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Old 04-13-2009, 10:15 PM   #1
engineerx
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Default FueLab: Alternative to Bosch 044, Aeromotive A1000, Walbro, etc

I've been getting alot of people asking me about the FueLab / Hydra setup I'm running, so I decided to make a thread. Hope this is helpful to those who want to give it a try.
So far, the pump is running as advertised. I'm quite surprised at how much quieter it is than the 044. It's not silent by any means, but the noise it makes is more subdued according to my ears, and it's not the annoying whine the 044 makes.

So here's the write up:

I decided to give the FueLab a try. I'm a sucker for testing unproven parts!
It's less noisier than the 044 I was using.
I bought it at http://www.brucesspeed.com/prodigyfuelpump.aspx last December for $357. (Looks like pricing went up by $30 recently ! )

Some info on the FueLab Prodigy pump:

http://www.fuelab.com
FueLab pumps have some interesting features according to the manufacturer's claims: integrated speed controller, brushless motor, lots of flow, can pump just about anything.

The speed controller unfortunately is not PWM (i called their techs - they did say they have an integrated PWM pump in the works - a few months away)

The pump comes with a voltage divider (3 resistors + a cap) already wired in that gives you a "low" and "high" speed. You can switch between the speeds via a relay (toggle switch). The relay can be activated by your standalone ECU, pressure switch, etc. Not as good as a PWM based controller but having the ability to switch to a low speed is interesting and being built into the pump saves $$. The aeromotive controller is $275! The FueLab pump runs about $355.

Here's the instructions sheet the FueLab tech emailed me http://subaru-wrx-sti.com/web/MODS/41401-c.pdf

Pump performance charts - I'm using the 4101




I like the integrated speed controller - I'm using a Hydra output to switch the speed. I'm using boost as a variable - The beauty of the Hydra is that I can use anywhere from 1 to 4 variables (there are more than 20 to choose from) in various AND, OR, XOR logics. I think boost @ 3 psi should be good enough.
The speed switch works well, whenever boost reaches the 3 psi target the Hydra output switches the pump speed via a Bosch relay. Whenever boost drops below 3 psi, the pump speed decreases.

Although this write-up is for a Hydra EMS application, the pump can be controlled by other ECU's, manually by a switch (I wouldn't) , automatically by a pressure switch (I wouldn't either). One can also just run it in high speed or just in low speed (depending on fuel demands of your power goals). Even at low speed the pump seemed to be flowing than the 044 I had as I saw higher static pressure after I replaced the 044 with the FueLab.

I noticed the static fuel pressure was higher than that of the 044 I was using (on Defi fuel pressure gauge) by about 2 psi at the slow speed setting and by about 4 psi at high speed.
Hopefully this pump will last and I won't have to get a new pump any time soon. I couldn't find much info on any forum regarding durability. I found some turbo diesel and Vette guys using it, but not much info.
The pump seems to be well-built and uses a brushless DC motor (see my previous post) which are known to be reliable and arguably better than the standard electric motors. I'll report back if any issues arise with this pump.

that's the 75 micron pre-filter on the left. The wire harness is for pump speed control. The -10AN fittings need to be purchased separately.



Compared to the Bosch 044



Mounted externally between the rear diff cross-member and the fuel tank. Right under the left rear passenger seat.

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Last edited by engineerx; 02-15-2010 at 12:47 PM.
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Old 04-13-2009, 10:16 PM   #2
engineerx
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Wiring:
clicky for very large images

Wiring pump power to enable switching using OEM pump controller:

A Bosch relay is used to turn on FueLab pump.
Just as the OEM in-tank pump, the secondary pump will prime on IGN ON and then it will shut off until engine is cranked.. safe!

Tapped into pump controller harness. Use a multimeter or voltage tester to confirm you have +12vdc on one of this wires and ground on the other
the +12vdc should have power only when IGN ON and the other wire should source ground for a few seconds after IGN ON (this primes pump and then turns it off) - I wired this a few weeks ago and I forgot which is which. The negative signal from the controller (black wire) connects to #86 on the relay. #85 relay terminal has to be connected to a switched IGN ON. I used the +12Vdc source that goes to the controller. As always check for yourself what each wire sources before you connect anything. Use a multimeter or even a cheap bulb tester. Cycle the IGN on and off and see what each source does.



Wiring from pump controller to Bosch relay that supplies power to the pump. Always use a fuse close to the battery for +12vdc source. My battery in in the trunk's spare tire well. Use a good thick gauge wire for both power & ground. Stereo stuff works well.


It's always best to use the appropriate wire gauge:

here's a useful guide

Wire gauge / diameter / current capacity
#4 = 5.19mm/.204" (70 amps)
#6 = 4.12mm/.162" (55 amps)
#8 = 3.26mm/.129" (40 amps)
#10 = 2.59mm/.102" (30 amps)
#12 = 2.05mm/.081" (20 amps)
#14 = 1.63mm/.064" (15 amps)
#16 = 1.29mm/.051" (10 amps)
#18 = 1.02mm/.040" (~8 amps)
#20 = 0.81mm/.032" (~4 amps)

Hydra EMS wiring:

I used PWM8 output from the Hydra pin A1. It sources +12vdc to the pump's speed controller switch via a Bosch relay. If you need wiring info on Bosch relays go here ->
http://www.bcae1.com/relays.htm



Pump's speed control switched wired into Bosch relay to switch speed from the Hydra EMS output


Last edited by engineerx; 02-15-2010 at 12:51 PM.
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Old 04-13-2009, 10:17 PM   #3
engineerx
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Hydra EMS pinout assignment, output and user logic settings







Refer to pages 211-216 of the Hydra user's manual for further details

Last edited by engineerx; 02-15-2010 at 12:57 PM.
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Old 04-13-2009, 10:36 PM   #4
engineerx
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this is an earlier pic of my fuel lines / pump set up from this thread http://forums.nasioc.com/forums/show....php?t=1382976
and here http://forums.nasioc.com/forums/show...2&postcount=17



More pics of the fuel line routing http://forums.nasioc.com/forums/show...2&postcount=17

Last edited by engineerx; 02-15-2010 at 01:00 PM.
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Old 04-13-2009, 11:58 PM   #5
pignoseSTI
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All I can add is that the pump is super quiet. I honestly couldn't hear it and i was sitting right over it lol. Quieter than my whinebro for sure. Hi Roland

Karlton
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Old 04-14-2009, 12:58 AM   #6
engineerx
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Quote:
Originally Posted by pignoseSTI View Post
All I can add is that the pump is super quiet. I honestly couldn't hear it and i was sitting right over it lol. Quieter than my whinebro for sure. Hi Roland

Karlton
Hey Karlton !

yeah.... I got my KW V3's serviced - had a chipmunk inside the strut I think... no more annoying chirping sound from the right rear... and now with the quieter pump I'm living it up !
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Old 09-03-2009, 01:10 PM   #7
06rexwagon
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Quote:
Originally Posted by engineerx View Post
Wiring:
clicky for very large images

Wiring pump power to enable switching using OEM pump controller:

A Bosch relay is used to turn on FueLab pump.
Just as the OEM in-tank pump, the secondary pump will prime on IGN ON and then it will shut off until engine is cranked.. safe!

Tapped into pump controller harness. Use a multimeter or voltage tester to confirm you have +12vdc on one of this wires and ground on the other
the +12vdc should have power only when IGN ON and the other wire should source ground for a few seconds after IGN ON (this primes pump and then turns it off) - I wired this a few weeks ago and I forgot which is which. The negative signal from the controller (black wire) connects to #86 on the relay. #85 relay terminal has to be connected to a switched IGN ON. I used the +12Vdc source that goes to the controller. As always check for yourself what each wire sources before you connect anything. Use a multimeter or even a cheap bulb tester. Cycle the IGN on and off and see what each source does.



Wiring from pump controller to Bosch relay that supplies power to the pump. Always use a fuse close to the battery for +12vdc source. My battery in in the trunk's spare tire well. Use a good thick gauge wire for both power & ground. Stereo stuff works well.

Thanks for these pics. They made it a lot easier to install my 044 last week.
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Old 09-03-2009, 08:11 PM   #8
vulpina
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excuse me , are those black fuel line safe enough to use in engine bay ?
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Old 09-04-2009, 12:07 PM   #9
wrx_driver_2002
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I went with a fuelab 42401-1 Fuel pump. It's good for 210 GPH at 43 psi and 175 GPH at 100 psi according to my flow sheet. Anyways, I went to start my car (After running the fuel pump for a few seconds to prime the lines and bleed the air from the system) and the fuelab pump ran for about 20 seconds total and then pulsed on for 1 second and off for 1 second and it would not output any pressure. When it did work I had 80 PSI of fuel pressure and my car ran beautifully for 10 seconds).

Fuelab received my pump back in their shop for work. I got a call from them yesterday telling me it appears a couple of resistors on the new PWM control board failed. They replaced the pump with a brand new one and are shipping it back to me today. They have awesome service and turn around time. Fuelab FTW!

Surgetank, Pre Filter and Post Filter without pump (cause pump is at fuelab)




Dual Fuel pressure regulators (One regulator for each set of injectors)



Couple of engine bay pictures




Fuel Feed and Return Lines
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Old 09-04-2009, 12:11 PM   #10
wrx_driver_2002
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Link to my gallery if anyone wants to view the rest of the pics

http://gallery.me.com/michael.talbot#100020
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Old 09-04-2009, 01:53 PM   #11
engineerx
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Very nice FueLab setup you got there.
They finally released the PWM pumps. Back when I got mine I talked to the FueLab engineers, who were very helpful, and they told me the PWM pumps were a few months away and theyd be out sometime around May. Nice to see they actually released the pumps already instead of taking months.
I have to say, the dual speed setup works extremely well and it is super simple to setup. Im quite happy with the pumps performance so far. The PWM version adds yet more options.

Ill be looking forward to your posts once you get the pump back into your car. So far, it looks like this pump will be good for me for quite some time.

Last edited by engineerx; 11-04-2009 at 12:18 PM.
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Old 11-05-2010, 03:05 AM   #12
methaddict
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How's this setup doing?
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Old 02-04-2011, 05:44 AM   #13
jibberjive
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2nd, how's it been?
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