Last night I went ahead and replaced the ailing and extremely noisey Bosch pump with a shiny new Walbro inline unit. Here are, roughly, the steps I followed. I tried to take a few pictures, but, the cammera just wasn't up to focusing close or on things under the car. The results of the conversion were fantastic (well, as exciting as a fuel pump gets). The pump is completely silent and is rated out of the box for more than enough flow at 28 psi for whatever that little 2L requires. It is a little longer and a little thinner, however, that requires just a little fabrication. The car starts up quicker and I seem to have a lot less WOT pinging and more pickup.

The web link is:
http://www.fuel-pumps.net/inline.html
I paid ~$160 for everything including some hose connectors and shipping from Florida to Washington.


Joel


Here are the steps I went through last night:

(a) determine your existing pump is bad.

This can range from hating the noise to not delivering the pressure and flow needed to keep the fuel system happy. My pump was able to produce 28 PSI staticly (jump the relay, engine off) but I suspected that as the fueling requirements increased it wasn't doing the job. Perhaps some of you remember my post about fighting ping a couple days back. It was also stunningly loud.

(b) take the tray all the way out of the car and pull the old pump
(c) install the new pump in the tray.

Drill a pair of holes in the tray for the new pump mounting hardware. I installed the pump on the drivers side of the tray to clear the huge fuel filter on the passenger side. I found it easiest to locate the inlet forward and the output rearward. The flow needs to make a 180 degree bend to get back to the filter, but, it's at pressure at that point and, well, that's just what pumps are designed to do. I used a pair of 3/4" long cap screws, nuts and washers to anchor the supplied brackets to the tray. The pump comes with a cool foam sleeve to avoid metal to metal contact. I put the fuel filter back in the tray and routed its inlet hose to the pump outlet. Route the fuel filter outlet out of the tray.

(d) prepare the electrical connections

Cut the existing fuel pump conntector off of the wires and crimp on the new, ring connectors. One of these wires will be switch power and one will go to ground. Both of mine were yellow, so out came the multimeter. The pump is marked (+) and (-) so once you determine which wire goes to ground wiring the pump up is trivial.

(e) jam everything back under the car.

The proceedure I found to work was: attach the front screw and hang the tray off the bottom of the car. Next make the electrical connections. Now attach the inlet hose. Since the Walbro pump is a good bit longer you'll need to trim that hose to fit. Next hook up the outlet. Make sure everything is tight and then put some gas into the tank and go drive.