Honda Fit Walbro 255 Fuel Pump Install with AN Return Line

Remove the center console and raise the handbrake lever out of the way. Undo the four Phillips screws that retain the fuel access cover plate and lift the plate off to reveal the pump assembly and its locking ring.

Set the tip of a flat-head screwdriver against the tabs on the locking ring and tap them counterclockwise with a rubber mallet. The ring backs off gradually and typically needs four to six turns before it spins freely by hand and can be lifted away.

Draw the cradle up slowly. The fuel gauge float arm projects out to one side, so rock the assembly gently left and right as it rises. Near the bottom of its travel, tilt the cradle at an angle so the float clears the tank opening without bending.

Unplug the two connectors on the upper section of the cradle along with the fuel pump connector. Release the three clips at the base of the cradle, then the three clips that hold the smaller retaining cage onto the pump. Ease the pump out by hand rather than yanking it, since it can pop free abruptly.

Set the Walbro 255 next to the stock pump to note the size difference. The lower fitting can be re-clocked: push its tabs back with a small flat-head, press it down, rotate it to the desired position, and let the tabs lock again. Aim it to open up room for the bulkhead pass-through you are about to add.

Plan the feed as a stacked assembly: a 6AN bulkhead fitting with a 5/16 nipple, feeding a 6AN-to-8AN expander, terminating in an 8AN 45-degree fitting for the line. Drill the top hat with a hole saw matched to the diameter of the plastic seal fitting. Reference your measurement from the edge of the lower ring rather than the top edge so the cradle still seats and seals correctly.

On the bottom face, relieve the web material so the sealing washer can lie perfectly flat. Use a #30 countersink bit on a drill extension and work slowly. A flush washer seat is what lets the bottom nut clamp down and form a reliable seal around the pass-through.

The stock pump seat routes fuel through the tank's integral regulator. Because this build regulates pressure at the fuel rail instead, that internal passage has to be opened up. Trim it back carefully until a 5/16 submersible hose slips onto the pump outlet, bypassing the factory regulator entirely.

The Walbro sits slightly longer than the factory pump. Where the pump meets the cradle, trim back the small ring on the underside so the plastic clip that captures the pump can seat fully and hold it in place.

Turn the top hat 180 degrees so the feed line comes off in line with the pump outlet and does not kink. Rotating the hat moves the fuel level sender leads away from their plug, so splice in additional wire to lengthen them until they comfortably reach the connector.

Confirm every fitting and hose clamp is tight and each seal is properly seated. Reconnect the wiring, lower the assembly back into the tank while guiding the float through the opening, and lock the ring down. Reinstall the cover plate and console. Pressurize the system and inspect all joints for leaks before starting the engine.