Aeromotive Fuel Pump: Ultimate Guide to Selection, Installation, and Maintenance for High-Performance Engines​

If you’re building, modifying, or maintaining a high-performance engine—whether for drag racing, street performance, or off-roading—one component will make or break your setup: the fuel pump. Among the market’s leading options, Aeromotive fuel pumps stand out for their precision engineering, durability, and ability to deliver consistent, high-volume fuel flow under demanding conditions. This guide breaks down everything you need to know to choose, install, and maintain an Aeromotive fuel pump, ensuring your engine runs efficiently, reliably, and at its peak performance. Whether you’re a seasoned gearhead or a DIY enthusiast, understanding how Aeromotive pumps work and how to pair them with your engine’s needs is critical to avoiding costly mistakes and maximizing your vehicle’s potential.

What Is an Aeromotive Fuel Pump, and Why Does It Matter?

Aeromotive, founded in 2001 by engineer Gary Mead, specializes in designing fuel delivery systems for high-performance and racing applications. Unlike generic aftermarket pumps or stock OEM units, Aeromotive fuel pumps are engineered from the ground up to handle the extreme demands of modern engines—especially those modified for more power. Stock pumps, often designed for standard engines producing 200–300 horsepower, struggle when engines are tuned to 500+ horsepower or run on ethanol-blended fuels. Aeromotive addresses this with pumps that offer higher flow rates, lower pressure pulsation, and superior resistance to heat and wear.

At their core, fuel pumps do one job: push fuel from the tank to the engine at the pressure and volume the engine demands. But in high-performance scenarios, this job becomes complex. Engines with forced induction (turbochargers, superchargers), aggressive camshafts, or high compression ratios require consistentfuel delivery—even under sudden throttle inputs or sustained high load. Aeromotive pumps achieve this through features like:

• ​High-efficiency impellers: Reduce heat and energy consumption while moving more fuel.

• ​Advanced motor technology: Brushless or high-torque motors that maintain speed under voltage drops (common in racing or off-road electrical systems).

• ​Integrated bypass regulators: Some models include built-in regulators to stabilize fuel pressure, eliminating the need for external components.

• ​Material durability: CNC-machined aluminum bodies, stainless steel shafts, and corrosion-resistant components that withstand ethanol, methanol, and high temperatures.

How to Choose the Right Aeromotive Fuel Pump for Your Engine

Selecting the correct Aeromotive fuel pump isn’t about picking the “most powerful” model—it’s about matching the pump’s capabilities to your engine’s specific demands. Here’s a step-by-step breakdown to ensure you get the right fit:

1. Determine Your Engine’s Horsepower and Fuel Type

The primary factor is your engine’s target horsepower. Aeromotive provides flow rate recommendations based on horsepower and fuel type (gasoline, E85, or methanol). For example:

• ​Gasoline engines: A pump rated for 1,000+ horsepower will support most naturally aspirated (NA) builds up to 800–900 horsepower. Forced-induction engines (turbo/supercharged) require more fuel, so a 1,200+ horsepower-rated pump is safer.

• ​E85 or methanol: These fuels have lower energy density than gasoline, meaning engines need 20–30% more fuel to produce the same power. If you’re running E85, multiply your gasoline horsepower by 1.25–1.3 to determine the required pump capacity.

Aeromotive’s website includes a handy “Fuel Pump Calculator” tool that factors in horsepower, fuel type, and boost pressure (for forced induction) to recommend specific models. Use it as a starting point, but always round up—overestimating fuel delivery is safer than underestimating it.

2. Consider Your Installation Environment

Pump size, voltage requirements, and mounting options matter based on your vehicle’s fuel tank and bay space:

• ​In-tank vs. external pumps: Aeromotive offers both. In-tank pumps (like the Stealth Series) are quieter, cooler, and better protected from debris. External pumps (like the Eliminator Series) are easier to access for maintenance but require proper cooling and vibration isolation.

• ​Voltage: Most Aeromotive pumps operate on 12V systems, but some high-output models can handle 24V for extreme duty. Check your vehicle’s electrical system—underpowered alternators or weak batteries can starve the pump, reducing flow.

• ​Fuel level sensitivity: Some pumps (e.g., the A1000) maintain consistent flow even at low fuel levels, critical for road racing or off-roading where the tank may run dry.

3. Match the Pump to Your Regulator and Fuel Lines

Aeromotive pumps often work best with the brand’s own regulators and lines, as they’re designed for compatibility. For example:

• The ​Regulator 1000​ pairs with the A1000 pump to provide precise, stable pressure for high-horsepower NA engines.

• The ​Pro Series Regulator​ is better suited for forced-induction setups, handling higher fuel pressures and pulsation.

Using mismatched components can lead to pressure spikes, reduced flow, or premature wear. Always check Aeromotive’s compatibility charts before mixing parts.

Step-by-Step: Installing an Aeromotive Fuel Pump

Installing a fuel pump is a critical job—mistakes can lead to leaks, poor performance, or even engine damage. Follow these steps carefully, and if you’re unsure, consult a professional mechanic.

Tools and Materials You’ll Need:

• New Aeromotive fuel pump (and compatible regulator/filter if required)

• Socket set and torque wrench

• Fuel line disconnect tools (for quick-connect fittings)

• Electrical crimpers/wire strippers

• Sealant (RTV silicone or thread locker, if specified)

• Multimeter (to test voltage)

• Clean rags and safety glasses

Step 1: Drain the Fuel Tank

Safety first—drain the fuel tank to minimize fire risk. Use a siphon or drain plug to remove at least half the fuel, then disconnect the negative battery cable.

Step 2: Remove the Old Pump

Locate the fuel tank (usually under the rear seat or in the trunk for in-tank pumps). Remove the sending unit assembly (if applicable) by unscrewing the retaining ring with a socket. Gently pull out the old pump and disconnect its electrical connector and fuel lines.

Step 3: Prepare the New Pump

Inspect the new Aeromotive pump for damage. Attach any included O-rings or gaskets—these prevent leaks at the tank connection. If your pump has a wiring harness, route it away from moving parts (e.g., tank straps) to avoid chafing.

Step 4: Install the New Pump

Insert the pump into the tank, aligning its tabs with the tank’s mounting slots. Press down gently until it seats, then secure the retaining ring with a torque wrench (follow Aeromotive’s torque spec—typically 4–6 ft-lbs). Reconnect the sending unit if removed.

Step 5: Connect Fuel Lines and Electrical

Reattach fuel lines using new fittings if necessary—old lines may be cracked or clogged. Tighten connections with a wrench, but don’t over-tighten (this can strip threads). Route the electrical wire to the ignition source, ensuring it’s fused (Aeromotive recommends a 15–20A fuse) and grounded to a clean chassis point.

Step 6: Test the System

Reconnect the battery, turn the ignition to “ON” (without starting), and listen for the pump priming—it should run for 2–3 seconds. Use a multimeter to check voltage at the pump (should match your vehicle’s system, ~13.5–14.5V). Start the engine and monitor fuel pressure with a gauge—compare it to the pump’s rated output (e.g., 75–130 PSI for the A1000). Check for leaks around the pump, lines, and regulator.

Maintaining Your Aeromotive Fuel Pump for Longevity

Aeromotive pumps are built tough, but proper maintenance ensures they last for years. Here’s what to do:

1. Replace the Fuel Filter Regularly

Clogged filters starve the pump of fuel, forcing it to work harder and overheat. Aeromotive recommends replacing inline fuel filters every 10,000–15,000 miles, or more frequently if you run E85 or dirty fuel.

2. Keep the Tank Above 1/4 Full

Running on empty exposes the pump to air, which acts as an insulator and causes overheating. For in-tank pumps, keeping fuel above 1/4 full ensures the pump stays submerged in coolant (fuel), extending its life.

3. Inspect Electrical Connections

Corroded or loose wires reduce voltage to the pump, lowering flow. Every oil change, check the pump’s electrical connector for fraying, and clean terminals with electrical contact cleaner.

4. Use Quality Fuel

Ethanol-blended fuels (E10, E85) and low-quality gasoline contain contaminants that wear down pump components. Stick to top-tier fuels and add a fuel system cleaner (like Aeromotive’s own EFI-Clean) every 5,000 miles to prevent varnish buildup.

5. Listen for Unusual Noises

A healthy Aeromotive pump hums quietly. Grinding, whining, or buzzing sounds indicate worn bearings or debris in the impeller. Address this immediately—ignoring it can lead to pump failure.

Troubleshooting Common Aeromotive Fuel Pump Issues

Even with proper care, issues can arise. Here’s how to diagnose problems:

• ​Low fuel pressure: Check the electrical connection (voltage drop), filter (clogs), or regulator (stuck closed). If voltage is low, test the fuel pump relay and alternator output.

• ​Pump runs but engine won’t start: Ensure the pump is priming (listen for 2–3 seconds of operation). If not, check the inertia switch (in some vehicles) or wiring to the pump.

• ​Engine surges at idle: Likely a pressure pulsation issue. Aeromotive pumps include dampeners, but adding an external pulse damper or upgrading the regulator may help.

• ​Overheating: If the pump feels hot to the touch, check for restricted fuel return lines or low fuel level in the tank.

Upgrading to an Aeromotive Fuel Pump: What to Expect

If your vehicle is experiencing poor throttle response, hesitation under load, or frequent stalling, upgrading to an Aeromotive pump could be the solution. Real-world results include:

• ​Smoother power delivery: Consistent fuel pressure eliminates lean spikes, making acceleration feel linear.

• ​Higher horsepower potential: Pumps like the 1,200+ horsepower-rated Dominator Series enable safe tuning to 1,000+ horsepower.

• ​Improved reliability: Reduced heat and wear mean fewer breakdowns during races or long road trips.

One user, a drag racer with a 1,000hp supercharged LS engine, reported switching from a stock pump to Aeromotive’s Eliminator Series eliminated fuel starvation at the top end, cutting his 1/4-mile time by 0.3 seconds.

Conclusion

Aeromotive fuel pumps are more than just components—they’re enablers of high-performance. By understanding how to select the right model, install it correctly, and maintain it properly, you can ensure your engine delivers power reliably, whether you’re on the track, the street, or the trail. Remember, the key is matching the pump’s flow rate, voltage, and design to your engine’s specific needs. With Aeromotive’s focus on engineering and durability, you’re not just buying a fuel pump—you’re investing in peace of mind and peak performance.