Several factors underlie the compatibility issues in fuel pumps, including the specifications of the pump, the design of the fuel system, as well as the requirements specific to different engine types. Searching for the proper in-tank or in-line fuel pump is an examination of things such as output pressure and flow rate, as well as the kind of fuel you are dealing with. As an example, performance motors require fuel pumps capable of higher operating pressures—usually over 70 PSI—to properly supply fuel to turbocharging or supercharging systems. Pumps not matched properly results in significant performance loss, stalling, and fuel lines eventually becoming trash. This is particularly true with aftermarket fuel pumps, where an incorrectly matched unit might affect the efficiency — or safety — of the entire fuel system.
More tangibly, the dangers of having a mismatched fuel pump are serious. Pump output—GPH, must closely match the engine requirements in gallons per hour. As an example, engines that develop more than 400 horsepower require fuel pumps that flow at least 255 liters per hour. If you install a lower capacity pump, this may lead to overheating, misfiring, or, in very severe conditions, total failure of the engine. In one high-profile case, a top auto maker had to recall thousands of vehicles as the fuel pump would be incompatible with the ethanol-blended fuels commonly sold throughout the world causing early wear and reduced engine performance.
It will also depend on the types of fuel one uses. Certain pumps designed for gasoline may breakdown using ethanol blends. Ethanol is corrosive and affects pump internals, seals and makes lines susceptible to leakage, reducing effective life by up to 40%. This incompatibility often comes as a surprise to drivers accustomed to flexible fuel systems due to the common misconception of universal compatibility.
As the late automotive guru Carroll Shelby once said of performance, "Everything is precision." We see this statement with fuel pumps, where even the slightest inconsistency in size, capacity, or fuel type compatibility causes havoc that is out of proportion to the issue. For example, a pump designed for diesel in a gasoline engine could clog filters and lead to full-on fuel system failure, with expensive repairs and hazardous consequences.
Those looking for a new fuel pump to buy for your car should follow OEM guidelines. OEM fuel pump usually provide the best fit, function and life, very often blowing aftermarket options out of the water. OEM guidelines also cover the proper electrical specifications, and proper mounting configurations for a proper and safe fit — which is vital to alleviate hazardous fuel leaks and maintain system longevity.
If you are considering the aftermarket route, just make sure the pressure rating, flow rate and material compatibility with modern ethanol blends is all squared away. Today, a large number of manufacturers standardize ethanol-compatible pumps with clear labels to help the consumer know more about the product they are buying. However, mistakes with compatibility account for about 15 percent of fuel system breakdowns each year, which is expensive for both drivers and insurers.
Fuel pump mix-ups are a problem that is evolving alongside the growth of hybrid and electric vehicles. In particular, many hybrid engines utilize electronically controlled fuel pumps that are very different from traditional mechanical pumps, requiring a more technical understanding of the entire fuel system.
Professional advise that ensuring every single aspect of the replacement pump matches your vehicles requirements — pressure, flow rate, and material compatibility — will avert potential problems. To learn more about compatible great fitment quality, check out the Fuel Pump variety of solutions suitable for different types of vehicles.