upgrading the fuel system is an essential part of any high-powered Hellcat engine swap project. In this tutorial, we'll go through the step-by-step process of replacing the fuel pump on a Dodge Charger SRT 8 that has been upgraded with a Hellcat powerplant.
Why Upgrade the Fuel Pump?
The stock fuel pump that comes on SRT 8 Chargers is only rated to support around 500 horsepower. Once you start pushing beyond that with a supercharged or turbocharged Hellcat swap, the stock pump just can't keep up with fuel demands. An upgraded high-flow fuel pump is necessary to ensure the engine receives an adequate fuel supply under heavy throttle.
Fuel Pump Replacement Procedure
Let's go through the process of swapping out the stock pump for an upgraded high-performance alternative:
Preparation
First, remove the fuel pump fuse to cut power to the pump. Start the engine and let it run until it stalls to bleed down any residual fuel pressure. Some vehicles may require dropping the fuel tank for better access - on our Charger, removing the rear seat provided plenty of room.
Remove Old Pump
Unplug the electrical connection to the pump sender unit. Use a screwdriver and hammer to remove the retaining lock ring, then pull off the pump hat. Disconnect the fuel lines and wiring harness before lifting the old pump out of the tank.
Install New Pump
Inspect the new pump's O-ring for defects. Lower it gently into the tank and reconnect the fuel lines and wiring. Install the pump hat and lock ring, being careful not to spark the fuel vapors. Plug everything back in and reinstall the fuel pump fuse.
Testing and Finishing Up
Start the engine to verify the new pump is functioning properly. Clean up any spilled fuel before reinstalling interior trim pieces like the rear seat. Your Hellcat swap is now equipped with a fuel system capable of supporting its increased horsepower!
Let me know if you have any other questions!
FAQs
Do I need to adjust my fuel pressure regulator as well?
It's a good idea to upgrade your fuel pressure regulator to one rated for higher pressures when installing an upgraded high-flow fuel pump. This will allow you to optimize fuel pressure for your new power level.
How can I test that my new pump is working properly?
The easiest way is to start the engine once installed. You should hear the pump priming loudly. You can also use a fuel pressure gauge to verify pressure rises within specification.
What size pump should I get for a 800hp Hellcat swap?
For an 800hp Hellcat engine, a top-quality 370lph or larger electric fuel pump should provide ample flow. Walbro, Aeromotive, and Fuelab pumps in this range are great options.