Bosh 044 in tank, to bosh 044 inline with pics. - SRT Forums

**NachO_SRT** · 07-30-2009, 05:46 PM

Here is what you need to do this mod.

1) Bottle neck fix
2) Return line
3) 2 bosh 044 fuel pumps.

and these:

How I got to the 044 in tank solution:

I started with a Walboro 255 in tank with the fuel pump rewire, it died when asked for 100psi.

I wanted a base rail pressure of 70 psi with my Injector Dynamics 1000CC's, these are plug and play so no driver box was needed and they came with a nifty little flow chart that gives me "dead times" at different voltages and flow at different pressures. the 044 has no issues up to 120psi. Perfect for my 100psi max.

@ 100psi The ID 1000's flow 1525CC.

Here is a pic of the kit, this one is for an evo, SRT's do not need anything but the direct fit, plug and play injectors. If you view the image full size you can see the deadtime and flow chart clearly.

On to the 044 in tank pics.

This (left: walboro 255) to This (right: bosh 044)

Getting started:

Test fitting, I tried to keep the bottom end intact fitment didnt quite work out that way as you will see:

Here you can see it gets close to "fitting, but, thats as far inward as the 044 can go.

PLAN B, GUT THE SUCKER!

I wanted to maintain the "fuel sock" in tank pre filter set up. This would ensure that the feeding pump was getting as clean a fuel flow as I could account for. Modified by KC set me up with a killer fuel sock attachment for the 044.

Here she is all completed and back together:

And reinstalled in the car:

As always, if you have any questions feel free to ask them here for all to share, or by PM.

Thanks for looking

NachO

**NoisufnoC** · 07-30-2009, 05:53 PM

are you using a queasy to return to the canister?

Chief · 07-30-2009, 05:56 PM

FREAKIN AWESOME!!! I can see alot of guys doing this after a wally fail

**NachO_SRT** · 07-30-2009, 06:03 PM

Quote: Originally Posted by NoisufnoC

are you using a queasy to return to the canister?

I am. -8 feed -6 return. Here are some pics of the rest of the fuel system.

BNF and Qeasy (Love it. simple and functional)

Inline Bosh 044 to Mangafuel post filter (25 micron metal filter element)

Boomba Fuel Rail, Magnafuel Regulator, Russell Pro classic Hose and Fittings, Russell Liquid filles fuel pressure guage. -8 Feed to rail, -8 from rail to Regulator, -6 return to Qeasy.

NachO

Adionik · 07-30-2009, 06:04 PM

Badass!!!!! i want to do this so bad

stxsrt · 07-30-2009, 06:08 PM

Thanks for posting these pics, i wanted to see the size comparision of the pumps.

amdguy · 07-30-2009, 06:22 PM

i may end up doing this, this winter. i have a 255 with a 255 inline

quicky4JR. · 07-31-2009, 03:58 PM

when did you upgrade the turbo. Last I checked you were stock turbo.....Still plan on running e85 I hope?

**NachO_SRT** · 07-31-2009, 08:40 PM

Quote: Originally Posted by quicky4JR.

when did you upgrade the turbo. Last I checked you were stock turbo.....Still plan on running e85 I hope?

I went from

Stocker - 308/400

To

3076R 422/460

To

S259 507/468

All on E85.

I plan on stay'n on E85, 98 or 100.

NachO

d_fl8ted1 · 07-31-2009, 09:36 PM

Ok so from what i am reading you have one bosch feeding the other...?

If this is the case are you having fuel starvation issues below half tank? and would you not have been better offer putting a surge tank between the intank and the inline pump...?

Specimen Kane · 08-01-2009, 04:40 AM

Initially I thought, "why bother to use any of the stock canister at all?" but after seeing the compete unit, I can see how simple it is to mod the canister, and retain all the factory parts like the fuel level.
So, I have to say nice job!

I have a couple questions.
Is there a specific fuel line needed inside the tank for the BNF, since it's always submerged in E85? The fuel must be pretty harsh on a rubber coated fuel line.
Do you really need to piggy back 2 Bosch 044 units together, just to run E85? You couldn't do it with just 1 intank?

**NachO_SRT** · 08-01-2009, 08:24 AM

Quote: Originally Posted by d_fl8ted1

Ok so from what i am reading you have one bosch feeding the other...?

If this is the case are you having fuel starvation issues below half tank? and would you not have been better offer putting a surge tank between the intank and the inline pump...?

I have not seen any starvation issues. The in tank 044 picks up fuel the same way the in tank walboro or stock fuel pump did. With a fuel sock off the bottom of the tank.

The idea here is to allow for a surge tank, it's just not completed yet.

NachO

**NachO_SRT** · 08-01-2009, 08:28 AM

Quote: Originally Posted by Specimen Kane

Initially I thought, "why bother to use any of the stock canister at all?" but after seeing the compete unit, I can see how simple it is to mod the canister, and retain all the factory parts like the fuel level.
So, I have to say nice job!

I have a couple questions.
Is there a specific fuel line needed inside the tank for the BNF, since it's always submerged in E85? The fuel must be pretty harsh on a rubber coated fuel line.
Do you really need to piggy back 2 Bosch 044 units together, just to run E85? You couldn't do it with just 1 intank?

I used Gates fuel line hose. I did have a Walboro 255 pusher in tank to a 044 in line. The 255 went tits up when asked for 100 psi of rail pressure at full boost. This lead me to a replacement for the intank. I left the 044 on the Pass side frame ril and put another in tank.

Overkill, yes for E-85 and ~500 HP. Should be plenty on the Road course with a surge tank.

NachO

Specimen Kane · 08-01-2009, 07:58 PM

That's interesting. I never had a single issue using the HP Walbro 255 as my pusher pump. As long as you are using the hi pressure model, (which goes up to 85 psi) it'll flow enough to keep the 044 happy.
Also, the in-tank pusher will never ever see 100 psi fuel pressure as long as the inline pump is pumping. The in-tank pump will actually see very little pressure for the rest of its natural life, as long as the inline pump is working properly. The 044 inline is the pump that's creating the pressure. The in-tank walbro is only feeding it fuel under bare minimum pressure. You can check for yourself by putting a pressure gauge between the two pumps. The only reason the in-tank pump will fail, is fuel starvation. If the stock canister wasn't kept full of fuel, (by putting the fuel return back into the canister) the Walbro will starve.
Trust me, I've been experimenting with this fuel system since 1997.

Specimen Kane · 08-01-2009, 08:03 PM

Quote: Originally Posted by NachO_SRT

I used Gates fuel line hose. I did have a Walboro 255 pusher in tank to a 044 in line. The 255 went tits up when asked for 100 psi of rail pressure at full boost.

I hope that fuel line will survive. I can't say whether it will or not, but I don't trust the rubber coating being submerged in fuel that is 85% ethanol. I guess you're a perfect candidate to find out. I really do hope it holds up. I found some Earl's fuel line that is alky compatible. I might try that stuff out.