Post by casias on Sept 29, 2015 15:40:09 GMT -5
This is the last time I will buy one of these Walbro kits. As seen below, the pump that comes with the kit is not clocked correctly, which requires losing the internal fuel filter. This filter is a 100 micron pre-pump filter. Without it, the pump may suffer premature failure. Bummer.
So here is how to modify a stock basket to fit a Walbro 255 (or similar), and convert to AN6 (3/8) line.
Pump is removed from tank. This is seen in the Durango build thread. lsdak1.freeforums.net/thread/101/2000-durango-4wd-swap.
And opened up using the three screwdrivers to the right.
In this case, there is a small vent, which I removed. The regulator, to the upper right, was snapped in with nylon clips instead of the usual rubber grommet. It was impossible to remove it without destroying the basket, so it is capped, and abandoned.
To fit an AN6 bulkhead fitting in the hole, I used a washer, and ground it down along the sharpie line. I made two. One inside, one outside. And installed the AN6 bulkhead fitting.
Next I drilled a hole for the 1/4 inch return line. Brass fittings are from Lowe's/Home Depot. You want the return line to dump into the bucket, to keep the bucket full, and the pump submerged.
Next the wiring. With the release facing you, the positive is on the left, the ground is on the right, and the fuel sender is in the middle.
Using a homemade tool (screwdrive ground down and rolled over), I pulled out the blue contact covers in the connector.
Using a small, flat blade screwdriver, pull back the release clips and remove the wires.
Ohms on this sender is 19 when full, and 220 when empty.
Cut the top off of the basket hold down, 7 o'clock position in this picture. (I would put an arrow, but photobucket is sucking right now).
Pull the pump, basket, etc. Here is a picture that shows the clocking problem with these pumps. These two pumps are held side-by-side, but the inlet nipples are not lined up (bottom of the pumps). This is just enough to prevent using the pickup tube and filter assembly. The Walbro engineers made it clear they don't give a rat's ass.
Cut the clip and remove this tube from the new pump. This is replaced with a corrugated tube, readily available from amazon, ebay, or other internet sellers.
New pump, tubing, and wires installed in new basket from kit. Unfortunately, this basket was about 2 inches too long. So much for kits.
So, in went the old basket with the new pump, tubing, and wires. Since I cut the top of the hold-down tube (seen here at 2:30 o'clock position), I used 3 aluminum sheet metal screw through the side of the basket to hold the ring in place. Actually, this is a much better solution. If I want to swap out the pump, for upgrade or whatever, I won't have to cut anything. Just unscrew it.
And inside the lid. AN 6 to 5/16 barb fitting pushed onto the end of the supply tube, and clamped. You can see the brass return fitting at the 12 o'clock position.
And reassembled.
Dropped back in tank, with stainless clips replacing the rusted hold-down ring. If I bought a new steel hold-down ring from the dealer, it would just rust again. I found these clips in a drawer. They came off of an old water-softener system.
And AN6 tube nut, and 3/8 steel poly-armour tubing, flared.
www.youtube.com/watch?v=46hFmkTGGV8
So here is how to modify a stock basket to fit a Walbro 255 (or similar), and convert to AN6 (3/8) line.
Pump is removed from tank. This is seen in the Durango build thread. lsdak1.freeforums.net/thread/101/2000-durango-4wd-swap.
And opened up using the three screwdrivers to the right.
In this case, there is a small vent, which I removed. The regulator, to the upper right, was snapped in with nylon clips instead of the usual rubber grommet. It was impossible to remove it without destroying the basket, so it is capped, and abandoned.
To fit an AN6 bulkhead fitting in the hole, I used a washer, and ground it down along the sharpie line. I made two. One inside, one outside. And installed the AN6 bulkhead fitting.
Next I drilled a hole for the 1/4 inch return line. Brass fittings are from Lowe's/Home Depot. You want the return line to dump into the bucket, to keep the bucket full, and the pump submerged.
Next the wiring. With the release facing you, the positive is on the left, the ground is on the right, and the fuel sender is in the middle.
Using a homemade tool (screwdrive ground down and rolled over), I pulled out the blue contact covers in the connector.
Using a small, flat blade screwdriver, pull back the release clips and remove the wires.
Ohms on this sender is 19 when full, and 220 when empty.
Cut the top off of the basket hold down, 7 o'clock position in this picture. (I would put an arrow, but photobucket is sucking right now).
Pull the pump, basket, etc. Here is a picture that shows the clocking problem with these pumps. These two pumps are held side-by-side, but the inlet nipples are not lined up (bottom of the pumps). This is just enough to prevent using the pickup tube and filter assembly. The Walbro engineers made it clear they don't give a rat's ass.
Cut the clip and remove this tube from the new pump. This is replaced with a corrugated tube, readily available from amazon, ebay, or other internet sellers.
New pump, tubing, and wires installed in new basket from kit. Unfortunately, this basket was about 2 inches too long. So much for kits.
So, in went the old basket with the new pump, tubing, and wires. Since I cut the top of the hold-down tube (seen here at 2:30 o'clock position), I used 3 aluminum sheet metal screw through the side of the basket to hold the ring in place. Actually, this is a much better solution. If I want to swap out the pump, for upgrade or whatever, I won't have to cut anything. Just unscrew it.
And inside the lid. AN 6 to 5/16 barb fitting pushed onto the end of the supply tube, and clamped. You can see the brass return fitting at the 12 o'clock position.
And reassembled.
Dropped back in tank, with stainless clips replacing the rusted hold-down ring. If I bought a new steel hold-down ring from the dealer, it would just rust again. I found these clips in a drawer. They came off of an old water-softener system.
And AN6 tube nut, and 3/8 steel poly-armour tubing, flared.
www.youtube.com/watch?v=46hFmkTGGV8