Bosch Motorsport 044 Fuel Pump Coupe Fitting Guide

[Doug_RS2]

Since I have had a few requests on how to fit the Bosch Fuel pump I thought I would start a thread.

Others can add to it on how they did it or anything I forgot.

First of you need to remove the fuel pump. On a coupe, you need to pull up the carpet in the boot - some of it is stuck down - just yank it up!

You will have to rotate the metal clip to unlock the pump cover - I think I had to knock it with a screw driver and hammer to release it.

Remove the multi plug on top and lift the level gauge out and you can disconnect the internal connector.

[Doug_RS2]

I had to modify the new mount so the bosch pump slips in.

First I cut the mesh bit of the top - red arrow pointing to it. I trimmed it to the green line so the new pump can slip in. I cut a bit of meash off the old pump and glued that on the top of the breather I just trimmed.

[Doug_RS2]

And now the pump will slip in the mount but not all the way down - you will notice the pump has 2 grooves that stick out.

You have to cut some grooves in the top of the mount so the pump will slip down that extra 10-15mm. You don't want to push the pump all the way down so it touches the bottom of th estrainer - that will restrict flow. And you don't want to leave it sticking up - you will run out of fuel and risk fuel starvation.

So cut the grooves bit by bit until it sits near the bottom of the strainer. I just used a cable tie round the top of the mount to hold the pump in - it won't be moving! Cuts marked by arrows in pic - I did 3 equally spaced around the mount.

If you leave it sitting too high - you could get the pump touching the top of the tank/gauge and it could make a funny drone.

[Doug_RS2]

You will also notice in the above pic that you have to reuse your wiring loom that was connected to your old pump. You need to use the new connectors Greg will have provided - note that brown goes to the -'ve terminal(blue) and green/yellow goes to +ve terminal(red) I won't mention who wired it wrong - must have thought they were wiring a mains plug

[Doug_RS2]

to remove the old mount from the fuel tank I made my own tool out of some lumps of wood - not very pretty but worked:

[audiman]

LOL, which muppet did that then? The ally welder pro?? LMAO

[Doug_RS2]

Is that everything? Others can add their experiences.

[Doug_RS2]

LOL, which muppet did that then? The ally welder pro?? LMAO

What did you do tom - just bung it in with some elastic bands?

[audiman]

its just hangin in there i just used some 3" self tappers to hold it down. Works a treat.

[Greg_S]

when you take the metal clip off a bit of metal about 7" long with a pair of mole grips on either end works a treat for twisting it off. I made a fitting guide the other week but its not on this computer.

Greg

[Mark Halligan]

LOL, which muppet did that then? The ally welder pro?? LMAO

Err I am not sure if you mean the gentleman I am thinking of Tom....but if it is 'him' the answer is no, 'he' fitted it well over a year ago and it is still going strong.

Having said that I do know who the person is that Doug is referring too.

[audiman]

So do i now!! LOL, he just got a txt message!! Hahahaha

[SteveH]

Ok, It was me
Who in their right mind uses green and frickin yellow as live and brown as earth. Took me a few days to work out what was going wrong..pump was buzzing away nicely, but not a drop of fuel was flowing. Thanks Doug for the info on the wiring

So do i now!! LOL, he just got a txt message!! Hahahaha

[S2central.net]

BROWN is ALWAYS earth on Audi's.

Come on - raise your game

[SteveH]

Doug's right, I've spent years wiring UK mains stuff. Even when I realised my mistake and rewired the pump, I attached the connections the wrong way round. This must be due to long term programming of my remaining brain cells...The few that still fire are like old dogs, they definitely don't like new tricks!