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:

6ft.6AN Nylon Braided Fuel Line
15/8 Adhesive Lined Heatshrink
76AN Hose End Fitting
36AN to 16mm x 1.5 Adapter
16AN 150 Degree Hose End
16AN 45 Degree Hose End
26AN to 3/8 Tube Hardline Adapter
26AN to 5/16 Hardline Adapter
16AN to 12mm x 1.5 Banjo Hose End
36AN 90 Degree Swivel Coupler Fitting
16AN to 16mm x 1.5 Adapter
26AN to 6AN O-Ring Adapter
18AN 120 Degree Push Lock
18AN to 18mm x 1.5 Adapter
16AN Fuel Filter
25ft.5/16″ Copper Nickel Fuel Line
25ft.3/8″ Copper Nickel Fuel Line
1Bosch 044 Fuel Pump
1Hengst H127WK Fuel Filter
1Fuel Pressure Regulator
1Fuel pressure Gauge
1Fuel Strainer and Seal
1Adjustable AN Billet Aluminum Wrench
1AN Magnetic Vise Jaw Inserts
16AN Fuel Rail
11/8″ x 2″ Aluminum Stock

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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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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