
EFI fuel pump technology is ever-evolving. New pumps are introduced almost every year from various manufacturers. This can make selecting a fuel pump for your application confusing. This brief article will walk through popular pump options that are compatible with Radium Engineering products.
Fuel pumps with both brushed and brushless motors are readily available and will be covered. There are many resources online explaining how these two types of electric motors work, so it will not be discussed in detail here.
NOTE: Currently, Radium only sells fuel pumps from Ti Automotive (Walbro), however pumps from other brands can be used as well.
TRADITIONAL BRUSHED FUEL PUMPS
Benefits: Low cost, readily available from every popular retailer, easy to have spares on hand, good performance for the price, proven reliability.
Drawbacks: Higher current draw (more heat), limited control over pump speed.
Ti Automotive (Walbro) F90000-Series Fuel Pumps
These pumps have shown excellent performance and reliability at a low price point, making them the most popular pumps we sell. Made in the USA. Originally an OEM fuel pump, Ti Automotive realized there was significant aftermarket demand for them and started offering them for sale through their aftermarket division back in 2014 or so.This family of pumps are offically called DCSS 39/50 pumps. (DC brushed motor, single stage pump mechanism, 39mm upper body, 50mm lower body). As different variations of the DCSS 39/50 were released, it became necessary to refer to them by their stamped-on part numbers to reduce confusion. This is how we at Radium Engineering still refer to these pumps.
Many DCSS 39/50 versions are available, but we are going to limit this conversation to the THREE most popular in the automotive performance aftermarket:
F90000274 (Stocked by Radium Engineering)
F90000285 (Not stocked)
F90000295 (Stocked by Radium Engineering)
Reference the graphic below for the differences:
Regarding compatiblity with Radium Engineering products (Fuel cells, fuel pump hangers, etc): Any product listed compatible with one F90000-series pump is compatible with all of them, because they all share the same electrical connector, hose barb size, and overall external dimensions.
Selecting which one to use is the decision of the consumer or installer. Some things to consider when selecting which version of the DCSS 39/50 pump to use:
F90000295 Pump - Great to use as a lift pump on high-HP applications. Does not have a built-in check vlave, so it will not hold pressure at the fuel rail when not running. Not advised to use in a multi-pump setup because of possible back-flow from lack of check valve.
F90000285 Pump - Great flow number. Higher current draw, so more heat goes into the fuel. Has a built-in check valve so it can be used staged with other pumps.
F90000274 Pump - Slightly less flow than the 285 pump, but also lower current draw, so less heat goes into the fuel. Has a built-in check valve so it can be used staged with other pumps.
Data from Radium Engineering in-house bench testing of DCSS 39/50 Pumps:
340 LPH Pumps
These fuel pumps are plentiful on the market and are sold under many different brands. They are mostly made overseas and come in a variety of different brand-oriented colors. They package a lot of flow in the same 39mm body as the Walbro 255 pumps. They are a great balance between flow rate and cost.
Radium previously sold AEM brand 340 LPH pumps, and you will see the part number 50-1200 in many Radium parts descriptions. However, there are many versions of these pumps from other manufacturers that work just fine as well.
For all Radium products (in-tank hangers, fuel surge tanks, etc), when selecting a "340" LPH pump from a different manufacturer, make sure it has the inlet and outlet on the same side of the pump, as shown below. The pump must also have the standard electrical connector, as shown below:
With these two physical size requirements met, any 340LPH pump will work in Radium Products with AEM 50-1200 in the description, like shown below:
WALBRO GSS342 (255 LPH)
This tried and true submerged fuel pump is very popular because of it's low price, excellent performance and outstanding reliability. This gearotor pump is not as quiet as more contemporary pumps, but it's reliability and low cost more than makes up for it.
This pump is made in the USA and features a check valve in the outlet stem, so it can be used in staged muti-pump setups.
As mentioned above with the AEM pump, this pump has the inlet and outlet in-line with each other and the traditional fuel pump electrical connector.
This pump has been proven safe to use in E85, despite no official rating from Ti Automotive.
BOSCH BR540 / DW400
This brushed fuel pump from Bosch has great performance, but at the cost of a large physical size. Because of this, it does not fit in all Radium Engineering products. Look for products that specifcially list compatibility with this pump.
Advertised flow rate is 460 LPH at 40psi.
NOTE: There are different versions of this pump on the market. Some do NOT have a built-in check valve on the outlet. Research before you buy!
BRUSHLESS FUEL PUMPS
Benefits: Low current draw, high flow rates
Drawbacks: Higher cost, more complexity, pumps require controllers
Ti Automotive E5LM & BKS1000/10001
The Ti Automotive E5LM brushless fuel pump was used as OEM equipment in several cars in the 2010's, such as the E70 BMW X5M and others. But without a stand-alone fuel pump controller, it was not much use for the aftermarket. Eventually, Ti Automotive released the BKS1000, which was the E5LM fuel pump combined with an aftermarket-friendly, and somewhat basic, fuel pump controller. A few years later, the controller was improved and the kit was re-released under part number BKS1001. This kit has solid performance and is relatively affordable for a brushless fuel pump system. NOTE: If using two brushless fuel pumps, a controller is needed for EACH pump.
This kit can be used with any Radium product that is compatible with the E5LM pump.Ti Automotive E5LM & Injector Dynamics BPC1100
Also using the E5LM pump, is the BPC1100 controller from Injector Dynamics. This sophisticated controller spent a decade in R&D before it was released to the public. It has many advanced controls and capabilities. As a result, it is able to spin the E5LM pump to shocking flow rates without drawing much electrical current. Click the photo below to be taken to Injector Dynamics website for more details.
This controller can be used with an E5LM pump in any Radium product listed as compatible with the E5LM brushless fuel pump.GENERIC COMPACT BRUSHLESS
This small brushless fuel pump, and variations of it, is sold in the performance aftermarket under several different popular brand names, but is also availble from overseas importers. Flow rates usually can be found anywhere from 500 to 800 LPH depending on the brand and the controller used.
Some Radium Engineering products are compatible with this pump. Please refer to the specific product page for more information, or contact Radium technical support.
SELECTING A FUEL PUMP
Radium Engineering has developed the chart below to help make your decision easier when selecting a fuel pump. By knowing target horsepower (at the flywheel) you can make a very good assumption of pump requirements. For high-horsepower setups, multiple pumps can be used to feed the engine, just add the pump outputs together.
NOTE: Plan for at least 20% more flow capacity than you need.