Replacing Walbro Car Fuel Seats: Step-By-Step Guide

Walbro fuel pumps are produced by TI Automotive and sold through their sales channels. Walbro carburetors are also widely used, and their repair kits can be found on the Walbro website. Walbro carburetors are known to be reliable, but when problems arise, they often involve the small filter on the fuel intake side, the float diaphragm, the internal needle valve, or the fuel pump membrane. To replace the fuel seat on a Walbro car, you will need to remove the old seat and press in a new one. This can be done by hand or with a machine, and it is important to be careful and use the proper tools to avoid damage.

Removing the plastic covers over the fuel cover

Firstly, gather the necessary tools, including a flat-head screwdriver and a needle-nose pliers. You will also need a plastic bag and some paper towels to catch any fuel that may leak during the process. Once you have gathered your tools, locate the plastic covers over the fuel cover. These covers are usually held in place with black silicon.

Using your flat-head screwdriver, carefully pry up the lid of the plastic cover. Take your time with this step to avoid damaging the surrounding components. Once the lid is removed, you will expose the electrical connectors. Using your needle-nose pliers, carefully disconnect both of these connectors. Move the cover to the side to give yourself some working room.

With the cover out of the way, you will now be able to access the fuel line cover. Use an 8mm socket to loosen the two nuts holding the fuel line cover in place. Again, be careful not to lose the nuts down the side of the tank as you remove them. Once the fuel line cover is off, use your pliers to carefully rotate the black hose back and forth to loosen it. If necessary, use your flat-head screwdriver to pry the black hose off.

At this point, you have successfully removed the plastic covers over the fuel cover. You can now proceed with the next steps of changing the fuel seat on your Walbro car. Remember to always exercise caution when working with automotive fuel systems and refer to a professional mechanic if you are unsure about any part of the process.

Disconnecting the electrical connectors

Before beginning, ensure you have gathered the necessary tools, including needle-nose pliers, a flat-head screwdriver, and an 8mm socket. It is also recommended to have a magnetic Phillips screwdriver to avoid losing any small parts down the side of the tank. Place a plastic bag with paper towels next to the fuel cover to catch any spills.

Now, let's begin the process:

• Using your needle-nose pliers, carefully disconnect both electrical connectors. Take your time with this step to avoid any damage to the connectors or surrounding components.
• Once the electrical connectors are disconnected, gently move the cover to the side to create some working space. It is important to be cautious and not force anything, as the plastic components can be delicate.
• With the cover moved, you will now have access to the fuel line cover. Using your 8mm socket, carefully loosen the two nuts holding the fuel line cover in place. Again, be very careful not to drop or misplace the nuts, as they are small and can be easily lost. If you have a magnetic Phillips screwdriver, use it to remove the nuts.
• After removing the fuel line cover, use your pliers to carefully rotate the black hose back and forth to loosen it. If needed, use a flat-head screwdriver to gently pry the black hose off. Be cautious not to damage the hose during this step.
• At this point, you should be able to access the electrical connectors more easily. Using your needle-nose pliers or a similar tool, carefully grasp the connectors and detach them from their housing. Take note of their orientation and any colour-coding to ensure proper reconnection during reassembly.
• With the electrical connectors successfully disconnected, set them aside in a safe place, keeping them organised and easily accessible for when you need to reconnect them.

Remember to work slowly and carefully throughout this process, especially when dealing with electrical components and fuel lines, to avoid any damage or spills. Always refer to a qualified mechanic or a detailed guide specific to your vehicle if you are unsure about any steps or procedures.

Loosening the nuts holding the fuel line cover

To loosen the nuts holding the fuel line cover, you will need an 8mm socket. Loosen the two nuts holding the fuel line cover first, being very careful not to lose a nut down the side of the tank. If you have a magnetic Phillips screwdriver, use that to remove the nuts.

Now that the fuel line cover is off, carefully rotate the black hose back and forth to loosen it. Try to use a flat-head screwdriver to pry the black hose off. If that doesn't work, use pliers on the hose just past the nipple (you can feel where it ends) and pull it off.

It is important to be cautious when performing this task to avoid any potential damage or injury.

Removing the fuel pump housing

Firstly, ensure you have the right tools and parts. You will need a flat-head screwdriver, a Phillips screwdriver, an 8mm socket, needle-nose pliers, medium pliers, a plastic bag, paper towels, and a new fuel pump. It is also recommended to have a magnetic Phillips screwdriver.

Now, disconnect the negative battery cable. Then, jack up the car to a safe height. Disconnect the fuel line and wiring harness from the tank. Be cautious, as there will be some pressure in the fuel line. Also, disconnect the lines from the EVAP canister and remove it.

Remove the filler hose from the tank. Then, carefully lower the tank by unbolting the straps that hold it in place. Support the tank with your knees or blocks as you do this. Once the tank is lowered, remove the FPR (Fuel Pressure Regulator) from the tank assembly top. Remember to note the green plastic keeper and transfer it to the new FPR.

Now, you will need to remove the in-tank assembly. Be cautious with the float arm and level sender device, as they are fragile. You will then need to remove the wires from the harness plug and pull them through the canister top. Use a small flat-head screwdriver for this. Ensure you mark the wires to remember which goes where.

Next, take out the sediment filter and then the canister top from the canister. This can be tricky, so use the wedge provided with the new fuel pump, as well as small screwdrivers. Remove the wire grommet from the canister top. Now you can remove the old fuel pump.

Replace the old pump with the new one. The new pump will come with a blue replacement seal that goes into the end of the canister. Once you have replaced the seal, put the canister back together with the new pump inside. Ensure that the end of the pump with the filter material seats into the new seal.

Now, put the canister back together, reinstalling the wire grommet and reconnecting the wires. Put the in-tank assembly back into the tank, using the new tank seal provided with the new pump. Reinstall the FPR and the tank, and reconnect the fuel filler hose, the EVAP canister, the EVAP canister lines, the fuel line, and the wiring harness.

Finally, lower the car, reconnect the battery, and start the engine.

Transferring old pump parts to the new pump

When transferring old pump parts to the new pump, you will need to reuse some of the old pump parts on the new Walbro pump. Using a flathead screwdriver, pry off the plastic top, rubber o-ring, and black plastic circle tab. Transfer the parts you removed from the old pump to the new pump.

If you are only replacing the fuel filter, disconnect the pump (do not cut any wires) and remove. Make sure you put the float unit back in the same location on the new fuel filter. Remove the float sending unit by pushing the retain clip toward the filter and sliding the float unit down and out. You will need to transfer the brass-looking cap from the old filter to the new filter.

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