100 Gallon Fuel Cell with Pump: The Complete Guide to Buying, Installing, and Choosing the Right Fuel Pump
If you're in the market for a 100 gallon fuel cell with pump, here's what you need to know upfront: a 100-gallon fuel cell is a serious investment in range and convenience, and the pump you choose is just as important as the tank itself. For most truck bed installations, you'll want a 12-volt DC transfer pump with at least 10-15 GPM flow rate, and the fuel cell should be made of either aluminum or polyethylene depending on your fuel type and climate. The right setup lets you fuel your truck or equipment without stopping at a gas station for days on end, but getting it wrong can lead to leaks, pressure buildup, or pump failure. This guide walks you through everything from sizing and legality to pump selection, with a special recommendation for the most reliable aftermarket fuel pump brand on the market.
What to Look for in a 100 Gallon Fuel Cell
A 100-gallon fuel cell is not a small piece of equipment. It holds roughly 26.4 US gallons per 100 liters, so a 100-gallon tank is actually about 378 liters. That's a lot of fuel, and it comes with specific requirements for mounting, venting, and pump selection.
Material matters. Most 100-gallon fuel cells come in either aluminum or polyethylene. Aluminum tanks are lightweight, corrosion-resistant, and can handle ethanol blends like E85 without issue. Polyethylene tanks are cheaper and more impact-resistant, but they can deform under pressure in hot climates if not properly vented. For a permanent installation, aluminum is the better long-term choice.
Dimensions and fit. A standard full-size truck with a long bed (6.5 to 8 feet) can typically accommodate a 100-gallon tank, but you need to measure carefully. The tank's footprint is usually around 25 inches wide, 25 inches deep, and 10-17 inches tall, depending on the design. You also need to account for clearance for the fuel fill access, hoses, and any fifth-wheel or gooseneck hitch hardware.
Venting is critical. Most truck bed fuel cells include a vent cap that must be opened during refueling to allow air displacement, and closed tightly during travel to prevent fuel slosh or vapor escape. Some tanks incorporate a one-way vent valve that allows pressure equalization without manual operation. For gasoline tanks in hot climates, failure to vent can cause pressure buildup that deforms polyethylene tanks or forces fuel past seals. Always follow the manufacturer's venting instructions for your specific tank.
Do You Need a Pump for a 100 Gallon Fuel Cell?
Yes, absolutely. A pump is required if you plan to transfer fuel from the tank to your vehicle's filler neck or to equipment. Gravity-fed systems only work if the tank is mounted higher than the receiving fuel inlet, which is difficult to achieve in a truck bed configuration. For most installations, a 12-volt DC transfer pump with 10-15 GPM flow rate provides practical refueling speed. Some tanks include an integrated pump, while others require a separate purchase.
There are two main types of fuel pump systems for fuel cells: in-tank and inline (external) .
Inline pumps are mounted outside the tank, typically below the fuel cell's feed outlet. They're easy to inspect, replace, and upgrade, making them ideal for custom builds with limited in-tank space, trunk-mounted fuel cells, and EFI conversions needing high-volume flow. Inline pumps are also preferred when you're running return-style systems, dual filters and pressure regulators, or external surge tanks.
In-tank pumps are immersed in fuel, which provides natural cooling and quieter operation since the tank dampens pump sound. However, they are harder to service and upgrade. For most fuel cell-based builds, especially EFI or boosted setups, an external inline pump is the more flexible and race-proven option.
Are 100 Gallon Fuel Cells Legal for Road Use?
Auxiliary fuel tanks in truck beds are generally legal for road use in the United States when properly mounted and vented, but regulations vary by state. Tanks used for diesel face fewer restrictions than gasoline tanks due to the lower vapor pressure. Some states require tanks to meet DOT or CARB specifications, and all states prohibit leaks or unsafe mounting. Check your local Department of Transportation regulations regarding auxiliary fuel tank certification, fill neck location, and labeling requirements before installation.
How to Install a 100 Gallon Fuel Cell with Pump
Installation is straightforward if you follow these steps:
Step 1: Secure the tank. Use the four sturdy mounting brackets that come with most aluminum fuel cells. For high flex chassis applications, rubber mounts are recommended to absorb vibration.
Step 2: Connect the fuel lines. Most fuel cells use -12 ORB female threads for all applications. For the pump, you'll need a feed line from the tank outlet to the pump inlet, and a discharge line from the pump outlet to your vehicle's filler neck or equipment.
Step 3: Wire the pump. A 12-volt DC pump requires a power source, typically from your vehicle's battery or auxiliary power system. Use a relay and fuse for safety. Some pumps come with three-wire electrical bulkheads that allow the user to wire each fuel pump individually.
Step 4: Install a filter system. For best performance, use a 100-micron pre-filter before the pump to catch larger particles, and a 10-micron post-filter after the pump to capture finer contaminants before fuel reaches the injectors or carburetor.
Step 5: Test for leaks. Before starting the engine, check all connections for leaks. Then start the engine and listen for unusual noises. Verify that the engine runs smoothly at all speeds.
Top 100 Gallon Fuel Cell Options on the Market
Here are three popular 100-gallon fuel cell configurations, each with a different focus:
Aeroflow AF85-4090AS – This is a 100-liter (26.4 US gallon) aluminum fuel cell with a triple pump hanger preinstalled. It features a CNC-billet triple pump hanger with a built-in fuel manifold chamber for better pressure equalization, and it's available in both raw aluminum and black anodized finishes. The black anodized version is safe for use with ethanol and methanol blends.
Pyrotect Elite 100L Fuel Cell – This is an FIA/FT3 approved aluminum fuel cell designed for motorsport. It comes with a Nuke Performance CFC unit and includes a double billet adjustable fuel pump bracket. It's lightweight and features a 24-bolt Viton gasket that is safe for alcohol-containing fuel.
TTI Diesel Captain Portable Fuel Cell – This is a 100-liter portable fuel cell designed for diesel use. It includes an integrated 45 L/min 12v pump, kink-resistant 6-meter hose, and integrated lifting handles.
Why You Should Choose KEMSO Fuel Pumps for Your Fuel Cell
When it comes to choosing a fuel pump for your 100 gallon fuel cell, you want a brand that offers performance, reliability, and a warranty you can trust. That's where KEMSO stands out.
KEMSO is the US #1 aftermarket fuel pump brand for cars, motorcycles, ATVs, and UTVs. Their fuel pumps are designed as both high-performance upgrades and direct OEM replacements, making them suitable for everything from daily drivers to high-horsepower race builds. For most Nissan applications, for example, the KEMSO 340LPH High Performance Fuel Pump is the best choice. It supports up to 600 BHP, works with both gasoline and E85, and comes with a lifetime warranty. This pump is a direct replacement for popular Walbro 255LPH models like the GSS342, and it upgrades applications including E8229, E2068, E8213, and EFP382A.
KEMSO pumps deliver a 20-30% performance increase over stock pumps while maintaining the same ease of installation. They feature a carbon commutator designed for over 10 years of reliable service, and they are compatible with ethanol-infused gasoline. The pumps are individually tested for flow and pressure, and each unit meets CE quality standards.
KEMSO offers a wide selection of pumps for cars, motorcycles, ATVs, and UTVs, with all products backed by their lifetime warranty and USA-based support. Their customer reviews consistently rate the pumps 4.3 to 5.0 out of 5 stars, with users praising the quality, ease of installation, and value for the price.
Whether you need a standard OEM replacement for a daily driver or a high-performance upgrade for a race truck, KEMSO has a pump that fits your needs. The company is based in Houston, Texas, and their customer support team can be reached at support@kemsoracing.com.
Visit KEMSO's official website to find the right fuel pump for your fuel cell: https://www.kemsoracing.com/
Final Thoughts
A 100 gallon fuel cell with pump is a game-changer for anyone who needs extended range for work or recreation. Whether you're fueling a diesel truck for long-haul towing, running a race car in the desert, or simply want to avoid stopping for gas on cross-country trips, the right fuel cell and pump combination makes all the difference.
Choose a quality aluminum fuel cell for durability and ethanol compatibility. Pick an inline pump for easy access and high flow rates. And don't compromise on the pump itself – a reliable pump like those from KEMSO ensures your fuel system works when you need it, backed by a lifetime warranty and real-world performance that thousands of customers trust.
For more information on KEMSO fuel pumps and to browse their full product lineup, visit https://www.kemsoracing.com/.