Dual Walbro's in a 1G AWD

[Halon]

For anyone wanting to install dual Walbro's in-tank, in parallel, into a 1G AWD, here is a quick rundown of how my install went.

Performed on a 91 TSi AWD using dual Walbro 255HP pumps.


- Pump is located in the rear hatch on the drivers side. Begin by removing the electrical plug, and the 2 screws holding the black cover down.
http://www.mitsustyle.com/photopost/data/538/medium/IMG_1027.jpg


- Next, using a 14mm flare wrench (important because using a standard open end wrench may cause you to strip the fitting), disconnect the fuel feed line.
http://www.mitsustyle.com/photopost/data/538/medium/IMG_1029.jpg

- With the fuel line disconnected, using an 8mm socket, remove the 6 nuts holding the fuel sending unit down.
http://www.mitsustyle.com/photopost/data/538/medium/IMG_1030.jpg

- Remove the fuel sending unit
http://www.mitsustyle.com/photopost/data/538/medium/IMG_1031.jpg

- I had a second fuel sending unit as my original one had a broken power terminal. Cut approximately where the red lines are. This simply allowed the pumps to sit a little nicer against the sending unit. And cutting the output tube will allow you to attach a normal fuel line to it.
http://www.mitsustyle.com/photopost/uploads/107/IMG_10342.JPG

- Attach a Y (I just used a barbed T from Ace), and attach high pressure fuel line with clamps. Clamp the fuel pumps to the fuel sending unit using a worm clamp. You can use 2 if you don't feel that 1 is enough. Land both the ground wires at the grounding point on the fuel sending unit. Land both the positive wires to the power stud on the bottom of the top plate.
http://www.mitsustyle.com/photopost/data/538/medium/IMG_1036.jpg

- Reinstall the fuel pump assembly. It is all simply the reverse of the removal.
http://www.mitsustyle.com/photopost/data/538/medium/IMG_1038.jpg



That is all. Thanks to various others who helped me with this. If there is anything you think I should have done different please let me know. Hopefully this will be useful to someday else at some point in time.

[DSM_421]

Nice write up, did you reuse your strainer?

[Shane@DBPerformance]

Did you use submersible fuel line? The normal high pressure EFI fuel line and SS braided lines doesn't like fuel on the outside of it and eventually fails. The line that comes with Walbro kits is submersible or you can get 1 foot sections from Napa.

[Shane@DBPerformance]

Do you have any upgraded wiring/relays/fuses powering both those pumps?

[Halon]

Do you have any upgraded wiring/relays/fuses powering both those pumps?

No wiring changes. Is this something I need to be concerned about?

[scheides]

Good info brandon!

In this situation where both pumps are always on, is an aftermarket FPR necessary?

[TkrPerformance]

very nice the same way craig and steve has it done. I would do a pump rewire on them also

[Halon]

I prefer to keep this as simple as possible which is the main reason I didn't rewire it. I shouldn't need a rewire for more voltage, because with 2 pumps it should be able to supply plenty of fuel even at 12V. But if I need a rewire because of Amperage, then I will definitely consider it. Any input is welcome and appreciated. I couldn't find a How To on this really, so I just went off what I could find and I never found any thing anywhere mentioning issues with amperage, but I'm open to hear anything anyone has to say.

[Halon]

Good info brandon!

In this situation where both pumps are always on, is an aftermarket FPR necessary?

I would say yes. With 2 you'd more then likely outflow the stock FPR. And on a 1G AWD, the rest of the stock fuel return system after the AFPR should easily be able to handle the 2 pumps. No need to upgrade that.

[AwdGSX13]

i was always curious how this was done, good write up.