How to Build and Install Fuel Lines on a Porsche 944 Turbo

How to replace an entire fuel line system front to back.

The existing fuel lines in the Porsche 944 Turbo were old, ratty, and even damaged. The rubber hoses, since being 30+ years old, have a tendency to crack and leak as well. So it’s a good idea to replace it all, front to back. Check out the video below to see how we did it, or scroll further down for a quick step by step with full parts list and installation diagrams.

Part 1 of How to Build & Install Fuel Lines in The Porsche 944 Turbo

Part 2 of How to Build & Install Fuel Lines in The Porsche 944 Turbo

Porsche 944 turbo pinched fuel line
Pinched return line causing high pressure in the fuel system.

We started with getting all of the correct parts and fittings, here is a picture showing most of parts and fittings used in this install.

Products Used:

Products used in these videos:

QTY.ProductLink
6ft.6AN Nylon Braided Fuel Linehttps://geni.us/6anhose
6ft.Heatshieldhttps://geni.us/5-8heatshield
15/8 Adhesive Lined Heatshrinkhttps://geni.us/heat-shrink
76AN Hose End Fittinghttps://geni.us/6anhose-end
36AN to 16mm x 1.5 Adapterhttps://geni.us/6an-16mmx1-5
16AN 150 Degree Hose Endhttps://geni.us/6an-150deg-swivel-fit
16AN 45 Degree Hose Endhttps://geni.us/6an45deghose-end
26AN to 3/8 Tube Hardline Adapterhttps://geni.us/6an3-8tubeadaptor
26AN to 5/16 Hardline Adapterhttps://geni.us/6anto5-16adapter
16AN to 12mm x 1.5 Banjo Hose Endhttps://geni.us/6anbanjobolt12x1-5
36AN 90 Degree Swivel Coupler Fittinghttps://bit.ly/6anto90degree6an
16AN to 16mm x 1.5 Adapterhttps://geni.us/6antom16x1-5
26AN to 6AN O-Ring Adapterhttps://geni.us/6ano-ring
18AN 120 Degree Push Lockhttps://geni.us/8an120degpushlock
18AN to 18mm x 1.5 Adapterhttps://geni.us/8antom15x1-5
16AN Fuel Filterhttps://geni.us/6anfuelfilter
25ft.5/16″ Copper Nickel Fuel Linehttps://geni.us/5-16cupronickel
25ft.3/8″ Copper Nickel Fuel Linehttps://geni.us/3-8cupronickel
1Bosch 044 Fuel Pumphttps://geni.us/bosch044pump
1Hengst H127WK Fuel Filterhttp://bit.ly/hengst-fuel-filter
1Fuel Pressure Regulatorhttps://geni.us/fuelregulator
1Fuel pressure Gaugehttps://geni.us/gauge
1Fuel Strainer and Sealhttp://bit.ly/fuelstrainer
1Adjustable AN Billet Aluminum Wrenchhttp://bit.ly/AdjustableAnWrench
1AN Magnetic Vise Jaw Insertshttps://bit.ly/magneticvisejawinserts
1Grinderhttps://geni.us/4-5grinder
QTY.ProductLink
1Injector Extensionbit.ly/injectorhat
16AN Fuel Rail Adapterbit.ly/fuelrailadapter
11/8″ x 2″ Aluminum Stockhttps://geni.us/clANL

The Setup

After getting all of the parts needed for the job, we set up the old fuel pump and filter, we measured out the distance and relation between the pump and filter.

Old Porsche 944 fuel pump and filter
Old Fuel Pump and Fuel Filter

Once we had the measurements, we installed the adapters and fittings required on the fuel filter and fuel pump. We then mimicked the old fuel pump and fuel filter relation with the new Bosch 044 pump and filter. From there we were able to measure the length of the new 6an hose required for the fuel line assembly. More info on how we measured this in the video above.

We used a grinder to cut the hose as it melts the nylon while cutting. This prevents the nylon from fraying, which makes installing the fitting much easier.

new porsche 944 turbo fuel pump and fuel filter assembly
New and Old Fuel Pump and Fuel Filter
Porsche 944 Fuel System Upgrade back of car
Fuel line setup at the back of the car by fuel tank
Fuel line setup at the front of the car under the hood and behind passenger wheel
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Chris

Thanks for the great detail on the specs. Is there a reason you chose cupro over running the braided lines front to back?

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