044 + Surgetank

[stÖrmy]

Hey guys few weeks ago i got my Bosch 040 installed intank, but im installing a surge tank now and using an 044 as the external pump. I get the general idea of how the system works, and what lines need to go where, But im having trouble identifying what lines are what under the car... the second hardpipe in the stock location seems to be an overflow pipe as its just a blank hardpipe that goes into the tank, but i dont know if the fuel line that went onto that hardpipe is the line that comes from the FPR or not?....

Im using this photo as a guide -

[boostn0199]

Easiest way is disconnect from fuel tank and track the lines to under the car and youll find which is feed and which is return.

[T04GTR]

simple. hose clamps are pressure. spring clips are return.

[stÖrmy]

I had a look under there and i can see the lines, But they connect to hard pipes and then travel all the way down the car. I think i have my feed and return bit right but dunno what to do with the overflow bit of the circuit.

simple. hose clamps are pressure. spring clips are return.

Ok so i have the feed bit correct with my red line as that one had a screw and clamp and the other just had a spring type one i undid with plyers.. So then the blue lines can only go as ive shown here then?

edit : Also, do i have to have another fuel filter after the external pump?? wont this restrict flow a bit? and can i just steal power for the external from anywhere?

[KiwiRS4T]

For max performance and life of the pump run a new heavy cable from the battery (easy if its in the boot but do it anyway) and fit a good earth and control the power supply with a decent relay and switch it from the original pump circuit. There are a couiple of "how to" s in the DIY section.

[boostn0199]

In regards to the return lines run the return line which is the blue one youve marked to the second nipple from the top of the surge then with the niple right at the top run that back into fuel tank where the return originally was connected.

With regards to the extra fuel filter i done run one, the stock one will be enough as your feed pumP filters it through its sock then the 044 will also filter through its inbuilt one.

[blind_elk]

Isn't the setup:

Top - return from fuel rail

2nd top - overflow to fuel tank

3rd top - inlet from fuel tank

Bottom - outlet to pump to rail

[stÖrmy]

alright cool thanks guys! now i have it sussed. gotta buy some fittings and more fuel line today. wanted braided steel but to expensive so buying normal shit lol.

[boostn0199]

Isn't the setup:

Top - return from fuel rail

2nd top - overflow to fuel tank

3rd top - inlet from fuel tank

Bottom - outlet to pump to rail

Nah the top is overflow since you want it only returning to the tank when the surge is full in order to try and keep the surge tank full at all times.

[blind_elk]

The idea is not to keep the surge tank full. The surge tank is really a "de-aeration system", to prevent the engine ingesting air because of fuel surge in the fuel tank, or because of air "dissolved" in the fuel. It is highly unlikely that the surge tank would ever get anywhere near empty enough to experience fuel surge.

[stÖrmy]

ok just had another look under the car...and i thought there was only 2 fuel lines, one going to rail and one coming back, but there is 1 more line that just goes from *somewhere* into the top of the fuel tank.... Do i just leave this one alone as im assuming its an overflow?

[JonnoHR31]

everyone has different ideas on which nipples should go where. personally i have the top to return, 2nd is return from the rail, 3rd is feed from tank and bottom is obviously always gonna be the feed for the main pump.

main reason i set it up like that was to try and keep the fuel in the surge tank as cool as possible as i was having issues with the pump cavitating on hot days.

[blind_elk]

ok just had another look under the car...and i thought there was only 2 fuel lines, one going to rail and one coming back, but there is 1 more line that just goes from *somewhere* into the top of the fuel tank.... Do i just leave this one alone as im assuming its an overflow?

Probably the line back from the carbon canister. So you can leave it as is.

[stÖrmy]

Guys just want to confirm once again before i actually bolt everything in, as i went and got all my required fuel hoses, fittings and clamps today.

The line circled in red there, do i go from surge tank over flow into that hard pipe, and then the fuel hose that WAS on there goes to the surge tank as well ?

the other line under the car that i said goes to tank and looks like another overflow also goes to what feels like a plastic container INSIDE the fuel tank...

[JonnoHR31]

yes, hook up the overflow on the surge tank (highest port) to that port circled in red. hose that was on there goes to the 2nd or 3rd fitting on the surge tank.

any other lines such as the breather, leave as per factory. those 2 hoses on that lid are the only 2 on or in the tank that need to be changed.

[stÖrmy]

Ok well almost done then. I have 2 lines different though, i have that overflow on the 3rd port from the bottom, above the port that fills the surge tank, so i need to switch them around. Which is GAY cause i just spent 60$ on fuel injection hose and cut it up to size now i gotta go spend more lol

[JonnoHR31]

na that'll be fine. aslong as the bottom is feeding the main pump, which it is, it'll work fine. the other 3 will work in any combo, its just slightly better for cooling to set it up the way i said.

[stÖrmy]

ooh sweet! well tomorrow i wire her up and see how it goes Thanks a tonne for the help and info!

[blind_elk]

I hope you are going to fit some grommets on that sheet of metal that the 2 hoses are passing through!

[stÖrmy]

yep im actually gonna leave right now to get some grommets, more hose clamps, some more wire and a fuse