Before Upgrading / Replacing your Fuel Plump, I highly recommend reading these resources so you can have an idea of what you are getting into.

This writeup does not outline the R&R of the fuel pump assembly only the modifications needed to upgrade to the Walbro GSS341

CLICK HERE FOR INFO ON HOW TO REMOVE YOUR FUEL PUMP by Dave F. from Audiworld

Additional Info:
Fuel Pump Relay Function
Fuel Pump Relay Installation

Options when replacing fuel pump

OEM 43mm Bosch Fuel Pump:
0 580 314 068 (the number on the black plastic housing)
0 580 454 032 (the number on the pump body itself)


(Audi P/N 8A0 906 091 G)
$150ish, Plug-N-Play
UrS4 basket/cradle P/N 895 201 779 J

Replacement VDO
43mm, drop in, crimp on terminal rings. $120ish

PIERBURG
7.18259.50.0

Bosch "005" / Requires 60mm basket (i.e. V8) & Banjo hardware
500HP capable, 250l/hr at 55psi and 160l/hr at 73.5psi
YMMV, 034 kit is $385

DIY PARTS REQUIRED:
Bosch Motorsport 005 Fuel Pump (p/n)
Audi 93 V8 Fuel Pump Cradle (895 201 779H) 60mm
Audi 93 V8 Fuel Pump Strainer (895 201 531 A)
Porsche M12x1.25 Cap Nut (92811047501)
034efi.com Banjo Fitting Nipple
Hose Clamp
http://www.034motorsport.com/product...products_id=31
2x Copper Crush Washers
1x Ear Clamp to crimp on Fuel Line

Bosch "040" - Requires 60mm basket (i.e. V8) & Banjo hardware

YMMV, 034 Kit $405

Bosch 040 Fuel Pump Specs:
Bosch Part Number: 0 580 254 040
Minimum Current: 12 Volts
Operating Pressure: 94 PSI (6.5 Bar)
Minimum Flow @ Outlet: 80 GPH (300 LPH)
Fuel Pump Location: In Tank
High Temperature Reduction: 8 GPH (30 LPH)
Weight: 930 Grams (2.05 Pounds)
Rated 600HP, 40psi boost.
Fuel Pump Connections:
Inlet: Open Base
Outlet: M10 x 1.0
Electrical: Positive M6 / Negative M5


Bosch "044" / Requires 60mm basket (i.e. V8) & Banjo hardware
Bosch 044 Fuel Pump Specs:
Bosch Part Number: 0 580 254 044
Minimum Current: 12 Volts
Operating Pressure: 72.5 PSI (5 Bar)
Minimum Flow @ Outlet: 80 GPH (300 LPH)
Fuel Pump Location: In-Line
High Temperature Reduction: 8 GPH (30 LPH)
Weight: 1030 Grams (2.27 Pounds)
Fuel Pump Connections:
Inlet: M18 x 1.5
Outlet: M12 x 1.5
Electrical: Positive M6 / Negative M5
YMMV, 034 kit is $425.

Bosch Motorsport 044 Fuel Pump (p/n 0 580 254 044)
Audi 93 V8 Fuel Pump Cradle (895 201 779H) 60mm
Audi 93 V8 Fuel Pump Strainer (895 201 531 A)
Porsche M12x1.25 Cap Nut (92811047501)
034efi.com Banjo Fitting Nipple
Hose Clamp
http://www.034motorsport.com/product...products_id=31
2x Copper Crush Washers
1x Ear Clamp to crimp on Fuel Line



Walbro 255LPH GSS341
500HP rating,
$110ish. 38mm pump requires foam/neoprene sleeve to increase diameter to 43mm, then drops into stock UrS fuel basket. Wiring harness req'd.

NOTE: The Walbro GSL392 is roughly the Bosch 044 equivalent but I dont know of any UrS owner using this pump.

I just ordered from APE:
http://www.autoperformanceengineering.com/


Item# Description
1- GSS341 High Pressure 255 ltr/hr fuel pump $105.00
1- FPWire Wiring pigtail w/ butt connectors $3.30
1- Foam-Sm Thin Foam sleeve for fuel pump $0.50
1- HC4 stainless #4 hose clamp $0.60
1- PkUp-Tiny Tiny pickup filter $6.00
FREE shipping, not tax, $115.40 total.




Here's my order from APE.
The OEM pump on the far left.


The Walbro pump itself is roughly 39mm




Offset Pickup end. The Walbro pump (right) is show w/ the Neoprense sleeve on, measures around 44mm.



A shot of the pickup filter assembly (which will not be used) I bought it "just in case".


ON the OEM Pump, You'll notice that the plastic itself is just a housing for the Bosch electronic pump inside.



I used a 1/4" 12 inch extension and "poked" the old fuel pump out of the sleeve by banging it on the concrete. Dont worry, the pump was dried out for the past few days, not fuel inside.

Pictured here: OEM Fuel pump housing, OEM Bosch, Walbro GSS341. The Walbro doesn't look so small now does it? :P



OK here's the pickup end again of both pumps. They are the same size OD. This is my main concern at this point, because I need to make sure the metal screen (on the OEM pump housing) is still part of the fuel system.



The Walbro pump itself is about 1-2 mm wider in diameter than the Bosch (shown below, roughly 37mm).



So look inside the Bosch sleeve and you'll see little raised grooves. These need to go. I used a flathead screwdriver, and stripped them off as best as possible. Kinda like peelin a potato.



Then i sanded it down little by little and checked the fitment of the Walbro as I went along.

Here it is almost in. DONT BANG IT ON ANYTHING. You should be able to push it firmly in with your hands. Careful not to break the pump outlet. Also, when you're done, wash the OEM housing out of any plastic debris and then air dry it.



Remember you need to check the orientation of the pickup as you test fit. This is the best illustration i could get you, but it will be obvious when you get to this point.



Here is the Walbro pickup firmly seated into the OEM housing.


FInal assembly. Top: Bosch housing/Walbro pump. Bottom Old Bosch pump.



Now, i have a few tips at this point. I removed the whole basket from the tank, and it is wise to do this because you need to reinsert the fuel pump into the basket a certain orientation because of the offest pickup. Very hard to do in tank. You can see here, i even shattered off a piece of the bottom of the basket when pushing the fuelpump assembly back in.



Not a big deal IMO. When you're done, hold the fuel basket in the light
and you should see the black pickup end poking through the opening at the bottom of the strainer. I couldn't snap a good photo of this, but here's the final assembly.



Do you need to purchase the harness for the Walbro?
Walbro left, OEM Right.



The answer is NO. It clicks in FIRMLY. Polarity is same orientation. Will not clip out without firm press of the release tab. Slack will be wire tired to the hose anyways. You're good!



To sum up, you dont need anything for the upgrade other than the GSS341 pump itself. You should have your old OEM pump housing, it will need to be modified as mentioned above. I would still replace the crush washer and clamps as needed.

You saw it here first. Brian

8-)

 

I'm looking to replace the stock fuel pump in my 2001 A4 1.8T Quattro seeing as it has 251K miles on it, and I'm having some issues with fueling with my K04 on stock injector/5BAR program.

My question is to whether GSL392 AND/OR GSS341 will replace my stock pump without issue? It appears that you don't need the installation kit if using the hardware/materials from the stock pump, but just want to make sure I'm reading everything correctly.

Which one do you suggest? I see both versions for anywhere between $80-$100 on Ebay through various reputable sellers, and all of the them claim it's 100% Genuine Walbro stuff.

Any information would be appreciated seeing as I'm trying to order and replace the stock one ASAP. The cheapest I've found the OEM type for is $72 shipped, but running a 5BAR I'd think an upgraded one would be the better idea.

Thanks!