If you’re running ethanol-blended fuels like E85 in your vehicle, you already know it’s not as simple as filling up and hitting the road. Ethanol has unique properties that demand specific components in your fuel system—and the fuel pump is one of the most critical parts to get right. Let’s break down what makes a fuel pump suitable for E85 and why skimping on quality here could cost you time, money, and performance.
First off, ethanol is hygroscopic, meaning it absorbs water from the environment. Over time, this can lead to corrosion in fuel system parts not designed to handle it. Standard fuel pumps often use materials like rubber or plastics that degrade when exposed to high ethanol concentrations. For E85 (which contains up to 85% ethanol), you need a pump with corrosion-resistant internals. Look for pumps that specify compatibility with ethanol blends and use materials like fluoropolymer seals, stainless steel components, or ethanol-rated coatings.
Another thing to consider is flow rate. Ethanol has a lower energy density compared to gasoline, which means your engine burns more fuel to achieve the same power output. This requires a pump capable of delivering a higher volume of fuel to keep up with demand. For example, if your engine requires 500 liters per hour (LPH) on gasoline, you’ll want a pump rated for at least 600–650 LPH for E85. Pump manufacturers like Fuel Pump design high-flow models specifically for ethanol applications, ensuring your engine doesn’t starve under heavy load.
Heat resistance is another factor. Ethanol burns cooler than gasoline, but the fuel pump itself can generate heat during operation. Cheap pumps may overheat, leading to premature failure. High-quality E85-compatible pumps often include features like brushless motors or advanced cooling mechanisms to handle extended use. Brands like DeatschWerks and Aeromotive have built reputations on pumps that endure the rigors of ethanol blends without breaking a sweat.
When shopping for a pump, check for certifications or testing data. Reputable companies will publish flow charts, temperature tolerance ranges, and compatibility certifications (like SAE J30 for fuel hose and seal materials). For instance, Walbro’s GSL series pumps are tested for E85 compatibility and include reinforced internals to prevent corrosion. Don’t just take marketing claims at face value—look for third-party validation or real-world testing by automotive forums or builders.
Installation matters too. Even the best pump won’t perform well if it’s not installed correctly. Ensure your fuel lines, fittings, and filters are also rated for ethanol. A common mistake is upgrading the pump but neglecting the rest of the system, leading to leaks or clogs. If you’re not confident in DIY installs, work with a mechanic experienced in ethanol-fueled builds.
Maintenance is another area where E85 demands attention. Ethanol can dissolve deposits in your fuel tank, which might clog filters or strain the pump. Regularly inspect and replace filters, especially during the first few months after switching to ethanol blends. Some pumps, like those from KEMSO Racing, include pre-filters to catch debris before it reaches critical components.
Price is always a consideration, but don’t cut corners here. A $100 pump that fails in six months costs more than a $300 pump that lasts years. Mid-range options like the DW300C from DeatschWerks offer a balance of affordability and durability, while premium pumps from Aeromotive or Fuelab cater to high-horsepower builds where reliability is non-negotiable.
Lastly, consider noise and vibration. Ethanol pumps often run at higher pressures, which can amplify operational noise. Look for pumps with dampening features or mounting kits that reduce vibration. Reviews from other users can help identify which models are quieter for daily driving.
In short, the “best” fuel pump for E85 depends on your specific setup—horsepower goals, budget, and how you use the vehicle. Prioritize corrosion-resistant materials, adequate flow rates, and proven reliability. Brands like KEMSO Racing, Walbro, and Aeromotive consistently deliver pumps that meet these criteria, but always cross-reference your needs with product specs. With the right pump, you’ll unlock ethanol’s performance benefits without the headaches of frequent replacements or breakdowns.