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Old 12-20-2019, 12:07 AM   #1
Dixie ZL1
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DIY DW400 Lowside Upgrade

My ZL1 ran out of lowside volume at around E40, so I decided to investigate retrofit of a DW400 into the stock fuel pump assembly. I purchased a new OEM fuel pump assembly, DW 9-403 pump and 9-1047 installation kit that worked out perfectly.

I went with the DW400 because it flows better than a Walbro 450 at 70 psi on E85, is a close physical fit, draws relatively low current for its flow, has an integrated check valve to retain fuel pressure, and includes a Venturi port for fuel transfer.

The stock pump body is 43mm and the DW is 46, so mild dremel work is required to make the pump fit in the stock assembly. Additionally the stock check valve / filter input feature is removed, but creates a nice feature hold the pump in place. I modified the bottom filter assembly to turn it into a retainer with clearance for the DW filter.

The only question at his point is if the FPCM will throw a code for the additional current draw. This pump will draw 17 - 20A at 13.5V
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Old 12-20-2019, 06:07 AM   #2
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Great idea, looking forward to seeing how it works out!
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Old 12-20-2019, 07:46 AM   #3
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Old 12-20-2019, 07:52 AM   #4
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This is great!
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Old 12-21-2019, 12:14 PM   #5
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Sooo I'm doing a little research and it looks like the ZL1 factory low side flows around 475 lph @ 0 psi. Do you think you will gain much fuel with thsy pump?
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Old 12-21-2019, 12:49 PM   #6
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Quote:
Originally Posted by danhr View Post
Sooo I'm doing a little research and it looks like the ZL1 factory low side flows around 475 lph @ 0 psi. Do you think you will gain much fuel with thsy pump?
I think the more interesting question is: What does the ZL1 low side pump do at say 70 psi?
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2017 Chevy Camaro 2SS A8 Kong ported Whipple 8.00/3.00, Mast Black Label heads, Fore triple in-tank pumps, 229/245 cam, Rotofab Big Gulp, 112mm TB, forged pistons & rods, LPE +52% injectors, LPE BB HPFP, AWE CB, GForce DS & axles, 2Ē coated headers, MM Wild CC, everything BMR makes, OEM 1LE wheels (street), Forgestar D5 bead locks (track). 927 WHP/917 WTQ, 9.65@146
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Old 12-21-2019, 01:40 PM   #7
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Quote:
Originally Posted by danhr View Post
Sooo I'm doing a little research and it looks like the ZL1 factory low side flows around 475 lph @ 0 psi. Do you think you will gain much fuel with thsy pump?
Unfortunately flow at 0psi isnít relevant.... itís flow at 50 - 70 psi thatís important.

The stock pump is likely closer to the Walbro 255 in terms of the volume curve with pressure.
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Old 12-21-2019, 01:46 PM   #8
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You can get a good sense for what the DW400 might flow at 0 psi if you extrapolate the this flow curve down to 0, but whatís really important is the flow characteristic over pressure.
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Old 12-21-2019, 11:34 PM   #9
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Quote:
Originally Posted by Joshinator99 View Post
I think the more interesting question is: What does the ZL1 low side pump do at say 70 psi?
Quote:
Originally Posted by Dixie ZL1 View Post
Unfortunately flow at 0psi isnít relevant.... itís flow at 50 - 70 psi thatís important.

The stock pump is likely closer to the Walbro 255 in terms of the volume curve with pressure.
I think that might be the million dollar question..... I was only able to find data on the lt4 pump at 0 psi.....
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Old 12-22-2019, 12:21 AM   #10
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Actually nvm.... doing a little more research, I found a flow rating of 300 lph @ 30 psi for the lt4 pump
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Old 12-22-2019, 12:49 AM   #11
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Quote:
Originally Posted by danhr View Post
Actually nvm.... doing a little more research, I found a flow rating of 300 lph @ 30 psi for the lt4 pump
Thatís really good data - thank you. So assuming a flow over pressure curve similar to the DW400 (which might be optimistic for the stock pump considering a 7mm smaller inlet and 3mm outlet on the DW400) the DW flows ~32% more than the stock pump, which is exactly what you need for E85.

You found more data on the stock pump than I did and I appreciate that. Thank you.
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Old 12-22-2019, 09:31 AM   #12
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Does the higher pressure ratings really matter though? I mean the low side is just supplying fuel to the high side, so as long as there is pressure behind it, it shouldnt change anything. It wont effect spray patterns or anything of that sort, like in a PI motor, if it starts running low at like 40 psi.

Post updates as it comes along.... I think you're onto something... a nice in tank pump would be a good fuel option for those who want to stay below 1000 rwhp or so
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Old 12-22-2019, 11:31 AM   #13
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Quote:
Originally Posted by danhr View Post
Does the higher pressure ratings really matter though? I mean the low side is just supplying fuel to the high side, so as long as there is pressure behind it, it shouldnt change anything. It wont effect spray patterns or anything of that sort, like in a PI motor, if it starts running low at like 40 psi.

Post updates as it comes along.... I think you're onto something... a nice in tank pump would be a good fuel option for those who want to stay below 1000 rwhp or so
In my setup the lowside starts to run out of gas around E37 resulting in a scary fast loss of high side pressure. I lost approximately 1200psi on the high side when the low side was down to around 40 psi.

As a side note - the car is street tuned and this shows up in WOT 3rd gear (M6) but it didnít show the same issue on the dyno.
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Old 12-28-2019, 04:12 PM   #14
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Awesome work, you wonder why no one came up with this idea before and there is not a plug and play kit available. Please keep us posted if the pump helps the issue. cheers!

Last edited by cirpower; 12-28-2019 at 07:48 PM.
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