Returnless Fuel Pump Upgrade Guide

[Joe@Trick Tuners]

This is intended to be a rough guide and i will continue to update this thread with new info as i come across it.

The Kenne Bell Boost A Pump (BAP)

This is the easiest way to get more fuel out of your returnless fuel system. A 99-04 GT pump with a BAP will support around 420-450rwhp. Its best to wire it pre-fpdm. I don't have a good set of detailed instructions on how to do it, but if you have a good thread link, please post it up for the DIY type of guys. The 20A bap is good for 1 pump, and the 40A bap is needed for dual pump setups. It works by raising the fuel pump voltage (to about 17V) to overdrive the pump.

The (in)famous Focus (SVT) pump.

Yeah i know that "people" on the internet say it can do crazy things like 500hp without a bap, but my experience is that they are only marginally better (if not worse) than the stock GT pump. Maybe they flow more at low pressure, but once the boost comes on these things choke in the low 400hp ranges WITH a bap. Ive seen at least 10 cars do this and the customers always argue "so and so on the net hit XXXhp" Good for them, but your pump is pegged. If you don't trust me just look at the datalog. If you plan on going for more than 400hp, the focus pump and a bap is not worth it. Just stick with the GT pump and see when it will peg.

The 03-04 Terminator dual fuel pump setup.

This is a quality setup good for the low 500rwhp range without a bap and about 650 with a bap. The hat (top of the fuel tank with the pumps) costs just over $300 from what i remember, and the tank is about the same. The hat will fit directly into a gt tank, but you will have to cut out that plastic holder thing. The cobra tank has a sump in it and is a much better design. If you plan on road racing, or cutting some low 60' times, the cobra tank is a must. The gt tank runs the risk of sloshing the fuel and sucking the sock dry. What happens then? The motor goes lean, then boom! The entire swap is plug an play with no fabrication or wire splicing needed (at least on my 02). I have heard the older GTs need to splice a few wires for the connectors. Either way its an easy swap.

Dual GT super car pumps

These pumps can flow some serious fuel! You cannot run 2 of them off the single FPDM (fuel pump delivery module) because it will go into thermal shutdown and cut off the fuel. This swap requires some minor fabrication to get them inside the tank, but nothing too tricky for a normal DIY type of guy. You can add a pre fpdm bap and do about 700hp with this setup. Add a 3rd pump and go for some crazy hp!

Fuel Tanks

The GT tank has no baffle and should never be used in performance applications when under 1/4 tank. The terminator (03-04 cobra tank) is a much better option due to the built in sump.

GT tank

GT pump



Cobra Tank


Cobra Pumps