion after someone touched them.. mine were.

[r3ckl1ss]

you can blow that hose with the stock intake pump seen it happen before.

[ovlov760]

you can blow that hose with the stock intake pump seen it happen before.
I don't see how that's possible unless the hose is in really bad shape or it's not fuel hose. The hose on my car was fine until the walbro install.

[BoxDriver2]

You may have been replacing it with fuel line, meant for a carb.

For those who don't know, there is a reaon fuel line for non-EFI motors is so cheap, it is VERY low pressure, NEVER use it for EFI hose replacement, it will never last.

[ovlov760]

You may have been replacing it with fuel line, meant for a carb.

For those who don't know, there is a reaon fuel line for non-EFI motors is so cheap, it is VERY low pressure, NEVER use it for EFI hose replacement, it will never last.
The stock fuel hose isn't fuel injection hose in that section on a 760 afaik. It was the stock Volvo stuff that burst on me.

[BoxDriver2]

The stock fuel hose isn't fuel injection hose in that section on a 760 afaik. It was the stock Volvo stuff that burst on me.

The one between the filter and main pump? I thought thats what we were referring to..