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Shop FUEL PUMP INSTALL

Fuel Pump Install 044 / HV / Stock

It's would best to run the fuel level down in the tank to as close to empty as possible if you are going to work with the fuel pump. Time things so when your new pump arrives, your tank is nearly empty. The less fuel you have to deal with the better.

CAUTION: You are about to work with fuel (a flammable). Work in a well ventilated area and away from spark or open flame. Make sure the battery is disconnected. If you're going to change the fuel tank to pump supply hose on a stock or HV pump, you will be needing to either drain the fuel tank or have a extra set of hands available to press a finger on the fuel tank outlet. You may squirt a little fuel around in the process so use care, common sense, and take precautions.

If installing a 044 pump where it's necessary to change the supply hose, take measures to block off the fuel flow once you remove the original pump like mentioned above. If changing the tank sock, you will need to drain the tank completely.

Support Strap




Remove the 13mm Tank Strap bolt. The other end is hinged so let it hang down.

Inspection Cover




Remove the two Phillips head screws and slip out the inspection cover.

Visual Inspection




What you're looking at here is our HV Fuel pump previously installed in this car. In this instruction, we are going to remove this and install a 044 Pump. Most steps are the same installing a HV or replacement Stock fuel pump. The HV pump retains the fuel stock supply hose you see here between the fuel tank outlet and the fuel pump inlet and the electrical connections are identical.

Remove Fuel Pump




Disconnect the power (7mm) and ground (8mm) nuts. Loosen the hose clamp at the fuel pump inlet hose and slip it down the hose. Pinch off the fuel supply line from the fuel tank. A pair of vise grips works well. You can place a couple of pennies on the top and bottom of the hose before you pinch it to make for a wider area for the vise grips to squeeze the hose completely off and protect the hose form the vise grip jaws teeth. Remove the cap nut on the fuel pump outlet.

Slip off the fuel outlet banjo fitting, the wire terminals, and pull the fuel pump out of the fuel supply hose.

If you're installing a Stock fuel pump, or our HV pump, and don't plan to change the fuel filter or pick-up sock, this is where you swap the pump and start putting things back together.

Changing Fuel Tank Pickup w/Filter




If you wish to change this part , here is the technique.

What we don't show is we installed a 3/4" ID hose about 2 feet long over the outside of the fuel-to-tank supply hose and stuck the end in a 6 gallon gasoline storage can. Then we removed the vise grips and drained the fuel tank.

With the fuel tank drained, simply put a 17mm deep socket on the fitting to unscrew it. Make sure the new supplied rubber gasket is in place on the replacement part and re-install and tighten.

This is the PERFECT time to install a new fuel filter. You will need two 19mm and one 17mm wrench or equivalent.

HV next to 044 Pump




Here you see the new 044 Fuel Pump (bottom) along side the HV pump we removed from the car.

Assembled for Install




There is another modification you can do at this point if your want to. See the end of this instruction for the optional mods.

This shows the pump ready to install. We have placed a piece of silicone hose over the pump to allow as a anti vibration cushion. The factory original black cushion will not work on the HV or 044 pump so you need to improvise.

Make sure the aluminum sealing ring is installed between the fuel pump inlet and the adapter fitting.

Here we used a 2" long piece of 1/2" ID hose as the tank to 044 Pump fuel supply line. We recommend high pressure fuel line hose. In this picture it's silicone, which we later found to swell with fuel.

Final Connections and Installation Position




The electrical posts on the Stock Fuel Pump and the HV Fuel Pump are opposite the 044 pump. On the 044 pump, the larger terminal is the Power, where on the HV and Stock pump, it's the negative.

You will need to enlarge the terminal on the green wire which is the positive. The stud on the pump is 6mm. We held the terminal near the ring end with a pair of needle nose pliers and drilled through it's ring with very light pressure careful not to snag.

The old nut from the Negative terminal can be used on the negative post on the 044 pump. The Positive terminal on the 044 pump will require a new M6 x 1.00 nut and a washer.

Ready to Install Main Cover




Rubber terminal boots are placed back over the terminals. The clamps are tightened on the 1/2" supply hose. It's ready to re-install the cover main cover and support strap.

Ready for Inspection Cover




Before you re-install the inspection cover, check to see if the hose between the fuel tank outlet and the fuel pump inlet is relaxed. Adjust the fitting or hose clamp holding the pump to the main cover to insure it is not bound or twisted.

Install inspection cover and re-install Phillips screws.


Optional Modifications



One thing about the stock pump, our HV pump or the 044 pump is the size of the passage through the one way check valve. The size of the opening is 1/8" or .125". So this really is the limiting factor of what that fuel pump will flow. Open up the holes, or remove the fitting and install an alternative, will allow for more fuel flow with the same pump.

In the picture below, you can see the hole size comparison from the stock check valve on the left, to the modified one on the right.

The check valve is not necessary in the system. Your fuel pressure will dwindle down when the car is off, and it may take a couple more cranks to get it started, but other then that, there is no downside to not doing this modification.



Here we are using a 9/32" (.281") drill bit all the way through the part.



Below we are about to enlarge the 4 holes on the side of the banjo fitting using a 5/32" drill bit.



Below you see the stock check valve on the left, and the modified check valve on the right. The fitting on the left side of the picture came on the 044 pump and is used between the check valve and the pump body. We remove this adapter as the hole through it is slightly smaller then our modified valve and it's not necessary to be there regardless.



If your still chasing restrictions, this is the inlet fitting on the 944 fuel filter. It's also 9/32 or .281" in diameter. You could drill this out as well although the filter itself has a hole of similar size in it. You have to drill that to. And since that's the same size as the new hole in the check valve, it's all sized equally. Ideally you can rid yourself of the filter restriction by our Fuel Pump to Rail line kit which uses a entirely different filter with more flow capacity.




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INTERNATIONAL ORDERING



TO OUR INTERNATIONAL CUSTOMERS:


In the past, we have used a separate order form for placing International orders. We have quit using that process and are requiring all customer to use the shopping cart system built into the web site and it's check out process.

If you simply want a quotation and are not ready to place an order, then cut and paste the contents of your shopping basket, take a screen shot of the basket, or make a list of items and send us a email requesting a quotation with shipping.

If you need shipping prices before you make your final decision to purchase, then you should request that quotation by email and not use the shopping cart checkout process because you will be paying for the parts at that time.

Since our shopping cart and shipping estimator will "NOT" correctly calculate shipping charges on International Orders, we have it set-up to where the shipping will be Zero Dollars ($0.00) when checking out. When the shopping carts address process learns you are not in the United States by selecting your particular country, that's when it switches to equal Zero. That does NOT mean shipping is free.

Upon completion of the check out process, you will have paid for your parts but NOT the shipping on those parts.

Once we look over your parts ordered and calculate shipping weights and box sizes, we will send you an E-Mail with at least one shipping option and maybe several. We utilize UPS, DHL and the United States Postal Service (USPS) to deliver your parts.

Once you pick a shipping carrier and agree to the quotation by returning the E-Mail, we will be sending a PayPal money request for the amount of the shipping to be collected. If the parts are expected to be shipping out quickly, then you may receive that email quickly. If the parts are going to need to be built or something is on back order from the list of parts, we may hold off sending that E-Mail until we have the shipment ready to go. It can vary from order to order as to how we do that. If you think you should be hearing from us quickly, but you don't, feel free to contact us.

If you have special shipping needs or requirements, during the checkout you will see a SPECIAL ORDER INSTRUCTIONS window. Enter that special information there.

A good bit of our business is International and we have been taking care of those valued customers since 1999.

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TURO LEVANEN

'88 944 TURBO S 3 Liter Street Legal Track Racer!

This car is the only one driven both daily on the street and in the Nordic Porsche Sports Cup series.





Engine Mods Include:

3 Liter 968 block bored to 105 mm
LR 65 Turbocharger (LR)
3” to 5” exhaust (LR)
Stainless steel 3” downpipe (LR)
Sport headers (LR)
Catcam cam
Link engine management and all new electrical wiring
Old mechanical rotor ignition changed to coil pack / EMS / digital ignition with new TDC measuring
Flex fuel for 85 ethanol to 98 gas--all mixtures go
Head with 48 mm intake valves
Comet 3 layer head gasket (LR)
140# valve springs (LR)
5 angle seat grind
Larger Intercooler with aluminum hardpipes w/ silicone hoses
LR silicon water hoses
LR fuel rail with 92 lb injectors
Intake Manifold – extrude honed and polished
Racing fuel pump with new hoses
Tial 38mm wastegate
Solenoid over boost controller. Two programs (1.0-1.3 bar). 400 hp-500 hp
Wössler pistons (105 mm 8.5:1 compression) LR
Pauter con rods LR
Light battery in race mount and cut-off switch
Silicon vacuum lines LR
Rod bearings, main and balance shaft bearings Calico metal coated
Oil Pan and Balance Shafts Reseal
Recent radiator, water pump, rollers, belts etc. new – Gates Kevlar/Blue Timing belt
Approx. max horsepower 480 rwhp with 720 Nm torque (531 ft/lb) with substantial dyno hours


Driveline/Transmission:

SPEC Stage 3 Clutch LR
Heavy duty motor mounts
Heavy duty trans. mounts
Recent Clutch Master/Slave with hoses
Heavy duty drive shafts LR
Torque tube with heavy duty bearings
Quaife mechanical differential
All wheel and drive shaft bearings new
All bushings non-OEM


Brakes:

GT3RS 997 brakes and 350 mm slotted and cross drilled rotors
Turbo s rear brakes
Brake bias valve changed


Suspension:

Koni Sport Front
Koni Series 30 racing rear
Front 500 lbs coil springs
Rear 900 lbs coil springs
Adjustable front camber plates
M035 sway bars LR
Elephant Racing Polybronze spring plate bushings
Poly bushings everywhere else
Front solid bushing ball joint kit
Strut tower bar
Lower caster block bar
New front and rear wheel bearings
Recent race alignment and corner balance


Body:

Front/Rear tow hooks
Fire extinguisher system in cabin and engine bay
Fender flares
GT3 front splitter
Rear diffuser in process
968 rear lights and bumper carbon fibre
Sunroof removed (GT parts)
997 gt2 rear wing
Glass fibre hood
Plastic rear window


Interior:

Sparco/GT3 Speed Seats (R & L) in black
Porsche GT3 Steering Wheel and hub
Sparco 6pt cam lock harnesses (R & L)
Geiko racing approved gauge
Stock seat belts remain functional
Track Mats, steel plates and Lightened pedals aluminum
Extra long shifter stick and short shifter
Electrical boost control 2 programs – center console
A/F meter-center console
Fuel pressure meter
Boost meter
Racing “kill” switch in cabin
Full fire ext. system cabin and engine bay with external switch
Back seat delete
Top

INTERNATIONAL ORDERING



TO OUR INTERNATIONAL CUSTOMERS:


In the past, we have used a separate order form for placing International orders. We have quit using that process and are requiring all customer to use the shopping cart system built into the web site and it's check out process.

If you simply want a quotation and are not ready to place an order, then cut and paste the contents of your shopping basket, take a screen shot of the basket, or make a list of items and send us a email requesting a quotation with shipping.

If you need shipping prices before you make your final decision to purchase, then you should request that quotation by email and not use the shopping cart checkout process because you will be paying for the parts at that time.

Since our shopping cart and shipping estimator will "NOT" correctly calculate shipping charges on International Orders, we have it set-up to where the shipping will be Zero Dollars ($0.00) when checking out. When the shopping carts address process learns you are not in the United States by selecting your particular country, that's when it switches to equal Zero. That does NOT mean shipping is free.

Upon completion of the check out process, you will have paid for your parts but NOT the shipping on those parts.

Once we look over your parts ordered and calculate shipping weights and box sizes, we will send you an E-Mail with at least one shipping option and maybe several. We utilize UPS, DHL and the United States Postal Service (USPS) to deliver your parts.

Once you pick a shipping carrier and agree to the quotation by returning the E-Mail, we will be sending a PayPal money request for the amount of the shipping to be collected. If the parts are expected to be shipping out quickly, then you may receive that email quickly. If the parts are going to need to be built or something is on back order from the list of parts, we may hold off sending that E-Mail until we have the shipment ready to go. It can vary from order to order as to how we do that. If you think you should be hearing from us quickly, but you don't, feel free to contact us.

If you have special shipping needs or requirements, during the checkout you will see a SPECIAL ORDER INSTRUCTIONS window. Enter that special information there.

A good bit of our business is International and we have been taking care of those valued customers since 1999.