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Old 03-26-2009, 12:56 PM   #1
Vlad
Scooby Guru
 
Member#: 46135
Join Date: Oct 2003
Chapter/Region: Tri-State
Location: NY
Vehicle:
02 WRX
Sti V9 Spec C

Default Installing an 08 Sti fuel pump into an 02 WRX

As the title suggests, I wanted to do this in a long time and yesterday, I actually completed this.
Here's some info:

The metal part of the pumps differs, the 08 Sti is shorter.
The 08 Sti uses a "pump in cannister configuration", so their assembly has the pump in a plastic box. Due to this, they have to get their plastic box machined, to make the walbro "255" fit.

This has no importance to a 2002 owner.

The overall length of the pump is the same
The overall diameter of the pump is the same

The 2002 fuel pump does have a filter sock

There was a forum member who was looking for this information recently.
I hope you're reading this, because I can't find your tread. Your answer is yes, there's a sock on the 2002 WRX fuel pump and my WRX is an early production model as well.

So, the sock duct does fit over the 08 Sti pump inlet. There is a slight variation (in the range of 0.2 mm) or there is a lack of conical taper, for the 08 Sti fuel pump inlet.
The result is that although it fits, it doesn't fit tightly.
So, I decided to put a small piece of teflon tape over the outside rim of the pump inlet, it fit tight with that.

I feel that because this is pressed between the metall of the inlet and the plastic of the sock duct, it's not going anywhere with the suction of the pump, because it is not in the path of the suction. Also, Teflon is used with fuel fittings, doesn't melt in fuel.

The metal clip that holds the sock in place can be re-used and fits.

The length and diameter of the hose on the outlet of the pump fits. Fits perfect, I would add.

The pump is held in place at the top, by this hose.

The connector fits perfectly.

At the bottom, there is a rubber "saddle".
Also, all pumps, the WRX, Sti ans Walbro have a small square opening at the bottom, almost like a secondary inlet.
The rubber saddle at the bottom is cut in such way as to accomodate this secondary inlet with a channel.

This is why, when you get the walbro, there is a rubber saddle to match it.

So, the 08 Sti and 02 WRX need this cahnned in opposite directions.
So you cut a channel into the rubber saddle, to match, with a knife.

It gets better/easier though:
Places that convert the cannister for walbro for 08 Sti should have a supply of 08 Sti fuel pumps, because they operate on a core basis, and shouls also have the 08 Sti rubber saddle, for the pump.
If Someone sells their pump, ask for the saddle as well, this way it's 90% plug and play.

I decided I wanted to go this route after reading a postin on the forum about the Sti fuel pump being tested at 175 liters/hour and the walbro 255 liters/hour being tested at an actual 200 liters/hour.
Also, there is another tread where someone that bought a brand new walbro had it malfunction after less than a year of usage.
When calling Walbro under warranty, the answer was that these pumps are not made by walbro anymore, they've licensed the name and model number to a different company.
I prefer the quality of an 08 Sti fuel pump, designed to run 200 k miles +
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Old 03-26-2009, 01:44 PM   #2
Noah
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Join Date: Apr 2006
Chapter/Region: MWSOC
Location: Chicago area
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05 WRX
03 SV650S

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Did you get any pictures?
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Old 03-26-2009, 01:59 PM   #3
Vlad
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Member#: 46135
Join Date: Oct 2003
Chapter/Region: Tri-State
Location: NY
Vehicle:
02 WRX
Sti V9 Spec C

Default

Nope, sorry.
But I'll take a photo of the WRX pump and point out what I'm talking about on that photo.
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Old 03-26-2009, 09:35 PM   #4
Vlad
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Member#: 46135
Join Date: Oct 2003
Chapter/Region: Tri-State
Location: NY
Vehicle:
02 WRX
Sti V9 Spec C

Default

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Old 03-26-2009, 09:55 PM   #5
Vlad
Scooby Guru
 
Member#: 46135
Join Date: Oct 2003
Chapter/Region: Tri-State
Location: NY
Vehicle:
02 WRX
Sti V9 Spec C

Default



This is a photo of a walbro installed. You can see how the sock fits over the inlet and you can see the rubber saddle under the pump. The channel makes a window visible on the side of the pump
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