D.I.Y Walbro Fuel Pump Install DC5 No Return Line

So I just finished installing my Walbro 255lb fuel pump in the RSX and instal time was just under an hour and it is very easy.

http://i573.photobucket.com/albums/s...l/100_4701.jpg


Tools Needed:
New Fuel Pump
Phillips/Flat screw drive
10,12,14 Sockets (for back seat removal)
1/2" drive extension
Hammer
5/16" Submersible Fuel hose
2 hose clamps
Knife/cutters
zip ties


First thing after taking your back seats out you'll see the fuel pump cover plate. There are 4 gold philips screws you will need to remove.

http://i573.photobucket.com/albums/s...l/100_4702.jpg

After lifting up the plate you will have to disconnect the two wire loom clips.

http://i573.photobucket.com/albums/s...l/100_4706.jpg

From there you will probably need a towel... but my cars been sitting forever and disconnect the fuel line. Just squeeze the tabs and pull back on the line

http://i573.photobucket.com/albums/s...l/100_4707.jpg


Here is where the extension and the hammer come in to play. You will need to pound off the lock ring. Placing the extension on the ring hit it to start loosing it up. It is on there tight. But remember it's still lefty loosey righty tighty. So go to the left!

http://i573.photobucket.com/albums/s...l/100_4711.jpg

Here is the ring taken off

http://i573.photobucket.com/albums/s...l/100_4713.jpg

Now you will need a plastic bag or a towel handy... something to put the fuel pump on once you've pulled it out. Maneuver it out of the gas tank and be very careful of the fuel sending unit plunger!

http://i573.photobucket.com/albums/s...l/100_4716.jpg

the plunger

http://i573.photobucket.com/albums/s...l/100_4717.jpg


Now take the pump to a work bench and we'll begin dissembling.

First thing is to separate the tower arms.

http://i573.photobucket.com/albums/s...l/100_4720.jpg

Then using a flat head screwdriver pop apart the tabs holding the top of the pump housing on. You'll also want to disconnect the fuel hose from the top of the pump and from the return.

http://i573.photobucket.com/albums/s...l/100_4721.jpg

Now you can pull out the actual pump

http://i573.photobucket.com/albums/s...l/100_4722.jpg

To start, remove the bottom lock ring on the fuel strainer. DO NOT DAMAGE THIS because we will be re-using it!

http://i573.photobucket.com/albums/s...l/100_4723.jpg

Now pull the strainer off

http://i573.photobucket.com/albums/s...l/100_4725.jpg

Now pull the pump out of the cage

http://i573.photobucket.com/albums/s...l/100_4727.jpg

Use the knife or cutters as I did and remove the head from the cage as it will not be needed for the new pump.

http://i573.photobucket.com/albums/s...l/100_4726.jpg

http://i573.photobucket.com/albums/s...l/100_4728.jpg


Now place the fuel pump back into the cage. Dont worry it will be to long for the fuel cage but we will make it work.

http://i573.photobucket.com/albums/s...l/100_4729.jpg

Now add the top and bottom portions of the cage. Don't forget to reinstall the bottom clip ring

http://i573.photobucket.com/albums/s...l/100_4730.jpg

http://i573.photobucket.com/albums/s...l/100_4732.jpg

Here you can see the cage doesn't snap back together...

http://i573.photobucket.com/albums/s...l/100_4731.jpg

This is where zip ties come in play! Zip tie the two sections together to keep them as one since the new fuel pump is longer than the original.

http://i573.photobucket.com/albums/s...l/100_4733.jpg


Now time to modify the cage. We need to cut an opening to let the new fuel hose come out. So place the pump inside the cage and mark the area where the hose will extend out and cut. I used a dremel because it's quick clean and easy.

http://i573.photobucket.com/albums/s...l/100_4734.jpg
http://i573.photobucket.com/albums/s...l/100_4735.jpg
http://i573.photobucket.com/albums/s...l/100_4736.jpg


Now clamp on the new fuel hose. I made mine at the pump he man tight.

http://i573.photobucket.com/albums/s...l/100_4737.jpg

Next we will have to modify the top of the housing cage. Because the pump is longer the housing will not shut. So place the pump in and mark off the area that needs to be cut. Then cut it out.

http://i573.photobucket.com/albums/s...l/100_4738.jpg

http://i573.photobucket.com/albums/s...l/100_4739.jpg

Now we will cut the old hose off from the top as we will not be needing it.

http://i573.photobucket.com/albums/s...l/100_4740.jpg


Put the cage back together and clamp down the new hose. Remember not to tighten this side of the hose down as tight because it is going on plastic!!

http://i573.photobucket.com/albums/s...l/100_4741.jpg


Now reinstall the fuel pump into the tank!

http://i573.photobucket.com/albums/s...l/100_4743.jpg

and you're all done!! Simple as that!