Notes for folks installing the Bosch high-flow 005 or 044 pumps
 

Did the fuel pump upgrade a couple of weeks ago, here's some things I found.

1. It's easier to remove the whole basket than just the pump. Slide a couple of long, thin flat-blade screwdriver down the side of the basket next to the notches to loosen the clips then turn and remove the entire pump and basket ;-)

2. May <B>NOT</B> need to use a clamp to secure pump like this:
<img src="http://pictureposter.audiworld.com/9882/p1010006.jpg">

If you are using the V8 basket, it comes in two halves. So simply turn to unclip the bottom half of the basket and then slide the pump up into the basket from the bottom. Then re-secure the bottom basket. Fit's perfectly and no need to dremel off the breather hose ;-)

3. The 12mm Banjo with ~8mm barb
<img src="http://www.034motorsport.com/images/thumbs/thumb-12mmBanjo_100_105.jpg">
may <B>NOT FIT</B> your Fuel Pump hose since the hose has an ID 8~9mm
<img src="http://pictureposter.audiworld.com/58573/img_2914a_medium.jpg">

It was so loose fitting there was no way I could really expect a clamp to hold it without leaking like a sieve. 034 is aware I found this problem but don't have banjo's with larger barbs. To solve this replace your stock hose with some high-pressure re-inforced fuel line (rated for at least 90 psi) with a 7~8mm ID, 034 has some of that, and then you can use the 8mm barb on the pump end and (with some effort) also fit on the stock 9.5mm barb on the sender-end.

Goody. Anybody want to buy a new-in-the-bag 8mm barbed banjo fitting?

You can make the 8mm barb work if you replace stock hose with narrow ID, 034 has some of that
 

It does require hacking up the connection on the sender unit to expose the barb (as in my photo) so you can remove the stock hose and re-attach the new narrower hose.