KJ Jones
Brand Manager, 5.0 Mustang & Super Fords
January 25, 2010

Those of you who own and operate high-horsepower Mustangs are plenty aware of the fuel demand that is brought about by having big-time horses under the hood. After all, a properly fueled engine is ultimately a happy engine. Thankfully most of you also endorse this way of thinking and install higher-volume fuel pumps, bigger fuel lines, and other fuel-system-upgrade hardware where necessary. This ensures that the boosted or nitrous-gulping bullet in your 'Stang has plenty to drink at all times.

While we always make it a point to have the right stuff in our project Mustangs-especially when it comes to fuel delivery-a recent problem with the fuel pump in our supercharged '02 Mustang GT prompted us to make a few changes that we think will benefit other enthusiasts with Ponies that are similarly outfitted with high-volume fuel systems.

Because our GT's fuel pump is mounted on the front panel of the fuel-tank cover and fairly close to the ground, it is often subjected to intense heat that radiates from the surface of Southern California's concrete freeways and asphalt streets. When you couple such high temperatures (we've measured ground temps of 130 degrees in the San Fernando Valley during the summer) with exhaust heat and no airflow, bad things can happen. Eventually the heat-despite some cooling from fuel that returns to the tank-will take its toll on the fuel pump's DC motor.

We unfortunately went through two incidents with this hot-pump condition (overheating that leads to fuel vapor lock and the pump eventually shutting off) before seeking assistance from the technical staff at Aeromotive Fuel Systems to find out how the problem can be corrected. Aeromotive's fuel-pump-speed control module (PN 16306; $316.95) is the answer.

The FPSC is designed to reduce fuel heating and vapor-lock issues by matching the duty cycle of the fuel pump to engine rpm. Basically, the small billet device is an rpm-referenced regulator for any aftermarket electric fuel pump. At low demand, like when you're stuck in heavy traffic, the FPSC slows down the fuel pump's duty cycle when the engine reaches a pre-set, minimum rpm.

In a return-style fuel system, the lower pump speed also lowers the fuel recycle rate, which helps keep fuel a bit cooler, and minimizes cavitation opportunities. When you finally get some room to run, the FPSC increases duty cycle as the revs climb, achieving maximum flow (100-percent duty cycle) at a pre-set rpm.

This month, we're rejuvenating the '02's fuel system with the fuel-pump-speed controller, as well as Aeromotive's new 100-micron filter with shutoff valve (PN 12331; $224.79). Regular filter maintenance is another key to an electric fuel pump's survival, and adding the trick, billet-aluminum filter housing (the valve stops fuel flow and allows you to make filter inspections and changes without needing containers to catch spilling fuel) will ensure we'll be diligent about performing such maintenance.

The following photos and captions take you through the steps of Saul "The Surgeon" Gutierrez's installation of our Pony's new gas goodies. This project is completely DIY friendly, and it definitely will help reduce the chances of finding yourself parked on the side of the freeway, waiting for the fuel pump to cool down ... or nightfall ... just so you can drive again.

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