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lot of work

...255lph gss340 how to install?
Get ready to work a little ;)

First, make sure your fuel tank is almost empty! You will have to get it off the car!
Then, make sure you have some gas-resistant fuel hose that match the orifices of the Walbro pump. Those from the stock assembly will not be re-usable, and regular hoses will not do the trick (the rubber/silicon will get eaten by the gas and sooner or later you will loose fuel pressure).

Lift the car;
Disconnect the contacts/electrical line going to the fuel pump, from the right side under the car. Work with care, those plastic sockets are exposed to a lot of dust/mud and they will rather broke than get off ;)
For the dual exhaust cars, the middle and final exhaust (cat-back) must get off :((
Think also for the stock... so some more work!
Unscrew the bolts holding the tank straps and assist the fuel tank with a height adjustable platform.
Take the fuel tank down and unscrew the cap of the tank. Again, be careful and use an appropriate tool.
Once the cap is off, you can access the fuel pump assembly.

Take great care when unclipping the two yellow fingers holding all the assembly together! Those usually broke and you end up searching for another fuel pump assembly!

Once the assembly opened, cut the old fuel hoses (you will not be able to re-use them, as I already told you: they are thermo-retractile) and install the Walbro pump.
Re-assemble the whole thing and go back-wards...

Do a check of the new install before putting everything back (use some gas and support the fuel tank in position, start the car and check the fuel pressure with a fuel pressure gauge-that connects on the fuel rail and has a loooong line, going all the way into the cabin. Rev the engine a little, just to see the fuel pressure being where it should be (mind what kind of FPR you have).

If all is clean, strap everything back and that`s it!
I am posting some pics, hope they help ;)

Good luck and let us know how it works out!

P.S. unfortunately, the og 9-3/900 ng don`t have a visiting hole under the rear seat, like the 9-5 :( There is such and opening, but not useful for the fuel pump install). Since you are there, you might get a cutter and make the hole bigger, for future interventions ;)
 

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If you don't care too much about the car you can cut a whole right over top of the pump... I did this with Brad's yellow vert on the side of the road two years ago on the way to carlisle because he did not put good clamps on... I can change a fuel pump in seriously 5 minutes by cutting a whole...
 

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P.S. unfortunately, the og 9-3/900 ng don`t have a visiting hole under the rear seat, like the 9-5 :( There is such and opening, but not useful for the fuel pump install). Since you are there, you might get a cutter and make the hole bigger, for future interventions ;)
Could you do the whole install through a hole? I cut a hole under my rear seat to access the fuel pump + lines and I could easily take the fuel pump out and reinstall a new one. That is stock however, maybe with a 255 there is more to it than that.
 

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I would avoid cutting the hole in the rear seat area personally because what if you get into an accident? That is a hole that could allow fuel into the passenger cabin and because of the fact that you will have sharp metal edges exposed from cutting, that will also increase chance of injury.

It is really pretty easy to drop the fuel tank but once you have the fuel pump assembly out, all you will need to do is enlarge the hole where the fuel pump insert slots into slightly. This will allow for the additional width of the Walbro to fit into the stock assembly. Also, you will need a harness adapter to splice the stock wiring into the quick connector that the Walbro uses:

http://www.clubrsx.com/cr/WAL-94-615.html?utm_source=froogle&utm_medium=search&utm_campaign=froogle
 

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...255lph gss340 how to install?
DO a search for walbro 255 install, there is a few threads on it with pictures.

http://www.saablink.net/forum/showthread.php?t=32489&highlight=walbro+255+install

Once you have the old fuel pump out, you need to open the basket up a little for the larger 255 pump to fit, then you need sumersable fuel line from Napa, its about 28 bucks for one foot and good quality fuel line constant torque clamps. Then the wiring kit is usually bought with the pump, but you can put simple electrical connectors on the oem saab electrical lines.

Then what I found works best is to just cut the oem saab plastic line as close to the old fuel pump and cut it there. Then take a piece of the 5/16th summersable fuel line and cut it at about 5" or so and slide it over the oem saab plastic line at least a few inches and clamp it there, it will hold, been doing it this way for years and then clamp other end of summersable line to the nipple of the 255 pump. Make sure clamps are tight, many people, myself included, have had the line pop off the nipple after a few weaks and the car goes dead in the water. If you dropped the tank to do, you are sol. If you had a hole in the top, it can be fixed in 15 minutes on the side of the road.

Its nice to not have a hole, but it sure helps to check and replace the pump if you do have a hole. I put absorbant pads on top of the tank and made a plug for the hole and capped it with thin sheet metal and some screws. This keeps the fumes out, the fuel out and if I need to get in there, its only about 3 minutes of work to get to the fuel pump.

good luck,

John
 

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Discussion Starter · #8 ·
shit i thought i posted this on SC (no wonder i couldnt find my thread on there)
lol i like making repeat threads on there just to annoy the admins for the lack of a search function


i already had found the threads on here bout how to install a walbro
so thank a bunch guys!
 

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Then what I found works best is to just cut the oem saab plastic line as close to the old fuel pump and cut it there. Then take a piece of the 5/16th summersable fuel line and cut it at about 5" or so and slide it over the oem saab plastic line at least a few inches and clamp it there, it will hold, been doing it this way for years

John
So if I understand this correctly I could use this method to make a custom fuel feed line for an 84 900 that originally had cis that now has a 16v in it?
 

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Discussion Starter · #10 ·
so got the job done.... one problem though

my gas gauge is intermittent
it now just stays at empty and i just put 12 gallons in my car
i checked to see if the float was stuck and it was not

maybe time to go in the parts car and get some parts to swap over
 

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so got the job done.... one problem though

my gas gauge is intermittent
it now just stays at empty and i just put 12 gallons in my car
i checked to see if the float was stuck and it was not

maybe time to go in the parts car and get some parts to swap over
Did it work before you replaced the fuel pump? If it did then something had to have happened in between.
 

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Discussion Starter · #12 ·
yes it worked no problem before replacing the fuel pump...

also i am able to hit a significant amount of boost in neutral... would having the boost gauge directly connected to the tb make me get these readings?
 
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