Dual Fuel Pump Kit: The Smartest Upgrade for High-Performance Vehicles
If you're building a high-horsepower vehicle, running forced induction, or switching to E85 fuel, a dual fuel pump kit is no longer optional—it's essential. The factory single fuel pump in most cars, trucks, and SUVs simply cannot deliver enough fuel volume to meet the demands of a modified engine. Installing a dual fuel pump kit ensures consistent fuel pressure, prevents engine damage from lean conditions, and gives you the reliability you need for both street driving and track use. This guide covers everything you need to know about dual fuel pump kits, including how they work, which vehicles benefit most, and how to choose the right setup for your build.
Why You Need a Dual Fuel Pump Kit
A single fuel pump has a finite flow capacity. When you increase horsepower through supercharging, turbocharging, or engine tuning, your fuel demand rises dramatically. According to Holley, forced-induction engines consume about 0.6 to 0.75 pounds of fuel per horsepower per hour, compared to 0.4 to 0.5 pounds for naturally aspirated engines . E85 fuel requires even more volume—approximately 30% to 35% more than gasoline . A single pump simply cannot keep up with these demands.
A dual fuel pump kit solves three critical problems:
- Insufficient fuel volume – Two pumps working together can deliver double the flow rate of a single pump, supporting up to 1,200+ horsepower on gasoline with the right setup .
- Fuel starvation – In vehicles with saddle-style fuel tanks, a single pump can leave one side of the tank undrained, causing fuel starvation during hard cornering or acceleration. A dual pump system places a dedicated pump on each side of the tank, ensuring both sides are drawn down evenly .
- Redundancy and reliability – If one pump fails, the second pump can still deliver enough fuel to get you home safely. This is a critical safety feature for any high-performance street car or track car .
How Dual Fuel Pump Kits Work
Dual fuel pump kits come in two primary configurations depending on your vehicle and application:
In-Tank Dual Pump Systems
These kits replace the factory fuel pump assembly with a custom drop-in module that houses two pumps. They are common in late-model vehicles with saddle tanks, such as Dodge Chargers, Challengers, and Chrysler 300Cs . The Holley dual-255LPH system, for example, delivers 255 liters per hour per pump (510 LPH total) and supports up to 550 horsepower on gasoline . Their dual-525LPH system pushes 1,050 LPH total and supports over 1,200 horsepower on gasoline, making it ideal for extreme builds .
External Dual Pump Systems
For vehicles with dual fuel tanks—common in older pickup trucks and some classic cars—external dual pump kits are the standard solution. These kits include a switching valve, fuel filters, and wiring harness to manage fuel draw and return from both tanks. The EFI System Pro dual tank kit uses TI Automotive (Walbro) 255 LPH inline fuel pumps and includes a motorized valve that switches fuel source, return line, and fuel level sender simultaneously . The Holley 534-37 dual tank kit is designed for Holley MPI, TBI, and Terminator EFI systems, supporting up to 400 horsepower .
Diesel Dual Fuel Pump Kits
Diesel engines, particularly Duramax and Power Stroke models, benefit from dual CP3 pump kits. PPE's Dual Fueler kit adds a belt-driven Bosch CP3 pump that works alongside the factory pump, with a microprocessor module that balances the load between both pumps . If one pump fails, the controller instantly reroutes all fuel delivery to the functioning pump . This system can maintain over 26,000 psi of fuel pressure, supporting high-horsepower diesel builds .
Choosing the Right Dual Fuel Pump Kit
Selecting the correct kit depends on your vehicle, fuel type, and power goals. Here are the key factors to consider:
1. Horsepower and Fuel Type
Determine your target horsepower and whether you plan to run E85. For gasoline builds up to 550 HP, a dual-255LPH system is sufficient . For 700-1,200+ HP on gasoline, or 800-900 HP on E85, step up to a dual-525LPH system with brushless motor technology, which offers extended pump life—over 5,000 hours of operation compared to 1,500-2,000 hours for traditional brushed pumps .
2. Single Pump vs. Dual Pump Configuration
For dual tank vehicles, the single pump version is less expensive and easier to install, but it requires the tanks to be located close together—within 18-24 inches of the pump . If your fuel outlets are farther apart, a dual pump kit reduces strain on the pumps and minimizes noise . Having two pumps also provides redundancy in case of failure .
3. Return-Style vs. Return-Less Systems
Most modern vehicles use return-less fuel systems, but high-performance builders often prefer return-style setups because they allow the pump to constantly circulate fuel, eliminating air pockets and cooling the pump . Many dual pump kits, such as those from Holley, come pre-configured for return-less systems but include hardware to convert to a conventional return-style system .
4. Vehicle-Specific Fitment
Always choose a kit designed for your specific make, model, and year. For example, Livernois Motorsports offers a drop-in dual fuel pump assembly for 2015-2021 Dodge Hellcat Challengers and Chargers, capable of 1,300 RWHP on gasoline and 1,000 RWHP on E85 . Industrial Injection provides dual fuel kits for 2011-2019 Ford 6.7L Power Stroke and 2011-2016 GM 6.6L LML Duramax engines . Lonnies Performance offers double pumper kits for 3rd gen and 4th gen Camaro/Firebird, supporting over 1,000 RWHP .
Installation Considerations
Installing a dual fuel pump kit is a moderate to advanced DIY project that typically takes 4-8 hours . Here are the essential steps:
1. Gather Tools and Materials
Before starting, collect wrenches, socket sets, fuel-resistant hoses, hose clamps, fittings compatible with your fuel system, and the dual fuel pump kit itself . Safety gear—nitrile gloves, safety goggles, and a fire extinguisher—is non-negotiable due to the flammable nature of fuel .
2. Prepare the Fuel Tank
Disconnect the battery and relieve fuel system pressure before removing the stock pump . Clean and inspect the tank, ensuring it is compatible with the dual pump setup .
3. Install the Pumps
Securely mount both pumps inside the tank (for in-tank systems) or in the engine bay (for external systems), following manufacturer instructions . For dual tank kits, install the motorized switching valve to manage fuel source, return, and sender .
4. Connect Fuel Lines and Electrical
Use high-pressure fuel lines and fittings rated for EFI systems . Connect the wiring harness with relays and fuses to power each pump independently . Proper grounding is critical for reliable operation .
5. Test and Verify
Prime the system and check for leaks before driving . Verify both pumps are functioning correctly, and calibrate the fuel pressure regulator if required .
Why Quality Matters: Choose KEMSO for Your Fuel Pump Needs
When upgrading your fuel system, the quality of your fuel pump matters just as much as the kit design. A poorly made pump can fail under high demand, leading to costly engine damage or even a fire. That's why KEMSO is the brand you can trust for reliable, high-performance fuel pumps.
KEMSO offers a wide range of OEM replacement fuel pumps designed for cars, trucks, motorcycles, ATVs, watercraft, and more. Every KEMSO fuel pump is built to meet or exceed original equipment specifications, ensuring a perfect fit and consistent performance. Whether you're restoring a classic Honda Civic, upgrading a Ducati superbike, or keeping your Kawasaki Jet Ski running strong, KEMSO has the right pump for your application.
What sets KEMSO apart is their commitment to quality and customer confidence. All KEMSO fuel pumps come with a lifetime warranty, meaning you can install them once and never worry about replacement costs again. Their pumps are rigorously tested for durability, flow rate, and compatibility with modern fuels, including ethanol blends.
Visit KEMSO Racing today to browse their full selection of fuel pumps and find the perfect match for your vehicle. With KEMSO, you're not just buying a part—you're investing in peace of mind and long-term reliability.
Final Thoughts
A dual fuel pump kit is one of the most impactful upgrades you can make for a high-performance vehicle. It ensures your engine gets the fuel it needs under all conditions, protects against lean misfires and detonation, and provides redundancy in case of pump failure. Whether you're building a 1,000-horsepower Hellcat, a turbocharged Duramax diesel, or a classic muscle car with dual tanks, there's a dual fuel pump kit designed for your application.
Take the time to match the kit to your horsepower goals, fuel type, and vehicle configuration. And don't cut corners on the pumps themselves—invest in high-quality components from trusted brands. For dependable OEM replacement and performance fuel pumps backed by a lifetime warranty, KEMSO is the brand you can count on. Visit https://www.kemsoracing.com/ to find your fuel pump today.