Tag: fuel pump

Fabrication & Fuel Pressure Woes

I managed to get the car to the tuner for some fab work and the tune prior to a quick 2-week trip offshore. As I arrived, he went through all the wiring and everything looked good, a sigh of relief from myself.

Unfortunately, it seems my modifications to the fuel pump housing failed and we could only build about 3psi of fuel pressure before dropping to zero. I suspect the fuel pump nipple is not sealing in the housing, having fallen due to a lack of support or was never seated properly in the first place.

We did manage to get the car running off brake cleaner – win.

Whilst offshore I ordered a new housing and bought the Denso 265 LPH pump I mentioned in my previous post. The pump is indeed identical to the factory one, going into the new housing beautifully.

The fabrication works looks absolutely awesome. I have a small to-do list before heading back to the tuner in the next week or so.

As you can see, some of the items are already complete, including a catch can.

Fuel Pump & Engine Sealed

Good progress recently. I had a bung welded in the sump just above max oil line by one of the guys at work. The fitting was a little worse for wear after welding but I think it should seal fine. I had to shorten my drain line a little, which I may have overcooked it as it was a bit of a pain to tighten but I think it will be fine.

I also installed the Walbro 255 which was a lot more difficult than expected due to the pump being slightly wider and a lot longer than the OEM pump. I made some modifications to the housing and got it to fit but it’s not the prettiest solution. In hindsight I should’ve just bought a Denso equivalent which would’ve dropped straight in with very similar specs to the Walbro.

I used the sanding wheel on a dremel to remove a small amount of material evenly from the inside of the housing. Then I cut various tabs and screwed in some stainless screws at the 3 factory tab locations to hold the pump up, allowing for the extra height and giving the filter sock about 3mm of clearance from the bottom. You have to be careful doing this as the pump housing has a cavity around it, you can only drill in to the ‘sleeve’ that has the tabs.

Before re-installing the fuel tank and pump I hot wired it to check it ran fine – which it did. Hopefully I am not missing anything!

I also got the engine all sealed up, pretty much ready to chuck back in once I sort out the wiring (which I am procrastinating a little). I also mounted the fuel rail with my 1000cc injectors. I’ll need to do a quick check once it’s in the car to see if they’re sealing properly. I will be adding a fuel pressure sensor, which I’ve added a tee for.

Here is the wiring table, all I’ve managed to do is some practice crimps using open barrel splices and putting a Deutsch connector on my boost solenoid. I have purchased some fancy wiring, including shielded ground wiring and nice heat shrink. There has been some revisions to my wiring/pin table too which you can see below.