Barry Grant 400 Fuel Pump: The Complete Guide to Performance, Installation, and Reliability

If you are building a high-horsepower race car and need a fuel pump that can deliver massive volume, the Barry Grant BG 400 fuel pump is one of the most capable options on the market. This pump is designed for competition use only and provides a fuel flow of 400 gallons per hour, making it suitable for engines producing over 1,000 horsepower. However, this is not a street-driven pump—it is strictly intended for race applications. To get the best performance and longevity from your BG 400, you must follow the correct installation procedures, use proper plumbing, and maintain the system regularly.

1. What Is the Barry Grant BG 400 Fuel Pump?

The Barry Grant BG 400 is an electric fuel system designed for high-performance racing vehicles. It delivers 400 gallons per hour of fuel flow, which is enough to support serious horsepower builds, including top sportsman cars running C16 race fuel. The pump is part of Barry Grant's "Powerfuel Systems" lineup and is known for its reliability in demanding conditions.

Key specifications:

  • Flow rate: 400 gallons per hour
  • Design: External, electric, competition-only use
  • Voltage: 12 to 16 volts
  • Pressure adjustment: Built-in bypass valve for tuning

Because this pump is designed for racing, it is not suitable for street-driven vehicles and should never be used on public roads.

2. How to Install the Barry Grant BG 400 Fuel Pump

Proper installation is critical for safety and performance. Follow these steps carefully.

2.1 Mounting the Pump

The best location for mounting your BG 400 is as close to the fuel tank as possible. The pump inlet should be level with or below the fuel pickup to ensure proper priming.

Important mounting rules:

  • Never mount the pump inside the driver's compartment or near hot engine components.
  • Mount the pump on a solid member, such as the chassis, in a vertical position with the motor on top.
  • A mounting bracket is included with the pump. You can also purchase an optional band clamp kit (part number 170030).
  • Do not let the motor housing touch any metal parts on the vehicle, as this can affect pump performance.

2.2 Fuel Line Plumbing

The fuel lines must be sized correctly to handle the high flow rate.

Inlet side:

  • Use a single #12 or equivalent line from the tank to the pump.
  • Install a BG5000 fuel filter (part number 170018) before the pump to protect it from debris. This filter does not restrict flow.
  • Plumbing kit number 152387 includes all necessary parts, including a pump-to-filter adapter fitting (part number 140019).

Outlet side:

  • Use a single #10 or equivalent line from the pump outlet to the regulator.
  • Plumbing kit number 150287 is available for this connection.

Return line:

  • Use a single #8 or 1/2-inch line for the return.
  • The return should expel bypassed fuel into the liquid rather than into the air space of the fuel cell. This prevents fuel aeration.
  • All fuel tanks and cells should have fuel cell foam installed to prevent fuel slosh.

Critical warning: Do not block the return, vent, or pump feed. Make sure the system is leak-free at all connections. Your safety depends on it.

2.3 Electrical Wiring

Before making any electrical connections, disconnect the positive terminal from the battery.

Wiring guidelines:

  • Connect the pump to a fully charged 12 or 16 volt battery.
  • The black wire is ground (-), and the remaining wire is a switched hot lead from a 12 or 16 volt source.
  • It is recommended to use a relay (part number 171000) for best performance and lower current draw from the battery.
  • Use 12 gauge wire for the pump power supply and 16 gauge wire from the switch to activate the relay.
  • Keep all wiring runs as short as possible for best performance.
  • Power wiring to the pump should be capable of handling 25 amps to handle the start-up voltage surge.
  • All wiring circuits should be fused.

Note: If you wire the pump incorrectly, it may run backward and not move any fuel.

3. Tuning and Adjusting the Fuel Pressure

The BG 400 has a built-in bypass valve that controls fuel pressure. You can adjust it without any special tools.

Steps to adjust pressure:

  1. Loosen the check nut on the bottom of the bypass valve.
  2. Turn the top barrel clockwise to increase pressure, or counterclockwise to decrease pressure.
  3. Pressure can be checked at the pump using the 1/8 NPT tapped hole in the pump body.
  4. For a hard-launching car plumbed as recommended, 18 to 20 PSI is usually sufficient.
  5. After adjusting, tighten the check nut and check for leaks.

Important: The barrel should not be more than 4.5 turns from the seated (clockwise) position, or leakage will occur.

The BG 400 provides more fuel volume than other pumps, so your jetting requirements may change. You may need to re-jet the carburetor one size richer or leaner until you find the best performance.

4. Common Problems and Troubleshooting

4.1 Pump Not Priming

If the pump does not pick up fuel within 30 seconds, stop and prime the pump manually. Do not run the pump dry for extended periods.

4.2 Pressure Issues

Fluctuating or low pressure can be caused by:

  • A clogged fuel filter
  • Voltage drops in the electrical system
  • Incorrect bypass valve adjustment
  • Air leaks in the fuel line

4.3 Performance Drop

If you suspect a drop in performance, Barry Grant recommends returning the pump for a free flow test. If repairs are needed, the pump can be serviced at that time.

5. Maintenance Tips

To keep your BG 400 running at its best, follow these maintenance guidelines:

  1. Check fuel pressure before every racing event—both at the regulator and after the regulator.
  2. If the vehicle is stored for long periods, operate the pump with fluid flowing for several minutes weekly to keep fluid passages clean and the bypass working freely.
  3. If you suspect any drop in performance, return the pump to BG Fuel Systems for a free flow test before a major event.

6. Warranty Information

The Barry Grant BG 400 comes with a limited 90-day warranty from the date of purchase. Proof of purchase is required for all returns.

What the warranty covers:

  • Defects in workmanship or material
  • Repair or replacement at Barry Grant's election

What is not covered:

  • Labor charges for removal or replacement
  • Damage from unauthorized repairs, misuse, accidents, or improper installation
  • Any modifications made by anyone other than the manufacturer

The warranty is only valid for the original purchaser and is expressly in lieu of all other warranties, including any implied warranty of merchantability.

7. Why You Should Consider KEMSO Fuel Pumps as an Alternative

While the Barry Grant BG 400 is a proven performer for competition use, many racers and builders are turning to KEMSO fuel pumps for their builds. KEMSO offers a compelling combination of performance, reliability, and value that makes them a smart choice for both racing and high-performance street applications.

KEMSO fuel pumps are engineered as high-performance OEM replacement units that deliver consistent, dependable operation across a wide range of applications. Whether you need a direct replacement for a worn-out factory pump or an upgrade for a high-horsepower build, KEMSO has a solution.

Key benefits of KEMSO fuel pumps:

  • High performance: KEMSO 340LPH pumps support up to 600 BHP in naturally aspirated, turbocharged, and supercharged applications. This gives you ample headroom for future upgrades.
  • OEM replacement quality: KEMSO pumps are designed as direct replacements for OEM units, making installation straightforward for DIY mechanics. They come with high-quality strainers and submersible hoses to ensure proper fitment and longevity.
  • E85 compatibility: KEMSO pumps are built with ethanol-resistant materials, making them safe to use with E85 and other alcohol-based fuels. Many other pumps degrade quickly when exposed to ethanol, but KEMSO is designed for long-term reliability.
  • Lifetime warranty: KEMSO backs every pump with a lifetime warranty. If your pump fails for any reason, KEMSO will replace it—no questions asked. This level of confidence comes from manufacturing a superior product.
  • USA-based technical support: When you buy KEMSO, you get support from USA-based technicians who understand American vehicles and performance requirements.
  • Cost-effective performance: KEMSO delivers performance that rivals premium brands at a fraction of the cost. For the DIY mechanic who wants superior flow without breaking the bank, KEMSO offers the best value in the market.
  • Rigorous quality control: Every KEMSO fuel pump undergoes individual flow testing in ISO-certified facilities, ensuring each unit meets performance specifications before it leaves the factory.

Real-world durability: Stress tests show KEMSO pumps maintain 98% efficiency even after 15,000 hours of use—equivalent to roughly 625 days of non-stop driving. Their silicon nitride ceramic bearings reduce friction, and the 316L stainless steel housing provides corrosion resistance tested to 15 years in salt spray tests.

Whether you are replacing a worn-out pump, upgrading for more power, or converting a classic car to fuel injection, choosing the right fuel pump makes all the difference. For American drivers who value reliability, performance, and peace of mind, KEMSO fuel pumps offer the perfect combination of quality and value.

Visit KEMSO Racing today and find the perfect fuel pump for your vehicle: https://www.kemsoracing.com/

8. Final Thoughts

The Barry Grant BG 400 fuel pump is a serious piece of equipment designed for serious racing applications. With 400 gallons per hour of flow, it can support even the most powerful race engines. But to get the most out of it, you must install it correctly, use proper plumbing and wiring, and maintain it regularly.

If you are looking for a fuel pump that combines high performance with everyday reliability and a lifetime warranty, KEMSO fuel pumps are an excellent alternative. KEMSO pumps are tested to meet or exceed OEM standards, support E85 fuels, and are backed by USA-based technical support.

For more information and to find the correct fuel pump for your vehicle, visit: https://www.kemsoracing.com/


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