For anyone wanting to install dual Walbro's in-tank, in parallel, into a 1G AWD, here is a quick rundown of how my install went.
Performed on a 91 TSi AWD using dual Walbro 255HP pumps.
- Pump is located in the rear hatch on the drivers side. Begin by removing the electrical plug, and the 2 screws holding the black cover down.
- Next, using a 14mm flare wrench (important because using a standard open end wrench may cause you to strip the fitting), disconnect the fuel feed line.
- With the fuel line disconnected, using an 8mm socket, remove the 6 nuts holding the fuel sending unit down.
- Remove the fuel sending unit
- I had a second fuel sending unit as my original one had a broken power terminal. Cut approximately where the red lines are. This simply allowed the pumps to sit a little nicer against the sending unit. And cutting the output tube will allow you to attach a normal fuel line to it.
- Attach a Y (I just used a barbed T from Ace), and attach high pressure fuel line with clamps. Clamp the fuel pumps to the fuel sending unit using a worm clamp. You can use 2 if you don't feel that 1 is enough. Land both the ground wires at the grounding point on the fuel sending unit. Land both the positive wires to the power stud on the bottom of the top plate.
- Reinstall the fuel pump assembly. It is all simply the reverse of the removal.
That is all. Thanks to various others who helped me with this. If there is anything you think I should have done different please let me know. Hopefully this will be useful to someday else at some point in time.
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