The Ultimate Guide to the Aeromotive Fuel Pump: Power, Precision, and Reliability for High-Performance Engines​

For any serious performance engine builder or enthusiast, achieving maximum, reliable horsepower comes down to one non-negotiable foundation: a flawless fuel supply. At the summit of this critical system sits the Aeromotive fuel pump. An Aeromotive fuel pump is not merely a component; it is the definitive solution for high-horsepower applications demanding unwavering fuel pressure, immense flow volume, and bulletproof reliability under extreme conditions. Whether you are pushing a turbocharged street car, a all-out drag racer, a high-revving track machine, or a specialized off-road vehicle, selecting and installing the correct Aeromotive pump is the single most important step in guaranteeing your engine receives the precise fuel it needs to make power and survive. This definitive guide will explain everything you need to know about Aeromotive fuel pumps, from their engineering philosophy and core technologies to selecting the perfect model and installing it for a lifetime of service.

​Understanding the Aeromotive Difference: A Legacy of Performance​

To understand why Aeromotive products are the industry benchmark, one must understand the company's origin and mission. Founded in the heart of American performance culture, Aeromotive was born from a direct need that existing parts could not fill. Early fuel system components often failed under the stress of competitive racing, leading to engine damage and lost races. Aeromotive entered the market with a singular focus: to engineer and manufacture fuel system components that would not fail. This commitment to ​absolute reliability and performance under pressure​ defines every product they make. Unlike mass-produced parts designed for a broad market, Aeromotive pumps are engineered for a specific customer: the individual who cannot afford failure. This mindset translates into the use of superior materials, innovative design, and relentless testing. When you choose an Aeromotive pump, you are purchasing an insurance policy for your engine investment, backed by decades of proven success on the world's most demanding racetracks and streets.

​How an Aeromotive Fuel Pump Works: Core Technology and Design​

While all electric fuel pumps share a basic principle—using an electric motor to drive an impeller or gerotor that pushes fuel—the devil is in the details. Aeromotive's engineering excellence is evident in several key areas of their pump designs. Most of their high-performance pumps utilize a brushless DC motor design. ​Brushless motor technology​ is a significant advancement over traditional brushed motors. Brushes physically contact the motor's commutator, creating friction, heat, and eventual wear. Under high-cycle, high-load conditions, brushed motors can fail. A brushless motor, as the name implies, has no physical brushes. It uses an electronic controller to manage the magnetic fields that drive the motor. This results in several critical advantages: dramatically reduced electrical noise, cooler operation, vastly extended service life, and inherently higher efficiency.

The fuel movement mechanism inside an Aeromotive pump is typically a gerotor assembly. This consists of an inner and outer rotor with offset lobes. As the motor spins the inner rotor, the pockets between the lobes carry fuel from the inlet to the outlet with smooth, continuous flow. This design is prized for its ​high volumetric efficiency and ability to deliver consistent flow with minimal pulsation. The materials used for these internals, as well as the pump housing, are selected for their compatibility with modern fuels, including aggressive ethanol blends (E85). Aeromotive pumps are built to handle these fuels without degradation of internal seals, diaphragms, or rotors. Furthermore, Aeromotive designs its pumps to be submersible in fuel when installed in-tank. The fuel itself acts as a coolant and lubricant for the pump motor, which is essential for sustained high-output operation. The physical construction is rugged, often using hard anodized or billet aluminum housings instead of plastic, to ensure integrity within a high-vibration environment.

​Decoding the Aeromotive Model Lineup: Choosing the Right Pump​

Aeromotive offers a wide range of fuel pumps, each designed for specific power levels and applications. Selecting the correct one is critical; an undersized pump will starve your engine, while an oversized pump may create unnecessary complexity and heat. The primary specification to understand is ​fuel flow, measured in gallons per hour (GPH) at a specific pressure. Aeromotive rates their pumps at both 40 psi and 70 psi, with the 70 psi rating being more relevant for forced induction (turbo/supercharger) applications which require higher base fuel pressure.

Here is a breakdown of key pump series and their intended use:

• ​Stealth Series (In-Tank):​​ This is Aeromotive's premier line of brushless, in-tank fuel pumps. Models like the ​Stealth 340​ and ​Stealth 525​ are legendary for their quiet operation, exceptional efficiency, and massive flow. The Stealth 340 can support over 1,300 horsepower on gasoline, while the Stealth 525 can support beyond 2,000 horsepower. These are the go-to choice for ultimate street performance, pro-touring, and high-end race applications where noise and maximum capacity are concerns.

• ​A Series (In-Tank):​​ The workhorse of the lineup, the A pumps (like the ​A1000, ​A2000) are brush-style pumps known for their incredible durability and high flow. The ​A1000​ is perhaps the most famous fuel pump in hot rodding, capable of supporting over 1,000 horsepower. It is slightly louder than a brushless pump but offers proven reliability and value. The A2000 is a twin-A1000 assembly for extreme power levels.

• ​Eliminator Series (External):​​ Designed for mounting outside the fuel tank, these pumps are typically used in drag racing or dedicated race cars where tank sumps or fuel cells are employed. Pumps like the ​Eliminator 125/225​ are built for extreme conditions with a heavy-duty billet housing. They are very loud but offer tremendous flow and the simplicity of external mounting and service.

• ​Quiet Series (In-Tank):​​ As the name suggests, these brushless pumps prioritize near-silent operation for luxury or restomod vehicles where OEM noise levels are desired without sacrificing performance. They offer substantial flow in a quiet package.

• ​Hi-Flow In-Tank Modules:​​ Aeromotive also produces complete drop-in assemblies for popular vehicles (like Mustangs, Camaros, Corvettes). These include the pump pre-installed in a bucket with necessary hangers, wiring, and often upgraded feed lines. This is the simplest, most reliable installation method for late-model fuel-injected cars.

Choosing the right model requires knowing your engine's horsepower goal, fuel type (gasoline vs. E85), induction type (naturally aspirated, turbocharged, supercharged), and the base fuel pressure your fuel injectors require. Always consult Aeromotive's flow charts and select a pump that meets your flow needs at your operating pressure with a safety margin.

​The Critical Role of the Fuel System: More Than Just a Pump​

An Aeromotive pump is the heart of the fuel system, but it cannot function correctly without healthy "arteries and veins." ​A complete system design is essential for success.​​ A common and costly mistake is installing a high-flow pump into a stock fuel system never designed for such volume. The key supporting components include:

• ​Wiring and Relay:​​ The single biggest cause of high-performance pump failure is inadequate wiring. Factory wiring is often too small gauge. An Aeromotive pump must be wired with the correct gauge wire (typically 10 or 8 gauge) directly from the battery, through a ​high-quality, high-amperage relay, triggered by a switched ignition source. This ensures the pump receives full voltage and current, preventing it from running hot and weak.

• ​Fuel Lines and Fittings:​​ Stock rubber or plastic lines can restrict flow and may not be compatible with race fuels. Upgrading to ​AN-style stainless braided lines or high-quality push-lock hose with dedicated fuel fittings​ is mandatory. The line size (-6AN, -8AN, -10AN) must match the pump's outlet and the engine's demand.

• ​Filters:​​ A high-capacity filter before the pump (in-tank or pre-pump) protects the pump from debris. A second, high-flow filter after the pump protects the injectors. Never use a restrictive stock filter with a high-performance pump.

• ​Fuel Pressure Regulator (FPR):​​ This is the brain of the system. The Aeromotive pump delivers more fuel than the engine needs. The ​Aeromotive bypass-style fuel pressure regulator​ controls system pressure by returning excess fuel from the fuel rail back to the tank. It is adjustable and must be matched to your fuel injectors and induction system. A dead-head system (no return) is never recommended for high-performance applications with an Aeromotive pump.

• ​Tank Modifications and Surge Control:​​ For in-tank installations, especially in vehicles that will see cornering or acceleration forces (road racing, autocross), the stock tank may starve the pump of fuel. Adding an ​internal sump, surge tank, or bucket-style baffling​ is crucial to ensure the pump inlet is always submerged in fuel, preventing dangerous vapor lock and pump cavitation.

​Step-by-Step Installation Best Practices​

Proper installation ensures performance, safety, and longevity. Here is a concise guide to key installation principles.

1. ​Safety First:​​ Disconnect the negative battery terminal. Relieve fuel system pressure by disconnecting the fuel pump relay or fuse and running the engine until it stalls. Work in a well-ventilated area with no sparks or open flames.

2. ​In-Tank Pump Installation:​​ If replacing an in-tank pump, carefully drop the tank or access the pump through the hatch. Remove the old pump assembly. ​Clean the tank thoroughly​ of any debris or sediment before installing the new unit. Ensure all supplied O-rings or gaskets are used and properly seated. For retrofit applications, follow Aeromotive's instructions for modifying the hanger or bucket. The pump should sit as low as possible to pick up fuel.

3. ​External Pump Installation:​​ Mount the pump as close to the tank as possible, and lower than the tank outlet if possible, to aid in priming. Use rubber-isolated mounting brackets to dampen vibration. Ensure the pump is mounted in a location with adequate airflow for cooling and protected from road debris and heat sources like exhaust.

4. ​Wiring:​​ This is paramount. Run a dedicated power wire of the correct gauge from the battery positive terminal to a fuse holder (within 18 inches of the battery), then to a ​40-60 amp relay. From the relay, run the power wire to the pump. Use a high-quality ground wire of the same gauge, connecting directly from the pump to a clean, bare metal point on the chassis or battery negative. Use the factory fuel pump trigger wire to activate the relay. Solder and heat-shrink all connections.

5. ​Plumbing:​​ Use fuel-rated hose and proper clamps or AN fittings. For push-lock hose, ensure the hose barb is fully inserted and the clamp is positioned correctly. For AN fittings, ensure they are properly assembled and wrenched. Route lines away from sharp edges, exhaust, and moving parts. Install filters as directed.

6. ​Priming and Testing:​​ Before connecting the final power, temporarily wire the pump to run and check for leaks at all connections. Once confirmed leak-free, complete the wiring. With the ignition on, the pump should prime. Check fuel pressure at the regulator with the vacuum reference line disconnected. Adjust the regulator to your target base pressure (e.g., 58 psi for many modern EFI systems). Start the engine and check pressure again; it should drop proportionally with engine vacuum. Recheck for leaks once the system is hot.

​Troubleshooting Common Fuel System Issues​

Even with premium components, issues can arise. Here is how to diagnose common problems related to your Aeromotive pump system.

• ​Engine Stumbles Under Load (Lean Condition):​​ This is often a fuel delivery problem. Check fuel pressure under load with a gauge taped to the windshield. If pressure drops, diagnose the cause: a clogged filter, pinched line, failing pump, or inadequate wiring causing voltage drop at the pump.

• ​High Fuel Pressure That Won't Adjust:​​ Likely a stuck or malfunctioning fuel pressure regulator, or a kinked or blocked return line to the tank.

• ​Low Fuel Pressure:​​ Could be a weak pump, a clogged pre-pump filter, a leak in the supply line, a faulty regulator allowing too much return flow, or severe voltage drop at the pump.

• ​Pump is Noisy:​​ For in-tank pumps, noise often indicates ​inlet starvation or cavitation. Check that the pump is fully submerged and the tank is adequately vented. For external pumps, noise can be normal but excessive noise may indicate wear or, again, inlet restriction.

• ​Pump Intermittent or Won't Run:​​ First, check all electrical connections, fuses, and the relay. Use a multimeter to check for battery voltage at the pump's power terminal when it is commanded on. If voltage is present, the pump may have failed. If voltage is low or absent, trace the wiring back to find the fault (bad ground, failed relay, broken wire).

​Maintenance for Maximum Lifespan​

An Aeromotive pump is built to last, but simple maintenance ensures it does.

• ​Always Use Clean, High-Quality Fuel:​​ Contaminated fuel is a primary enemy. Change your fuel filters regularly according to your driving conditions. If the car sits for long periods, use a fuel stabilizer.
• ​Keep the Tank from Running Extremely Low:​​ Running the tank consistently on "E" can cause an in-tank pump to overheat, as fuel is its coolant. It also increases the chance of picking up sediment from the bottom of the tank.
• ​Periodically Inspect the System:​​ Visually check lines and connections for leaks or wear. Listen for changes in pump sound. Monitor fuel pressure occasionally to catch drifts that indicate a developing issue.
• ​Protect the Electrical System:​​ Ensure your vehicle's charging system is operating correctly. Low system voltage or voltage spikes can stress the pump motor.

In the pursuit of performance, the fuel system is not the place to compromise. The Aeromotive fuel pump represents the culmination of decades of focused engineering, track testing, and real-world validation. It provides the peace of mind that when you demand power, the foundational system delivering it is incapable of letting you down. By understanding its technology, carefully selecting the correct model, integrating it with a complete and properly sized system, and installing it with precision, you secure the most critical link between your fuel tank and your engine's combustion chambers. For those who define reliability as never having to worry about a part, the choice is unequivocal.