2.0 FSI Low Pressure Fuel System

The 2.0T FSI fuel system is composed of two distinct sections: the high-pressure (50-130bar) and low-pressure (3-5bar). While the high-pressure system has been enhanced by products such as the APR upgraded rail pump, the low pressure system has not been upgraded until now.

The low-pressure system is nearly maxed out when producing around 350whp with A/F ratio landing between 11.0:1 – 11.5:1. This limitation is a result of the in-tank fuel pump being pushed beyond its limits. Simply replacing the factory in-tank fuel pump with an APR unit raises the safe limits to around 400whp.

Developing a low pressure fuel system to work properly with the complicated components and electronics of the 2.0T FSI was no easy task. The in-tank fuel pump that runs the FSI does not function like a traditional fuel pump. Meaning, the fuel pump does not always receive a full 12volt signal while the car is running like a traditional fuel pump does. Instead, the ECM controls the fuel pump through a Pulse-Width Modulated signal (PWM). This quickly ruled out the ability to add an inline fuel pump. Other options were explored but, adding a secondary in-tank fuel pump was the end result.

Function:
The main purpose of the USP Motorsports auxiliary fuel system is to provide enough fuel flow to the high pressure fuel pump to support 400+ horsepower safely. This was done by incorporating a secondary in-tank fuel pump that alone can support 600 horsepower. However, incorporating a secondary in-tank fuel pump by itself will not function properly as the FSI low pressure fuel system is return-less. To combat this issue USP Motorsports created a load-based fuel pump controller. The result is the secondary fuel pump only being turned on when it is needed.

This system is estimated to be good for around 700 wheel horsepower and is the same system used on our in-house MK5 GTI which produces 605whp.

What's included: