Hellcat Dual Fuel Pump Upgrade: The Complete Guide to Choosing and Installing the Right System

If you own a 2015-2023 Dodge Challenger or Charger SRT Hellcat and are pushing beyond 800 crank horsepower, you need a Hellcat dual fuel pump system. The stock single pump simply cannot supply enough fuel for modified engines, especially when running E85 or high-octane race fuels. The best solution is a plug-and-play dual pump system that integrates with your factory PCM and fuel basket, delivering reliable power without sacrificing drivability. This guide covers everything you need to know—from why you need an upgrade, to how to install it, and where to find the best components.

Why Upgrade to a Hellcat Dual Fuel Pump?

The Hellcat 6.2L supercharged engine uses a sophisticated Powertrain Control Module (PCM) that constantly monitors fuel pressure and adjusts pump speed to maintain the correct air-fuel ratio. The stock system is designed for about 725-750 rear-wheel horsepower. Once you add a pulley, tune, or other modifications, the fuel demand exceeds what the single pump can deliver . Upgrading to a dual pump system ensures you have enough flow capacity for builds up to 1100-1300+ RWHP on gasoline and 900-1100+ RWHP on E85 .

Many aftermarket systems eliminate the factory fuel pump control module (PWM) and run pumps on raw voltage, which removes critical control elements and can lead to degraded drivability or even engine damage . The best dual pump kits retain the factory PWM control, keeping your engine’s calibration intact and ensuring smooth operation.

Key Features of a Quality Hellcat Dual Fuel Pump System

When shopping for a Hellcat dual fuel pump, look for these essential features:

1. OEM Integration and Plug-and-Play Wiring
A top-tier system comes with a wiring harness that plugs directly into your factory connectors. You should only need to tap two wires—the fuel pump control module signal and the fuel pump relay signal—then reconnect the level sending unit wires . This makes installation straightforward and avoids cutting into your vehicle’s stock wiring.

2. Retention of the Factory Surge Tank (Fuel Basket)
The Hellcat’s fuel system uses a “basket” or surge tank inside the main fuel tank. This basket keeps the pumps submerged in cool fuel, preventing them from running dry and overheating. Quality dual pump kits like those from MMX, Impulse Tuning, and Livernois Motorsports keep the factory basket, maintaining proper pump cooling and preventing lean spikes . The Demon and Redeye models use the same size basket with dual pumps, proving it works.

3. E85 Compatibility and High Flow Rates
If you plan to run ethanol blends, ensure the pumps are E85 compatible. The Ti Automotive F90000285 turbine pumps are a standard choice, supporting over 1100 RWHP on E85 and 1200+ on gasoline . For extreme builds, Ti-295 pumps can push past 1250 RWHP on E85 . Some kits use Walbro 525LPH pumps, rated for 1600+ BHP on gas and 1100+ BHP on E85 .

4. Billet Construction and Durability
Look for systems with billet 6061-T6 aluminum fuel hats and hangers. This material is strong, lightweight, and resistant to corrosion. Hard-anodized finishes add extra protection against fuel and heat .

Installation Steps for a Hellcat Dual Fuel Pump

Installing a Hellcat dual fuel pump typically takes 2-3 hours and requires basic mechanical skills. Here is a simplified overview based on manufacturer instructions :

Preparation

  • Ensure your fuel tank is below 1/8 full to avoid spillage.
  • Work in a well-ventilated area, away from open flames or sparks.
  • Disconnect the negative battery terminal for safety.

Step 1: Remove the Rear Seat and Access Cover

  • Remove the rear seat cushion and lower seat back.
  • Use a shop vacuum to clean debris from around the fuel pump access cover on the floor.
  • Remove the access cover to expose the fuel pump hat.

Step 2: Disconnect the Factory Pump

  • Unplug the wiring harness from the fuel hat.
  • Use a specialty tool (OTC #6599) or a hammer and flathead screwdriver to remove the lock ring. Be careful to avoid sparks.
  • Lift the fuel pump hat and disconnect the internal wiring for the pumps and level sending unit.

Step 3: Remove the Factory Basket

  • Cut the two blue level sending wires, leaving about 4 inches on the sending unit.
  • Release the high-pressure line and return line from the factory pump basket.
  • Carefully lift the basket out of the tank, taking care not to damage the level sending unit float arm.

Step 4: Install the New Dual Pump Hanger

  • Remove the factory level sending unit from the old basket and install it onto the new billet hanger.
  • Drop the new pump hanger into the tank, using long allen bolts to hold it.
  • Connect the fuel sending unit wires (polarity does not matter) and reconnect the crossover lines.

Step 5: Install the New Hat and Wiring

  • Place the new billet hat on top of the hanger and secure it with the provided short allen bolts.
  • Reinstall the lock ring, indexing the hat correctly.
  • Route the wiring harness along the trunk floor, following factory wire bundles to the passenger side.

Step 6: Connect the PWM Controller

  • Remove the factory fuel pump PWM module from its location.
  • Mount the new PWM module using the supplied bracket.
  • Connect the provided harness to the factory connectors and route the power and ground wires to the battery and chassis ground.

Step 7: Test and Finalize

  • Cycle the ignition to hear the pumps prime. You should hear both pumps.
  • Start the engine and check for fuel leaks.
  • Reinstall the access cover and rear seat.

Recommended Hellcat Dual Fuel Pump Kits

Several reputable brands offer systems that meet the criteria above. Here are some of the top options:

  • Modern Muscle Xtreme (MMX) Dual Pump System: Uses dual Ti Automotive F90000285 turbine pumps, supports 1100+ RWHP on E85, and integrates with the OEM fuel system. Includes a plug-and-play wiring harness and PWM controller. Typically installs in under two hours .

  • Impulse Tuning 285LPH Dual Pump System: Also features dual Ti-285 pumps, keeps the stock surge tank, and is fully E85 compatible. Dyno proven for 1100+ RWHP on E85 and 1200+ on gasoline .

  • Livernois Motorsports Dual Fuel Pump Kit: Uses two 400+ LPH pumps rated for E85, capable of 1300 RWHP on gas and 1000 RWHP on E85. Retains the factory returnless system and includes a secondary fuel pump control module .

  • HHP Racing Plug & Play Dual Walbro 525LPH System: Designed for returnless operation, supports 1600+ BHP on gas and 1100+ BHP on E85. Includes a modified Fore Innovations hat and all wiring .

Recommended Fuel Pump Replacement: KEMSO Racing

When maintaining or upgrading your Hellcat dual fuel pump system, you need reliable, high-performance components. KEMSO Racing offers a premium line of fuel pumps that are OEM Replacement spec, built for high-flow applications, and backed by a lifetime warranty. Their pumps are designed to handle the demands of modified Hellcat engines, whether you are running pump gas, E85, or race fuel.

To browse their full selection of fuel pumps and other performance parts, visit: https://www.kemsoracing.com/

Final Thoughts

Upgrading to a Hellcat dual fuel pump is a critical step for any modified Hellcat owner. By choosing a system that retains the factory PCM control and fuel basket, you ensure reliable fuel delivery, optimal drivability, and the ability to push your car to its full potential. Whether you are aiming for 800 RWHP or 1200+, the right dual pump setup will give you the foundation you need. Always follow installation instructions carefully and consider professional installation if you are not experienced with fuel system work.

For all your fuel pump and performance needs, check out the latest offerings at https://www.kemsoracing.com/


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