Aeromotive Brushless Fuel Pumps Deliver Game-Changing Power

Decades in the making, Aeromotive Brushless Fuel Pumps continue to push the envelope several years after hitting the market. Meet the complete lineup, as well as a few new innovations, and learn how more flow can equal more go for your ride.

As a leading manufacturer, Aeromotive’s in-house engineers commit themselves to producing the finest fuel-related systems in the auto aftermarket. The company’s level of detail is particularly obvious when sub-assemblies relating to high-volume fuel pumps apply – including brushless motors that extend pump life-cycles, while maintaining maximum efficiency throughout.

The Brushless Difference

First, what are brushless motors, and what advantages are involved? Before we dive into fuel pump particulars, here’s a useful video that shows how this style of electrical motor works, and how its operation applies to customer use.

“Brushless electric motors offer reduced rotating mass/weight, and operate with no brush-to-commutator contact. These characteristics eliminate carbon dust emissions normally found with inline brush motors,” explained Aeromotive’s Director of Technology, Brett Clow. “Additional benefits include reduced friction and a meaningful drop in current draw for the same torque. The net effect is a lighter, more efficient, higher flow, cleaner-operating fuel pump.”

Meet the Aeromotive Brushless Fuel Pump Line

Aeromotive introduced its first series of brushless fuel pumps in 2018. Designed specifically for extremely high horsepower vehicles, the new technology offered improved performance and efficiency by creating less heat, drawing less power and eliminating the potential for wear – an ideal solution for ethanol-fueled, street/strip applications requiring a continuous duty fuel pump.

As the market demanded even larger pumping mechanisms to support major increases in power, Clow said Aeromotive’s brushless motor development program continued to pick up steam. “Consequently, we’ve been able to take fuel delivery with electric pumps to flow and performance levels never before seen,” he said.

The original Aeromotive brushless lineup included four pumps (A1000, Eliminator, 3.5 GPM and 5.0 GPM Gear Pumps), available in three different configurations:

• In-tank module, which serves as a direct drop-in replacement for any Aeromotive fuel cell style pump.
• Complete fuel cells, available in 6-, 15-, and 20-gallon options.
• External inline mounting option, which allows you to put the pump wherever you need it.

The Future of Fuel Delivery

By 2019, the company announced further impressive innovations to the line. First, was the addition of Variable-Speed Controllers to reduce fuel flow during low-demand situations. This helps combat overheating of the fuel, while limiting the noise bigger pumps produce, thereby enhancing the ability to take high flow pumps and put them on the street.

Introduced alongside the controller were two new pumps – the 7.0 GPM and 10.0 GPM Brushless Gear Pumps – capable of supporting up to 6,900 horsepower.

“Aeromotive took its proven line of A1000 and Eliminator pumps and brought them into the future with brushless motor options, including built-in True Variable Speed control, while simultaneously developing gear pumping mechanisms to combine with brushless motors to produce extreme flow from 3.5 GPM to the 10.0 GPM,” summarized Clow. “The revolutionary inline, spur-gear pumping mechanisms, the built-in True Variable Speed Control options and the overall expanded pump performance eclipse any competing fuel pumps in the industry.”

NEW In-Tank Fuel Pumps for Late-Model GM 1500 Pickups

Not one to rest on its laurels, Aeromotive continues to push its brushless fuel pump line forward. The company recently added two new in-tank fuel pumps for 2005-18 Chevrolet Silverado and GMC Sierra 1500-series trucks. Available in 3.5 GPM and 5.0 GPM configurations, these pump assemblies are Aeromotive’s first direct drop-in units for a specific application.

“The late model GM truck market has been gaining momentum over the last few years, and there were not many options for this platform,” explained Aeromotive Applications Engineer Matt Brewer. “Aeromotive originally developed an in-tank multi-pump product line for these trucks that gave the customers many different options for all levels of horsepower, but some customers still needed more. The benefits of the reduced amp draw of the brushless motors and the variable speed pump controller made these pumps a great fit for the GM trucks, since a large majority of them are used in a street/strip application.”

It’s simple, he said, “to make more horsepower, you need more fuel.”

“In some instances, we’ve had customers that are making 1,200+ fwhp on E-85 with a turbo or supercharger. This amount of horsepower requires 3.5-5.0 GPM of fuel flow, [something the OEM fuel pump can’t do].”

Relevant Specs

Designed to directly fit factory fuel tanks, the new GM truck pump assemblies feature unique OEM-style brackets to accommodate different applications and fuel level sending units. Each part number includes the pump, foam/basket assembly, and remote mount brushless controller. A fuel filter, regulator, and hoses/fittings are all sold separately.

The 3.5 GPM Brushless Spur Gear Fuel Pump (Part # 18087) can support:

• naturally-aspirated gasoline applications up to 2,400 horsepower,
• naturally-aspirated E-85 ethanol applications up to 1,680 horsepower,
• forced-induction gasoline applications up to 1,800 horsepower
• forced-induction E-85 ethanol applications up to 1,260 horsepower

For those seeking more flow, the 5.0 GPM Brushless Spur Gear Fuel Pump (Part # 18088) supplies enough fuel for:

• naturally-aspirated gasoline applications up to 3,400 horsepower,
• naturally-aspirated E-85 ethanol applications up to 2,380 horsepower,
• forced-induction gasoline applications up to 2,600 horsepower,
• forced-induction E-85 ethanol applications up to 1,820 horsepower.

A Note on Direct Replacement

These fuel pumps can be used in the same manner as the OEM fuel pump, but because they are mounted externally, they are not *technically* a direct replacement, explained Brewer.

Additionally, “the product works in the factory setting, but has a much higher flow rate than the OEM fuel pump,” added Design Engineer, Josh Bruehrer. So, “due to EPA and CARB compliance concerns in how they might interpret our product, we include a disclaimer that the product is not legal for on-road use.”

Bruehrer said that may change in the future, since Aeromotive plans to seek regulatory compliance with a reasonable basis testing for EPA and an EO for CARB.

Installation Q&A

Now that you have a sense of how the brushless product plays and what vehicles are compliant, let’s get to brass tacks on installation expectations.

Q: What is the typical installation time for any of Aeromotive brushless pumps?

A: “Installation time could be as little as 1-1/2 hours, if the system receiving the pump is already optimized for the increased flow, to as many as 8-12 hours if a completely new fuel system will be installed to support the dramatic increases in flow that are possible. This is very application-specific, of course.”

Q: What level of experience is typically necessary to execute a successful DIY install? 

A: “Basic hand tools and experience assembling braided line and hose-ends are necessary for a complete fuel system installation. Beyond that, presuming the correct system and companion components are on hand – i.e., the correct filters, regulator, and a sensible plumbing approach – it helps to have some experience routing fuel lines through the chassis to avoid excess heat and moving parts. Overall, it takes common sense and attention to detail.”

Q: What tools are required?

A: “Installing a pump requires very little in the way of tools if it’s going into an existing system. A good set of end wrenches – maybe AN wrenches for the hose-ends – but if a completely new system is being installed, a decent toolbox with common mechanics hand tools along with a cordless drill, a drill bit set, and some basic electrical plyers and wire cutters, etc., would be needed.”

Q: What resources are there for DIYers requiring a little extra guidance?

A: “Aeromotive has a number of technical resources available, including our website at www.aeromotiveinc.com. There you’ll find a Tech Section that features a set of 4-segment FAQs, a Tech Bulletin section, a System Diagram Section, and a Power Planner Section. In addition, Aeromotive offers telephone Tech Support at 913-647-7300 ext. 2, and a Tech email for basic questions at tech@aeromotiveinc.com”

So, there you go. Everything you need to know about Aeromotive Brushless Fuel Pumps. With innovation and performance baked in, we’re confident you’ll enjoy the flow.