How to install an aftermarket fuel pump
I recently aquired a walbro 255 high pressure fuel pump and thought it would be a good idea to share the step of how to go about installing it in a EP82 Starlet. So I will try to illustrate how you go about doing so.
First the tools needed are:
1. 14mm spanner
2. 17mm spanner
3. Philips screw driver
4. Wire cutting pliers (optional)
5. Cutting knife
First thing you need to do is remove the back seat of the car as beneath the seat is where u can gain access to the pump. The seat is removed simply by lifting it and unsecuring some nap in that hold it in place.
Once the seat is removed you should see something look like the pic shown above
Unplug the connector from the ignition to the pump, and then remove the 3 screws that hold the cover plate in place. Once the plate is removed you will now be able to see the three hose that lead to the fuel tank.
At this point you can then remove the clips that hold the hose in place and use the 14mm spanner and 17mm spanner to pull the middle hose ends. You can then go ahead to use the Philips screw driver and remove the screws that hold the fuel pump assemble in place as illustrated.
Once this is done you can now remove the assembly in which the fuel pump is housed. Extra care should be taken when removing this assembly so as not to damage anything when pulling out the assembly. Once removed it should look something like this.
Its now time to remove the old pump from the assembly. Firstly unplug the electrical connection to the pump. Then use the pliers to remove the top clamp from the hose and then you can pull the pump from the assembly. Once the pump is removed it should look something like what is shown below
At this point you may have to cut the wires connecting the electrical connector as the connector supplied with the new pump may be different.
Reconnect the wires with new connector supplied with the pump and then install the new pump ensuring that the clamps on the hose are properly secured. Having done that it should look something like this
Replace the assembly with the new pump in the fuel tank and replace the screws that hold the assembly in place. Reconnect the hoses making sure not to connect the wrong hose to the wrong line. Reconnect the battery terminals and then fire it up.
Once started just check and make sure that the middle hose is tight enough and that there is no leaking. Once this is done replace the cap that covers the hoses and replace the seat and you should be good.