Look for opinions-Return fuel line pumping in tank

[LJS]

Seems the plastic connector for the semi rigid plastic fuel return lines in the tank is worn to the point that it no longer clamps correctly to the lid of the fuel pump.....
I've tried zip ties and safety wire and can't get that clamp to stay in place.
When it falls off the hoses within the tank interfere with the float of the fuel gauge and I can't get that gauge to indicate over 3/4 of a tank.
Here's the question---
I know a lot of folks here simply replace this foolishness with a simle hose directing the return fuel flow to the fuel pump basket.....I keep wondering WHY is this shit here to begin with...The Audi Engineers obviously felt it was necessary...Is there any downside to eliminating this stuff and running a simple hose down to the basket....
Thanks for not laughing too hard...

[S4Y_BYEEE]

Those hoses go to they venturi jet to get the fuel from the other side of the tank saddle, that being said I have all of those lines deleted in my tank (due to dual 525 setup) and a radium Venturi jet installed.

Problem is with the stock lid it’s hard to get any hoses to stay on the connection for the return line. Long story short if you delete the in tank return/syphon lines you may run out of fuel a bit faster.

Link to radium part - https://www.radiumauto.com/Venturi-J...-Kit-P760.aspx




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[CELison]

I was able to run the car until the gas light came on with just running a line straight into the tank. I had to do this bc the 525 likes to overrun the FPR with the factory shit.

[LJS]

WOW-
THANKS for the input
Jet-pumps and tank saddles....I learned something new today!
Celison-I really ilke your approach-nice and simple
S4Y_BYEEE the old engineer in me likes that reworked system with that RADIUM jet pump
A 5/8ID rubber hose fits nicely over the nub on the fuel pump lid--the rest is simple fittings and more hose once I remove the OE stuff
Something to do to the old Girl over the Winter sleep.....
THANKS again Guys!

[eurogz]

From my understanding a lot of people delete the suction jet in sedans as it can cause flow issues on the return side with big pumps, but avants have a different tank shape and they will definitely run out of gas sooner with no suction jet than a sedan will. I’m using a radium one as well


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[S4Y_BYEEE]

Yes - forgot to mention my car is an avant - different tank shape.


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[LJS]

OK
Thanks for the update----
Looks like we'll be going the simple route....
FWIW-I don't have the fueling requirements you folks have with your high power builds---I'm running hybrid K04's (SRM) using the new Bosch 200 pump (044 replacement) since my original Walbro 450 shit to bed. I also run the GFB Fuel Pressure Regulator set at 4-bar base pressure and a conservative tune (GET-Brad)
THANKS again for the valuable input.
This group is GREAT
PS-
I had NO idea that the tank in an Avant differered to that in a sedan....
ALSO
I run ID 1050X injectors that yield a DC of only 40% at WOT at 7200RPM----they were used to allow me an easier upgrade to a larger turbo when I felt the need for more juice on a built motor....In the 4 years since my build I 'm still happy with my small frame turbos

[LJS]

Follow up
Seems I'm my own worst enemy....
Looking at that connector again I noticed that one of the o-rings wasn't seated corrrectly....l removed the damaged o-ring and reassembled the connector to the lid and heard the engaging click.
Connector is now tight and doesn't come off without squeezing the sides and pulling....
Live and learn

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