DeatschWerks DW65v install issue

[SO WAGN]

Is anyone able to help me here, I'm installing a DW65v high flow fuel pump in my 1.8TQ APR Stage 3+.
My APR chipped ECU had fried and as a result I've swapped a stock ECU in the car with the car booked in for a custom tune next week. I'm prepping the car for E85 fuel with the DW65v fuel pump and Bosch 1000cc injectors (to be installed on the day of the tune).

I've already custom fit the DW65v pump into the basket, I just need to work out how to get the filter sock to work at the inlet side.

I've hooked up to the outlet port but what is the second port (smaller vertical port) that is shown in the image below. The AWD pump does not have it. At first I thought it was an overflow and hooked a second line from it back to the overflow on the outside of the basket.



I was able to prime the pump and start the car but it kept cutting out after a couple of seconds. Interestingly enough it would run with the MAF unplugged. I unplugged the MAF given that the APR MAF housing is 3" and given that I'm on the stock tune at the moment I though that the inaccurate MAF readings (lower than actual flowrate given the bigger housing) would lean out the AFR. As soon as I plug the MAF back in, the car stalls

I was able to drive the car for about 20 mins with the MAF unplugged and could see off the Short Term Fuel Trims that it was leaning out +25% under part to full throttle. At this point I ran into fuel starvation and the car then stalled under part throttle. Being concerned about damaging the pistons and plugs from running lean I got her straight back to the garage to see what I could do about it.

At this point I'm not sure firstly what the small port is on the DW65v pump, and there's nothing in the documentation or website as to what it is, and I'm also unsure of whether I'm getting inconsistent pressure at the rail because I could be overloading the stock Fuel Pressure Regulator in the fuel filter.

Also worthy of noting is that both the MAF and Fuel Filter have been replaced recently so I wouldn't be expecting them to be contributing to the issue.

Thanks in advance to anyone willing to shed some light!

[Wet0willy01]

Did you drill out your filters return port with the high flow fuel pump? The fact that you're going lean doesn't correlate with too high of fuel pressure.

[SO WAGN]

I haven't modified the fuel filter at all. I have read in another thread that the high flow fuel pump can overload the FPR within the fuel filter but the symptoms I'm getting feel worse than just a little inconsistency in pressure at the rail (ie, no fuel at all at times).

That's why I'm wondering if I should block that second port on the DW65v because it might be bypassing a larger portion of fuel straight out that port. This might be creating a path of least resistance for the fuel instead of the FPR deciding how much fuel to send back to the tank, and I'm thinking this is why I'm getting the fuel starvation issue?

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[SO WAGN]

This was a set up from another thread which I'll have to dig it up again. By the look of it, they were just running the second port out as an overflow:



The other thing I will be doing today is priming the pump with the fuel line broken at the fuel rail to make sure I've released as much air as possible.

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[SO WAGN]

Aaaa huh!

For those interested, going off the thread below, the second outlet port is meant to drive a "mechanical lift pump" for the split tanks. The stock pump never had this outlet port, so would I damage the DW65v pump if I just block off that second outlet port? I am really starting to think that I'm not getting full 4bar pressure because too much fuel is escaping the second port, which currently is just getting fed back to the main tank.

http://forums.vwvortex.com/showthrea...1#post85471883

[SO WAGN]

Closing the loop here more so for the benefit of anyone else that stumbles across this thread looking for info on the DW65v, even though it kind of feels like I'm talking to myself on this one..

I've blocked off the second outlet port and modified the stock fuel sock to match the wider intake base on the pump. The car now runs with the MAF installed and no fuel starvation issues at all. Winning!

The car will be going in for a custom tune on Friday with the new 1000cc injectors. My next concern will be whether the returnless system is able to hold up to the required flow on E85 at 4bar. We might have to play around with duty cycle on high boost, otherwise I will be following a similar setup to what you've got Wet0willy01.

[FromS60toB61.8t]

Closing the loop here more so for the benefit of anyone else that stumbles across this thread looking for info on the DW65v, even though it kind of feels like I'm talking to myself on this one..

I've blocked off the second outlet port and modified the stock fuel sock to match the wider intake base on the pump. The car now runs with the MAF installed and no fuel starvation issues at all. Winning!

The car will be going in for a custom tune on Friday with the new 1000cc injectors. My next concern will be whether the returnless system is able to hold up to the required flow on E85 at 4bar. We might have to play around with duty cycle on high boost, otherwise I will be following a similar setup to what you've got Wet0willy01.

wish i saw this thread sooner, i have the same pump installed and could have answered all of the questions haha.

Glad you got it to work! Works great paired with 1000cc injectors on 93, idk how it is on e85.

[SO WAGN]

wish i saw this thread sooner, i have the same pump installed and could have answered all of the questions haha.

Glad you got it to work! Works great paired with 1000cc injectors on 93, idk how it is on e85.

Haha, so you've been running the pump with the second port blocked off also? I've actually emailed DeatschWerks about it to check with them that I won't damage the pump by doing this but haven't yet heard back from them.

That's good to know that you've had success with it paired to 1000cc injectors. I'll post back in this thread once the tune is finalised though, fingers crossed the stock returnless fuel system is up to the task. I'm not intending to push the car too far on the E85, it's been running on an APR 3+ tune on 98 for years on stock bottom end. I don't intend to go for higher HP output than the APR tune, but will be getting a heap more mid range along with the added cooling benefits of the E85 fuel. Further down the line I'll be doing a bottom end build to safe guard myself and see what I can squeeze out of the current setup. It's my daily driver so I've got to be realistic.

[FromS60toB61.8t]

Haha, so you've been running the pump with the second port blocked off also? I've actually emailed DeatschWerks about it to check with them that I won't damage the pump by doing this but haven't yet heard back from them.

That's good to know that you've had success with it paired to 1000cc injectors. I'll post back in this thread once the tune is finalised though, fingers crossed the stock returnless fuel system is up to the task. I'm not intending to push the car too far on the E85, it's been running on an APR 3+ tune on 98 for years on stock bottom end. I don't intend to go for higher HP output than the APR tune, but will be getting a heap more mid range along with the added cooling benefits of the E85 fuel. Further down the line I'll be doing a bottom end build to safe guard myself and see what I can squeeze out of the current setup. It's my daily driver so I've got to be realistic.

Yea, that port should be blocked off. Not sure if yours came with instructions or not, but mine actually said to block it if its a returnless setup and came with a plug for it. Mine sits in the 034 bosch 044 pump basket bracket with a perfect fit bearing in the middle holding it in place. Pretty much like an OEM setup. Just cut off the old filter net off of the old fuel pump and clamped it over the bottom of the DW65v.

i was pushing around 320 whp on it with the fuel nowhere near being topped off. One of my valve seats broke and blew my motor so im doing a 2.0 stroker now, fully built bottom end paired with a GTX2867r t3 .82ar twin scroll setup. my goal is a quick spooling 400+whp. should be finished sometime next month.

[SO WAGN]

Yea, that port should be blocked off. Not sure if yours came with instructions or not, but mine actually said to block it if its a returnless setup and came with a plug for it. Mine sits in the 034 bosch 044 pump basket bracket with a perfect fit bearing in the middle holding it in place. Pretty much like an OEM setup. Just cut off the old filter net off of the old fuel pump and clamped it over the bottom of the DW65v.

i was pushing around 320 whp on it with the fuel nowhere near being topped off. One of my valve seats broke and blew my motor so im doing a 2.0 stroker now, fully built bottom end paired with a GTX2867r t3 .82ar twin scroll setup. my goal is a quick spooling 400+whp. should be finished sometime next month.

I've just had a look over the supplied instructions again (in case I missed it) and there is no mention of blocking it off, and I didn't get a plug to block it off either. No harm done though, it's all a learning process haha!

I'm very keen to see how your build turns out. The twin scroll setup would be such an awesome addition. What company makes the manifold or is it a custom design? Also, whilst on topic, did you go to a return setup on the fuel system because you needed more fuel on high boost or was the returnless system still good to a certain point at 4bar? I know my situation will be different because I will be flowing ~30% more fuel with E85 but I'm just curious to see at what time you knew the stock fuel setup wasn't going to cut the mustard.

[FromS60toB61.8t]

I've just had a look over the supplied instructions again (in case I missed it) and there is no mention of blocking it off, and I didn't get a plug to block it off either. No harm done though, it's all a learning process haha!

I'm very keen to see how your build turns out. The twin scroll setup would be such an awesome addition. What company makes the manifold or is it a custom design? Also, whilst on topic, did you go to a return setup on the fuel system because you needed more fuel on high boost or was the returnless system still good to a certain point at 4bar? I know my situation will be different because I will be flowing ~30% more fuel with E85 but I'm just curious to see at what time you knew the stock fuel setup wasn't going to cut the mustard.

OEM Returnless setup with an 034 fuel rail. Haven't run into any issues yet.

Manifold is a custom tubular manifold.

[J.Grundy]

Questions guys....don’t mean to bring back an old thread but long story short. I have a deatschwerks pump as well....wondering what everyone is using to get it to fit into the stock basket?? One of those aftermarket girdles or something else? Any input would be greatly appreciated...wanna get the audi back on the road tmrw!


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