The process of selecting the correct fuel pump starts at establishing both vehicle HP and fuel flow requirements. For instance, a 300-hp naturally aspirated engine will typically need about 250-300 liters per hour (LPH) of pump for a given base fuel pressure. On the other side of things, a 600-horsepower turbocharged or supercharged engine may require an ultra-high-flow pump that can deliver well more than 400 LPH just to provide peak fuel pressure. The beauty is that fuel starvation (or the exact reason for our broken engine) can kill an engine faster than a wrecking ball, so whatever fuel pump you're running must support all of the recipes — even the most wild.
The type of pump is also another important consideration, but so too is the fuel pressure being seen. The majority of today's fuel-injected vehicles run at 40-60 psi, but high-performance applications might require a pump able to provide between 70-100 psi--some even higher than that in boosted setups. For example, a Walbro 450 LPH fuel pump for example will perform well at 60 psi but it can support up to 750 hp in forced induction applications with the right fuel injectors.
Another important consideration is fuel compatibility. There are pumps for gasoline and others designed for alternative fuels such as ethanol (E85). If running ethanol leads to a need for 30 percent quantities greater than found in petrol, you will also require a fuel pump designed to handle ethanol. This means that a pump rated at 340 LPH for gasoline may result in only 270 LPH of fuel flow when using E85, which can lead to poor performance. They are also designed to work with the corrosive nature of alcohol fuels without sacrificing longevity, as offered by manufacturers like AEM and DeatschWerks.
Also to consider is if you want an inline or in-tank fuel pump. The most common design is an in-tank pump, which provides quieter operation, and improved cooling as the pump sits under fuel. For most street applications, these pumps will support up to 450 LPH. On the other hand, inline pumps are typically utilized in racing or high-performance vehicles requiring added fuel flow. Inline Bosch 044 will give you up to 700 LPH and they are used widely in motorsport where fuel requirments are much higher.
Fuel pump prices are range from different performance brands. A stock OEM replacement pump might be $150-200, while a high performance aftermarket pump from brands like Walbro or AEM could go anywhere from $250 up to $400. Once you factor in the cost of the pump, installation will run another $200-300 depending on if it is a simple or complex vehicle A classic example is the labor cost for installation- in-tank fuel pumps that require dropping down the gas tank need greater effort compared to inline fuel pumps that are easier to approach and remove.
The fuel system must be upgraded when performance upgrades to the engine are desired. For instance, if you're pulling out all stops to tune your engine to 800 hp, it's quite obvious that the whole fuel system should be great with that kind of high flow rate from the size of fuel lines and injectors. Not providing an upgraded system to work with the increased fuel volume and/or pressure of the new pump can turn a simple upgrade into a bottleneck which doesn't improve the intended application.
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