Bosch Motorsport Fuel Pumps

XTRA Motorsport stocks both Bosch Motorsport FP200 inline fuel pump variants as an authorised EU dealer: the FP200-7 (7.5 bar, internal pressure valve) and the FP200 8 bar (FP200-E, no pressure valve). Both are roller cell inline pumps delivering over 200 l/h, rated for gasoline, E85, and diesel, and designed for external mounting outside the fuel tank.

FP200 Model Comparison

	FP200-7	FP200 8 bar
Max pressure	7.5 bar	8.0 bar
Flow (gasoline, 5 bar / 22°C)	>220–270 l/h	>200 l/h
Flow (diesel, 7 bar / 22°C)	>185–235 l/h	>180 l/h
E85/E100	Compatible (reduced lifetime)	Compatible (reduced lifetime)
Pressure limiting valve	Internal — opens at 8.0–10.0 bar	None — external FPR required
Current draw	≤17 A @ 5 bar / 13 V / 22°C	<20 A @ 8 bar / 13 V / 22°C
Weight	750 g (864 g with cable kit)	750 g (864 g with cable kit)
Installation	See FAQ	See FAQ
Replaces	0580.254.044	—

Choose FP200-7 for gasoline and E85 port-injection applications up to 7.5 bar where the built-in overpressure valve simplifies system design. It directly replaces the 0580.254.044 aftermarket pump with higher flow and motorsport-grade construction.

Choose FP200 8 bar when you need sustained pressure above 7.5 bar, diesel compatibility, or a reliable low-pressure lift pump for a high-pressure direct injection system. In GT3 and prototype builds running Bosch GDI engines, the FP200-E is the standard lift pump feeding the Bosch Motorsport HDP 5 high-pressure direct injection pump (HDP 5 requires 4–7 bar inlet supply). This variant is also the correct pairing for the Bosch Motorsport MS25 SPORT diesel ECU.

Installation and PDM Sizing

Both FP200 variants are external inline pumps — in-tank installation is not supported. Mount in the fuel feed line in a location with continuous operating temperature below 80°C. The FP200-7 draws ≤17 A at 5 bar / 13 V — size the relay, fuse, or PDM output at 20 A minimum. The FP200-E draws <20 A at 8 bar / 13 V — same 20 A sizing applies.

The FP200-E has no internal pressure valve: an external fuel pressure regulator on the pressure side is mandatory. See the Bosch Motorsport FPR DR2-Mini 5 bar and FPR Mini-A (3.5–5 bar adjustable) for compatible regulators.

Bosch Motorsport HP Fuel Pump HDP 5

For direct injection engines, XTRA Motorsport can also supply the Bosch Motorsport HDP 5 — a high-pressure single-piston cam-driven pump delivering 200 bar nominal pressure (up to 500 bar in the iPRV variant) directly to the GDI rail. The HDP 5 mounts on the cylinder head or adapter flange and is driven by the camshaft via a flat or roller tappet.

Property	Value
Nominal pressure (standard)	200 bar
Nominal pressure (iPRV variant)	Up to 500 bar
Supply pressure required	4–7 bar (FP200-E is the standard lift pump)
Max displacement	1.1 cm³/rotcam
Fuel compatibility	Unleaded, E22, E85, M15
Operating temperature	−40°C to +120°C
Order numbers	0261.520.08F-01 (standard); F02U.V03.542-01 (motorsport connector)

The HDP 5 is a made-to-order pump — cam profile, tappet type, connector orientation, and flange configuration are specified at order. Contact us via the website for availability, cam profile recommendations, and a quote.

FAQ

What is the difference between the FP200-7 and FP200 8 bar?

The FP200-7 has a built-in pressure limiting valve that opens at 8–10 bar, simplifying system design for most gasoline and E85 port-injection builds. It also directly replaces the 0580.254.044 aftermarket pump with higher flow. The FP200 8 bar (FP200-E) has no internal valve and reaches 8 bar maximum pressure — an external FPR is required. Choose FP200-7 for port injection up to 7.5 bar; choose FP200 8 bar for diesel, GDI lift pump duty, or when precise external pressure control is needed.

Does the Bosch FP200 work with E85?

Both pumps are rated for gasoline up to E10. E85 and E100 are compatible on both variants but reduce pump lifetime — this is specified in the Bosch Motorsport data sheets. For sustained E85 use, factor a shorter service interval into the build plan.

What fuel pressure regulator is needed with the FP200?

For the FP200-E (8 bar, no internal valve): an external FPR is mandatory. The Bosch Motorsport FPR DR2-Mini 5 bar suits return-style gasoline systems; the FPR Mini-A (3.5–5 bar adjustable) is the choice when rail pressure adjustment is needed. For FP200-E used as an HDP 5 lift pump, the system pressure is controlled by the high-pressure pump’s internal demand control valve — no separate FPR is required in that configuration.

Can the FP200 be mounted inside the fuel tank?

Bosch Motorsport states that in-tank installation is not proven for either FP200 variant — this is noted in the official product documentation. In practice, many GT3 and rally cars mount FP200 series pumps directly inside the fuel cell, and this is widely accepted in professional motorsport. If you choose an in-tank installation, ensure the pump remains submerged in fuel under all expected g-loading conditions for your application, and verify that your fuel cell material, fittings, and seals are compatible with the pump dimensions and fuel type.

What is the HDP 5 and how does it relate to the FP200?

The HDP 5 is a high-pressure cam-driven direct injection pump delivering 200 bar nominal to the GDI fuel rail. It requires a 4–7 bar low-pressure supply, which is provided by the FP200 8 bar in most system designs. The FP200 handles lift duty (tank to HDP 5 inlet); the HDP 5 handles high-pressure duty (HDP 5 outlet to injector rail). Contact us via the website for HDP 5 availability and specifications.