twin walbro 255 intank install pics

[onewhiteguy]

1g FWD dual walbro 255 intank set up, here are some pics for reference if anyone is interested in doing this…the AWD hanger is a little different but the concept is the same….

Here is a parts list of what I used…
2 -6an 90* bulkhead fittings
2 -6an bulkhead fitting nuts
2 -6an pushlock straight hose ends
1ft 5/16 fuel hose
4 3/8 hose clamps
2 walbro 255 lph fuel pumps with install kit
2 relay’s
14 gauge wire
2 1/2” rubber flat washers
2 1/2” steel flat washers
4 -6an straight hose ends
1ft -6an SS hose
Dual -6an in single -8an out Y fitting
-8an aluminum coil hard line
2 -8an tube nuts and sleves

If you have any questions about the process feel free to ask….




















 

[whitebread]

Good lookin set up. What snail you running to use that much go juice?

Edit: Nm hx40 niice

[redyute]

Me like

[AlphaVision]

I like it too. I don't know how much the pumps will move when in duty or when the car shakes, but I think you better secure them with another clamp on the upper side

[onewhiteguy]

I like it too. I don't know how much the pumps will move when in duty or when the car shakes, but I think you better secure them with another clamp on the upper side

the 1g FWD dsm's have a bolt the protrudes through the bottom of the fuel tank and holds the fuel pump hanger assembly in place, as well as a metal clip the the oem fuel pump snaps into, the single hose clamp exceeds the holding power of the stock fuel pump clip..... i can assure you that the pumps are not going anywhere...lol...

fella's i couldn't justify paying for a $400 hanger assembly or sending mine to Buschur, for this mod when i can do it myself......

[1990talonfast]

1. Can I do this on my AWD 1990 TSI?

2. Where does the fuel level Floater go?

[onewhiteguy]

1. Can I do this on my AWD 1990 TSI?

2. Where does the fuel level Floater go?

yes you can do this on your AWD, the AWD hanger assembly's  have the fuel level sender on the hanger the  pump mounts to. so yours will be a little different but it can be done, it will just be tighter fit as far as the fuel pumps go...the FWD level sender is separate from the fuel pump hanger....if you get your hanger out send me some pics of it and i can give you a few pointers....

[Ibbanez]

Hey there man, looks good with what you are doing.  I to always find myself doing things myself, even if I have no clue on what I am doing before I start   But thankfully, usually by the time I am done with the adventure, most things work themselves out and turns out ok.  Couple of quick questions/comments.  You should do a complete writeup on it.  If you could go into some more detail about running the two relays and how you wired them up, that would be pretty beneficial to most people I think.  Cuz if you think about it, the fuel flow part, is pretty straight forward as long as you are afraid of cutting up your stock stuff and kinda learn as you go.  I just think that the wiring and having it all done correctly is where lots could benefit from knowing ahead of time.  Keep up the good work.

[onewhiteguy]

Thanks for the comments ibbanez, yeah i didn't think about doing the write up until i had the hanger all done and modified, that is why i just posted pics and a parts list of the the job. yes the fuel flow is pretty much straight forward, and overcoming the fear of cutting and modifying the fuel pump hanger is the hardest part of the whole job, unless you have spare hanger, in case you totally fubar yours.

As far as the wiring of the fuel pumps with twin relays it is pretty much the same concept of the fuel pump rewire mod with one relay, you just have two relay's, this is how i wired it..

30amp Fused 8 gauge wire from the battery back to the fuel pump area
Relay pin out for both relays
 battery power supply, ran 8 gauge wire to pin 30 and jumped to pin 30 on other relay
factory fuel pump power supply from harness ran to pin 86 and jumped to pin 86 on other relay
relay ground, ran one wire from pin 85 on both relay's and grounded together on the body
fuel pump power, ran one wire from  pin 87 on each relay to both power wires through the hanger top, to each fuel pump
fuel pump ground, ran ground wire from each pump through hanger top and grounded them together on the body....

hope this helps, as far as wiring. again if you have any questions let me know i will be more than happy to help....

on another note, i would recommend running an -8an fuel feed line from the y block to the filter and from the filter up to the rail, i have seen guys run a -6an line and i don't think that is quite big enough fro a supply line, also i had to upgrade my return line as well, wasn't big enough to handle the added fuel flow and volume of the twin 255's. I just used the stock fuel feed line from my return, it is bigger than the stock return line.....

[Ibbanez]

Hey there onewhiteguy, great addition to your last minute write up.  Yeah, that is what I was talking about as far as the electrical side.  I think this will help some people that may want to attempt this themselves.