BOSCH 044 fuel pump install - i'm in trouble

[andream88]

Hi guys.

I'm trying to install a BOSCH 044 pump on my RS4, and i have a few issues.




1) the fuel pump does not fit the V8 basket i've bought. If inserted from below, the notch on the pump is blocked inside the basket...and the pump doesn't slide all the way up. If inserted from above, there's a little filter protruding inside the basket which blocks the pump.

installed from below


installed from above

2) the second problem is with the fuel lines. The RS4 fuel system seems to be different from the S4 one. On the RS4 the fuel pump output separates in two different pipes...one goes to the fuel pump cap and then to the injectors. But what about the other one? Do i have to keep it or should i tap it off?



I'm thinking about removing the small filter on top of the basket with a dremel to insert the fuel pump from the top.
This way i'd get it installed like the 034Motorsport one. BUT doing so the fuel pump pickup will sit a couple cm higher than the OEM pump....could this lead to pickup problems when low on fuel? (see pic below for reference)



P.S.
Should i use copper washers here even though the fitting is aluminium?


P.S.2
Do i really have to remove the check valve on K04 hybrids and EV14 750cc injectors? I'd prefer to leave it on, but i don't want it to limit the power output etc....

Thank you!

[osiris07]

with the RS4 fuel system you must cap off the extra fuel line, I can help you with that

[titikaka]

http://www.audizine.com/forum/showth...ht=044+install

[davenew]

Maybe your RS4 pump is bad.. For the top of the basket, you can heat the plastic with a heat gun and press/flatten the piece with a flat head screwdriver enough to get the pump past it. If you do it right, you'll still have the small mesh piece in place to keep particles from getting inside the basket area.


Why replace the RS4 pump? Running 25psi to redline with 10:1 air to fuel ratio you need around 46-48gal/hr of fuel. The RS4 pump, at 4bar base pressure + 25psi, still flows over 60 gal/hour.

If you had a 5 bar regulator, that's 72+25=97psi operating pressure.. so with that you would cut it close to max rs4 pump flow if you ran 25psi to 8k rpm.:)

[hercfe]

Don't use copper washers on alum fuel lines. That is trouble waiting to happen. Use the appropriate sized rubber o-rings. Source them in a kit from your local parts shop. Have you considered running the 044 inline or in a surge box? That will alleviate all your in-tank issues, plus a surge box would be nice peace of mind for keeping up with all that power.

[lotusgardener]

I have an IE surge tank available in the classifieds if your interested.

[arotished]

Did you resolve the problem? I'm getting a 044 pump as well and I guess I will have the same problem.

[andream88]

the new pump is now ready to be fitted in the car.

i've attached a couple pictures!

modified basket. i've lowered the upper-inner part with a dremel tool, this way the pump will slide further in...avoiding pickup issues when low on fuel.
I've also modified the small filter (making the grille smaller), but it is not necessarily needed.


here you can clearly see the level the pump inlet settles at. not too far from the bottom of the strainer, and not touching it as well.


the machined fitting to accept a 8mm hose (which replaces the redundant check valve+banjo fitting)


fhished product.
i'll add a ziptie around the pump (and the small filter) to stop it in position.



HTH!

[arotished]

Thanks!! Any picture of the hose connection from the car to the pump?