Walbro 255lph high pressure fuel pump install.

[[badmoon]]

So I spent the better part of Friday night doing this installation. While the instructions were done up on this somewhere I figured maybe you guys would be interested as there has been a proliferation of Stage 3 and higher cars showing up (with the K04 GB that number will assuredly increase even more). The OE options we have are to buy a new stock S4 pump ($360 and not enough flow) or an RS4 ($700...that's kinda spendy). OR go with a pump like the Walbro 255lph which is the route I went. Unfortunately through searching there really wasn't much information on what specific pump to use (Walbro makes a TON of pumps for different import and domestic applications). The pump that was referenced the most throughout searching was the GSS340. Supposedly that pump is being replaced by the G20000169 which is what I purchased rather blindly (it was the only one that Evolution Imports had that they thought would work) it ended up working out perfectly. Anyways on with the installation:

I won't go into painful minutae as this HAS been written up along with pictures. But I'll simply point out a few things I learned along the way that might save you guys a little time and headache.

First things first, make sure you have good ventilation and make sure you drive the car down to about 5 miles DTE. You'll be getting fuel on stuff, but if you can minimize the amount you have to dip your hand into the better.

Do the typical things associated with fuel related mods. Pull the fuel pump fuse and let the car idle til it turns off, crank the key a few times to get the last remaining fuel out. Disconnect the negative lead on your battery.

Now start taking apart your fuel pump. For sedan guys...I pity you. I have an avant and it was a big enough pain...I can't imagine having the rear deck above me while I did this. Anyways, disassemble everything. Pretty easy, pretty straight forward. The only tricky part is when you have the cover off and you're looking down into the tank. If you don't have the tool or don't know what to do next you could be staring blankly at the fuel pump harness for a good few hours. I didn't have said tool and so I made my own. Rather hastily and rather crappily (is that a word?) I might add. Basically I made what looks like an odd horseshoe that could span the pump itself and still fit between 2 of 4 notches on the top of the harness. Gave it a good twist and the assembly will come out.

Now one thing you'll immediately notice is that the Walbro is smaller in diameter than the S4. I fabricated a piece of plastic that I fit onto the Walbro to make up this gap. I made sure it was a pretty snug fit so the pump didn't move around at all when I snapped it back into the harness. Now just slap on the filter to the inlet, the outlet hose (original), and the lead wires. Note the black wire = '+', red wire = '-'. It's counter intuitive and tricked me I assembled everything thinking I had it all done right...no dice, had to disassemble and do it all over again...don't make this mistake unless you're a glutton for punishment...Vandy you're allowed to make this mistake jk.

So you have it all back together, just reassemble everything in reverse order, reconnect battery lead, put fuse back in, crank the car. Mine only took a few second to spring to life...yours may take a little longer.

So there you have it. I have pictures of every step that I'd be glad to post along with step by step instructions but only if people are interested. Otherwise feel free to email me and I can put together a pdf with all these instructions.

These are the details on the pump:
Import Evolution
Item: walbro g20000169 (it isn't listed on their site, call them and ask for it)
Price: $94.00 pump only

Good luck!!!

[Imolavirus@BuehnEngineering]

[wagongotya]

I'd definately be interested in seeing those pics too...but i have to admit i haven't searched/researched yet since i'm still a few months off of doing the upgrade. If you have the time i would really apprecaite it, if not, no worries

[[badmoon]]

[[badmoon]]

I can source the parts and could probably get it in your car in a few hours. When are you back in the cities?

[wagongotya]

So won't be back (with my car atleast) for a long time...But definately loving it out here, there are soo many nice audi's

I heard a rumor that your car made it into eurocar? Congratulations!!! I've got to go pic up a copy of it when i get a chance...you should scan it so we can all dream and drool at your baby!

Thanks again for the write-up!

[Snow Trooper Is Numb]

[[badmoon]]

It's in the March 06 issue so I don't think it'll be coming out til Feb. I phoned Karl who wrote the article to see if I could get some advanced copies and a copy of the layout so I could get it framed.

[[badmoon]]

I can't even hear the Walbro...but I yet to start the car up in the cold (when the stock one was loudest).

[wagongotya]

i'll want mine autographed naturally...