absolutcq20v

Almost identical to my '85 and '87 Audis! Things don't change much!!

baskinblack4.2L

I decided to go inside and forget about it for a while. Your post is great thanks for the detailed picks..Should be seeing this in the stony fact page soon I am sure

RLG

out of curiousity, how are you mounting the Walbro? In the stock basket?

Let me know if you want part numbers for the V8 basket and strainer - perfect fit for the new 255 Walbro.

One word of caution - if you've got sensitive ears, be prepared for a little whirring sound coming from the pump. It's not bad in the S4's with the pump located in the trunk, but was definitely audible in the under-the-seat location. If you've got some spare dynamat, might want to lay a layer or two down over the pump area.

Anyhow, if you run into any trouble, call me up - (310) 486-0901...

Good luck!


R

RLG

LOL!!

baskinblack4.2L

I will need it. Mike at vast said that I might be able to get the pump to fit in the old basket. I will try it on the stock basket and let you know. But I would rather just buy a new one just in case I break it.
feel free to E mail me with the info

Thanks again. Its good to see other people like your self that are not afraid to dig into there cars for more power

Once again my hat is off to you not only for the wright up but that fact that one of the picks you took on your trip is now my background pick (the one of the RS6 all by it self on the road) Great pic

RLG

The problem with installing the Walbro pump in the stock location with stock parts is that the diameter of the Walbro pump is less than the diameter of the stock pump. Consequently, installation invariably requires some "rigging" of the Walbro pump in the stock basket, as well as some modification of parts (snipping filter socks, etc). The outcome is a good pump but a pretty ghetto installation, typically held together by an odd assortment of sliced hoses, clamps, and (god forbid) zip ties. However, by using stock Audi parts, the Walbro can be installed cleanly and securly with a perfect fit that won't leave you feeling like you're looking at a Frankenpump.

This is actually my THIRD attempt at this. First I used ABS to make a pump housing, then aluminum. BernieBenz then pointed me to this stock part which turned out to be the holy grail of Walbro pump integration attempts. Used is a fuel pump basket, strainer, and "spring pin" (aka pump adapter cylinder) that gives the Walbro pump an OE look and fitment in the stock location with stock-like fit.

For a really clean installation of a Walbro 255LPH High Pressure fuel pump into the Audi C5 A6 / B5 S4 (and maybe other models as well), the following parts are required:

Fuel pump reservoir / basket, upper part: 895 201 779 H
Strainer (snaps onto bottom of basket): 895 201 531 A
Spring pin / adapter cylinder: 441 201 791
Walbro 255LPH HP fuel pump (new type): F20000169
Standard foam sleeve for Walbro pump (included with pump)


Well, here's Audi part number 441 201 791, the "spring pin" aka fuel pump adapter sleeve for the later model fuel pump. The adapter sleeve snaps right into the basket from the bottom. Really nice, secure fit.

<img src="http://audifahrer.com/aw/project/RS4Walbro/064.jpg" border="2">



Things to note: Frst, there's a screen on the side of the adapter sleeve. On the inside of the sleeve, there's a rectangular cutout / channel that lets fuel flow from the top of the pump sleeve, down the channel, and through this screen where it would empty into the strainer. The apparent purpose of this channel and screen is to allow fuel to escape through the channel rather than pool / collect on top of the pump. Kinda nice.

The following two images are of the adapter installed into the basket.

<img src="http://audifahrer.com/aw/project/RS4Walbro/068.jpg" border="2">

<img src="http://audifahrer.com/aw/project/RS4Walbro/069.jpg" border="2">



Second thing to note: The hole for the pump's intake nipple is off center.

<img src="http://audifahrer.com/aw/project/RS4Walbro/070.jpg" border="2">

<img src="http://audifahrer.com/aw/project/RS4Walbro/071.jpg" border="2">



The GSS340 Walbro pump (the "old style" pump with centered intake nipple) will not work with this part as-is. I'd recommend using the "new" version of the GSS340, namely, the F20000169 fuel pump instead (available at http://apeusa.com among other places). It flows the same as the GSS340 it replaced, but the intake nipple is offset from center and snaps perfectly into the hole at the bottom of the adapter sleeve with no modification.

<img src="http://audifahrer.com/aw/project/rs4walbro/077.jpg" border="2">

<img src="http://audifahrer.com/aw/project/rs4walbro/078.jpg" border="2">



The new version pump can be inserted into the adapter, and the nipple snaps into place in the baseplate just as the pump housing bottoms out on the plate's existing ridges. No modifications need to be made to the adapter whatsoever. When fully inserted, there is about 8mm of exposed pump housing between the bottom of the adapter cylinder and the baseplate. To keep things clean, I cut off 7mm from the foam sleeve supplied with the pump so it would not extend beyond the adapter cylinder.

<img src="http://audifahrer.com/aw/project/rs4walbro/079.jpg" border="2">



I then fitted the cut foam sleeve to the bottom of the pump (only about 1/3 of the way onto the pump housing), and inserted the pump, sleeve-first, into the adapter cylinder. I then walked the pump into the foam sleeve, and the foam sleeve simultaneously walked into the adapter sleeve cylinder (it's a really tight fit). I made extra sure that the pump's intake nipple was properly aligned before pushing the pump completingly into the foam sleeve and adapter sleeve cylinder.

<img src="http://audifahrer.com/aw/project/rs4walbro/080.jpg" border="2">



I pushed the pump down until the nipple snapped into place and the pump housing bottomed out on the baseplate ridges. It really is a perfect fit. VERY clean, and with the foam sleeve in place, the pump is very secure in the adapter.

<img src="http://audifahrer.com/aw/project/rs4walbro/081.jpg" border="2">

<img src="http://audifahrer.com/aw/project/rs4walbro/082.jpg" border="2">



I then installed the adapter into the basket from the bottom (being sure to align the apparent notch on the side of the adapter with the cutout in the basket), snapped it into place (you will feel the adapter snap into place as you pust it up into the basket), and then snapped the strainer onto the basket by aligning the nubs on the basket with the slots on the strainer, then turning the strainer clockwise to the locked position. I was stoked - it's a perfect fit using all OE parts (more or less!). No modification or cutting required, really clean and nice!!

<img src="http://audifahrer.com/aw/project/rs4walbro/083.jpg" border="2">

<img src="http://audifahrer.com/aw/project/rs4walbro/084.jpg" border="2">



From there, the pump / basket assembly can be installed just as the stock pump. &lt;start Borat voice&gt;I like it, Very nice!!&lt;/end Borat&gt;

RLG

Glad you liked that pic... I posted the info on the Walbro installation below...

baskinblack4.2L

start the upgrade. Did you know the part # for the tool to take out the pump? I know I may only us it once but maybe some friends will need some help. The pump upgrade is a great idea on any high mileage car.

RLG

Honestly, you are not going to need either, but if I were required to buy one or the other, I'd buy the ring-removal tool. That at least will save you some time, whereas the basket can be removed in a jiffy, either with the screwdrivers like I described, or, as in Lin3y's case, simply by hand.

Either way, good luck. You shouldn't have any problems...



R

Kris Hansen

This is now an official Tech Article... Thanks Robert!