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Old 08-06-2013, 11:40 AM   #1
cwczx3
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Lets talk about our stock fuel pump modules and modifying them.

Recently had my fuel pump module out and had one of the gaskets that seal the fuel pump outlet.



There are no replacements for this, only option is to buy a whole new module or steal one out of another module. When i removed the damaged one i was surprised at how small the outlet is going to the fuel rail.





From the outside it looks like a 5/16" hose but the hole is only 1/8". Granted the system was never designed to handle the power that some of us are requiring from it with turbos or superchargers.

There is also a check valve inline from the fuel pump to the outlet of the fuel pump module that is also 1/8".





This is just to keep fuel in the system pressurized so that you can just crank and go. By eliminating it all i should have to do is cycle the key two 2-3 times to prime the system. Not much different than having to let a return style system run for a couple of seconds before starting.

The outlet that returns fuel to the canister and venturi setup is the same 1/8" diameter.

I am currently running the gt40 fuel pump which does flow more than the stock pump. I have data logged both back to back and the stock pump on my current setup will max out about 2/3 the way through a 3rd gear pull from about 2-3000rpm to red line. The gt40 pump just maxes out just before red line.

What i am going to try next is running 5/16" hose straight from the pump to a 5/16" tee then run 5/16" hose to both the fuel pump module outlet that feeds the fuel rail and to the connection that feeds the canister/venturi setup. This should increase flow to the rail but drop pressure slightly. The computer will then increase voltage to the pump to maintain the desired pressure at rail in theory.

Yes i know switching to return fuel will eliminate all of this but i am willing to try this to see if it could work for some people that don't wanna go through the trouble of switching to return fuel. Also i want to eliminate the seal that failed and try to get a little more out of the gt40 pump before i do switch to return style fuel system.


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Old 08-06-2013, 12:59 PM   #2
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What psi isur gt40 um mmaxing out at? The svt one I'm running isholding great at 16
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Old 08-06-2013, 01:06 PM   #3
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I'm currently running 18psi.
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Old 08-06-2013, 01:13 PM   #4
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Hmm. I wonder how much the svt can take.I mean it is brand new. but I have to wait to bump it upuntili get a quafie
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Old 08-06-2013, 02:18 PM   #5
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I guess i should of mentioned that this is in one of the recall pump housings since i have a 2000 that had the recall done.

Can you give some specifics on your year, model, engine to add some info about the pump module. Like 2004 2.3l ZX3 or whatever it is.

I know Randy from FSWerks said us older Focus guys could run the 03-04 duratec pump module but that there are different settings in the tune.
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Old 08-06-2013, 03:05 PM   #6
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Yea I had the same set u until I threw it away. Iswitched to the svt gas tank and fuel pump
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Old 08-07-2013, 04:32 PM   #7
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Started mocking it up.

First a 5/16" tee that i cut one barb off each side so it wasn't so big.





Then fitting the hose in and figuring out the best routing so as not kink the hose.









I have another piece of hose coming and more clamps tomorrow. Hopefully get to try this out soon.
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Old 08-07-2013, 06:14 PM   #8
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Been there done that lol

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Old 08-07-2013, 06:24 PM   #9
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Tom, with what pump and how long ago?
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Old 08-07-2013, 06:59 PM   #10
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