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ragpicker
Reims


Joined: 14 Apr 2013
Posts: 4030
Location: North East England


PostPosted: Sat May 17, 2014 8:32 pm    Post subject: 996 Turbo Fuel Pump Replacement DIY Reply with quote

For months my fuel pump had been whining from the turn of the key until I turned it off. The whining was getting progressively louder and I thought I could sense some 'hesitation' at WOT and full boost.

After considering the options I decided to take JonnyDangerous's suggestion of a Walbro replacement pump.

My options were: New pump from OPC - £450ish, 2nd hand from breaker £200, or walbro for £120. You are not able to source the pump on its own even from the pump manufacturer VDO.

The 996 fuel pumps are 'in tank' and are enclosed in a swirl pot which is permanently filled with fuel so that even during hard cornering the pump is not starved of juice.

There is a variation in the pumps across the 9*6 range even though at first glance they look similar. There is also a difference in the swirl pots as the 2 wheel drive cars have a large fuel tank and need one venturi tube to suck the fuel in. The 4WD cars have effectively two small tanks straddling the prop shaft and therefore need 2 venturi tubes.

The 996 turbo fuel pump has a maximum output of 5 bar. The 996 carrera fuel pump is 3.5 bar.

The Walbro E85 pump I chose has a maximum output of 455 L/h at 8.0bar.

As I intend to tune my car to approx 650bhp an upgraded fuel pump is recommended and this seemed like the ideal time.

I took a lot of instruction and inspiration from this thread: http://www.6speedonline.com/forums/996-turbo-gt2/324376-diy-tank-fuel-pump-upgrade-pic-heavy.html

Towards the end of the thread the author starts machining out the ports from the swirl pot to further increase fuel flow but fails to subsequently increase the diameter of the rest of the tubing. Therefore this seemed completely pointless to me.

old pump:


New vs Old:


New pump secured into top of swirl pot by large jubilee clip. Small piece of tubing used to connect to the Y connector and some staggered rewiring done (just awaiting the finishing of the heat shrinking):


I'm not sure if its placebo but the car feels more powerful, is a LOT quieter and the hesitation at WOT has gone!

I would say this job is a 2/5 in terms of difficulty and is a viable option when looking for a fuel pump replacement.

Judge
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996 turbo - FOR SALE, Price reduced: http://911uk.com/viewtopic.php?t=131025&highlight=
986 S - usually in pieces: http://911uk.com/viewtopic.php?t=112626
955 Cayenne Turbo - a work in progress: http://911uk.com/viewtopic.php?t=131286&highlight=
 
  
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kas750
Shanghai


Joined: 31 Mar 2013
Posts: 4570
Location: Chorley lancashire

2006 Porsche 911

PostPosted: Sat May 17, 2014 9:08 pm    Post subject: Reply with quote

Nice work! Thumb
 
  
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Jethro
Spa-Francorchamps


Joined: 03 Jun 2012
Posts: 307



PostPosted: Sun May 18, 2014 1:29 pm    Post subject: Reply with quote

Nice work and a bottle of Becks to quench the thirst too.
I fitted a 255 litres per hour pump to a highly tuned Scoob that I had once, so I imagine 455 l/hour will be more than enough
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ragpicker
Reims


Joined: 14 Apr 2013
Posts: 4030
Location: North East England


PostPosted: Sun May 18, 2014 2:22 pm    Post subject: Reply with quote

Thanks guys...

Yeah, I'm hoping that the new pump is a good base for future modifications, in particular the 5 bar fpr which I will do initially (after new intercoolers) and then uprated turbos.

Is its a tip I understand that the maximum safe power before you need to start fiddling with the 'box is 650bhp so this is what I'm aiming for initially.

I'm thinking max out the stock injectors with a 5 bar fpr, gt2rs intercoolers, some bigger blowers (?which?) and a remap should get me there......

Thoughts?
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996 turbo - FOR SALE, Price reduced: http://911uk.com/viewtopic.php?t=131025&highlight=
986 S - usually in pieces: http://911uk.com/viewtopic.php?t=112626
955 Cayenne Turbo - a work in progress: http://911uk.com/viewtopic.php?t=131286&highlight=
 
  
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Ocean Blue
Kyalami


Joined: 04 Jul 2009
Posts: 1788



PostPosted: Mon May 19, 2014 12:03 pm    Post subject: Reply with quote

Nice one Ragpicker,
I'll park this thread up somewhere for future use. Thumb
I think 5bar will take you to 750 - 800, and if so very useful if you change your mind about 650 one day.
 
  
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EGTE
Imola


Joined: 06 Jul 2015
Posts: 836



PostPosted: Mon Jan 22, 2018 3:30 pm    Post subject: Reply with quote

100 gallons an hour (455 litres) at 60mph would be 0.6 MPG...should be enough! Very Happy
 
  
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ragpicker
Reims


Joined: 14 Apr 2013
Posts: 4030
Location: North East England


PostPosted: Mon Jan 22, 2018 4:48 pm    Post subject: Reply with quote

Bloomin 'eck!

Talk about thread resurrection. Interesting how things worked out... Rather predictably I had the turbo and 5bar FPR set up for about 4 months I think before doing the job properly with some bigger injectors...

To bring it right up to date I picked her back up a couple of days ago after a full engine and tip rebuild only for the alternator to die on me today, so I've just removed the alternator and hopefully will be putting a new one in tomorrow.

PC
_________________
996 turbo - FOR SALE, Price reduced: http://911uk.com/viewtopic.php?t=131025&highlight=
986 S - usually in pieces: http://911uk.com/viewtopic.php?t=112626
955 Cayenne Turbo - a work in progress: http://911uk.com/viewtopic.php?t=131286&highlight=
 
  
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