So I have the walbro 255 mounted but when i drop it into the tank the cap won't fit on it will not sit flush. Any ideas why?

This happened with mine too, but I forget exactly why it was. What I did was cut the tip of the tube that went through the cap, and relocate the bottom peice of the bracket. Don't cut any part of the pump, just the metal tube in the "cap."

Just get creative and it'll work.

Brian

Maybe these pics will help.

I drilled a new hole for the bottom support bracket about 1/4" above the old location (this actually lowers the bracket slightly) and then shortened the rubber hose that connects the output of the pump to the outlet pipe nipple. This was on a 98 Eclipse with a Walbro 255LPH (P/N GS 342).

Nothing new, I just followed examples I researched here.

yeah thats what i did and still had problems

Cut the fuel sender at the brass nipple (greenish gold) until it fits. If you have the old 2G sender it will be a big bell looking thing, the newer one is just a nipple. Cut it off. You'll only have about 1/3" sticking out from the metal sender. A dremel with Red cutting disk works well for this. You will need to trim the rubber hose with a razor blade as well. Don't cut any part of the Walbro pump. Just the brass sender. Make sure you don't lose the little metal checkvalve crimped to the tip of the Walbro nipple.

In the illustration above, you can see the tube that can be trimmed at the very top of the rubber hose, near the wires.

You can go back to stock anytime, just replace with a longer fuel hose.


I don't really agree with lengthening the bracket because that puts the filter sock really close to the bottom of the tank. You might have problems like flow, rubbing, vibration, and other random abuses of the prefilter. I'm almost certain you can't close the tank lid because the pump is bottoming out.

Originally posted by thedawg
I don't really agree with lengthening the bracket because that puts the filter sock really close to the bottom of the tank.

Agreed. You don't want the noise and possible vibration damage from the filter touching the tank bottom. I measured 1/8" clearance from the sock to the tank bottom on mine so I let it ride. Had it touched or needed forcing to fit the lid closed I would have had no choice to shorten the brass nipple on the pump cover as suggested.

Keep in mind that some fuel tanks could have damage to the bottom from off-road excursions so...YMMV.