ZLI Fuel Pump Upgrade & Conversion

ZLI Fuel Pump Upgrade & Conversion

Brand: Aftermarket Industries
Product Code: ZL1-FS1000
Availability: In Stock
Price: $1,445.00AUD
Ex Tax: $1,445.00AUD

Available Options

Weld-On Flange:

* Wire Harness:

* Hobbs Switch:

* Walbro Fuel Pump:

* Fuel Pressure Regulator: Horsepower Rating:

ZLI Fuel Pump Upgrade & Conversion ZLI Fuel Pump Upgrade & Conversion ZLI Fuel Pump Upgrade & Conversion ZLI Fuel Pump Upgrade & Conversion ZLI Fuel Pump Upgrade & Conversion ZLI Fuel Pump Upgrade & Conversion ZLI Fuel Pump Upgrade & Conversion ZLI Fuel Pump Upgrade & Conversion ZLI Fuel Pump Upgrade & Conversion

The BETTER ZL1 fuel pump upgrade alternative: ZL1-FS1000

  • Supports up to 700hp
  • Applications:
    • Pontiac G8 (all years/models)
    • Holden VE (all years/models)
    • Cadillac CTS-V (2009-2014)
    • Universal applications; aluminium weld-on flange available (see OPTIONS)
    • Custom fuel tanks; requires minimum internal depth of 139mm


  • Bulkhead Design: We've eliminated the need for 90 degree external fuel hose adapter fittings and simply incorporated a 90 degree thread profile for the Supply & Return ports directly into the bulkhead​


  • Active Valve System: The ZL1-FS1000 Active Valve System significantly reduces to time required to re-fill the bucket faster than the ZL1 fuel pump module by 83%!​

  • Venturi Pump: The ZL1-FS1000 surge tank features a billet venturi vacuum pump which out performs the ZL1 PLASTIC venturi pump by more than 200%; up to 2 litres a minute of fuel flow!

Plug & Play?

While the drop-in surge tank isn't "Plug & Play" per se, the installation can be completed in a mater of hours and will depend on whether the fuel system is setup as a return or non-return system.

Do I Need to Upgrade The Fuel Lines, Fuel Pressure Regulator or Fuel Rail ?

a) Fuel Lines: 

  • Non-Return System (Recommended for Supercharged Applications) The factory fuel supply line is sufficient to support the flow & output of compatible fuel pumps (Walbro 255, 460 and 520 fuel pumps); please note, an external fuel pressure regulator MUST be installed and a new fuel pressure regulator return fuel line installed between the regulator and the ZL1-FS1000 surge tank (-6AN recommended)
  • Return System (Recommended for Turbocharged Applications): The factory fuel supply is sufficient to support the flow & output of the compatible fuel pumps HOWEVER the fuel rail MUST be upgraded and a return fuel line installed (-6AN return line recommended).

b) Fuel Rail:

  • Non-Return System: Testing has revealed that the factory fuel lines and fuel rail is more than sufficient to support the fuel volume without excessive pressurisation.
  • Return System: Yes, the factory fuel rail MUST be upgraded.

c) Fuel Pressure Regulator: Yes -The OEM fuel regulator is far too small must be upgraded. See AVAILABLE OPTIONS above- "Fuel Pressure Regulator"

ZL1-FS1000 Surge Tank Additional Features

  • Quiet Operation
    • Specially moulded Viton fuel pump noise dampener inserts significantly reduce fuel pump vibration to ensure you have a peaceful in-cabin experience
  • Single Fuel Pump Port
    • Perfect fuel pressure control (staged fuel pump operation) & fuel pressure stability due to our design protected 2-to-1 internal fuel pump manifold.
  • 100% Ethanol Compatible
    • Zero fuel vapour loss and Zero smell GUARANTEED due to anodising process and materials used
  • Quality & Engineering
    • 90% of the components are precision machined from aerospace grade 6061-T6 billet aluminium & the lightweight fuel bucket is designed using best practice engineering principles and stress tested to ensure safety for all motorsport applications. Due to the complexity and the high degree of engineering involved, the lower section of the surge tank is injection moulded with a proprietary super thick, durable and super strong composite fuel (unleaded, race, ethanol) resistance grade of aerospace plastic used by only the most advanced super car manufacturers.
    • Floater valves designs to trap fuel in the fuel bucket
    • Venturi (pump) tube engineered specifically for the GM models.​​
ZL1-1000 Fuel Surge Tank Power Support Guidelines
Fuel Pump
Power HP*
Power HP*
Base Fuel Pressure*
Peak Fuel Pressure


1x Walbro 460
1x Walbro 520
2x Walbro 460
2x Walbros
(1x 460/1x520)


(Recommended Fuel Injector: Bosch Motorsport 1650cc)

**Maximum Total Peak Fuel Pressure (Base Fuel Pressure + Boost Pressure)

***Maximum Voltage

  •  Includes 1x Camaro ZL1 fuel level sender (requires calibration: import fuel tables) (part # GM 13592329)
    • Venturi Cross-Over Hose: Aftermarket Industries will provide a direct replace FREE of charge
  • Aftermarket tune is necessary to ensure correct AFR's and optimal performance
  • OEM FSCM may trigger errors or read lean at WOT due to higher values than OEM settings - please consult with an experienced tuner or ECU manufacturer

WIRING (Universal - Optional - see 'AVAILABLE OPTIONS' above - Wire Harness):

  • Mil-Spec Aviation-grade high current wire
  • Compact & Easy to install Power Distribution Module

Wiring Guidelines: Required for WARRANTY

Fuel Pump Qty Main Power Wire Fuel Pump Power Wire Relay Wire Size Relay Size Fuel Pump Circuit Breaker
Single Pump 10 AWG Tefzel Mil-Spec 22759/34 10 AWG Tefzel Mil-Spec 22759/34 16 AWG Tefzel Mil-Spec 22759/16 50A

30A Circuit Breaker or Fuse

Twin Pump 4 AWG (70A) Main Wire Tefzel Mil-Spec 22759/16 (60A Type 1 Circuit Breaker) 12 AWG Tefzel Mil-Spec 22759/34 16 AWG Tefzel Mil-Spec 22759/16 50A 30A Circuit Breaker or Fuse

Do I Need To Stage My Fuel Pumps? YES! Fuel pump operation MUST be staged via a Hobbs Pressure Switch, Aftermarket ECU or PDM. See AVAILABLE OPTIONS above - "Hobbs Switch"

  • ​Harness MUST be modified to integrate the Hobbs Switch


Hobbs Pressure Switch

Package includes the following items: Requires Assembly (estimated assembly time 30 minutes; assembly guide supplied)

  • ZL1-FS1000 bulkhead (machined from aircraft grade 6061-T6 billet aluminium)
  • Billet (6061-T6) twin (2) fuel pump bracket (includes stainless steel fasteners and Viton rubber insert/s)
  • Billet (6061-T6) fuel pump manifold
  • Billet (6061-T6) Venturi inlet adapter
  • Billet (6061-T6) Venturi (pump) tube
  • Billet two (2) piece fuel bucket (upper section machined from 6061-T6 grade billet aluminium, lower section injection moulded)
  • Bucket (Composite Plastic Injection Moulded)
  • Viton rubber o-rings included
  • Aftermarket Industries six (6) way male electrical connector with two (2) female connectors and 12 pins
  • Two (2) stainless steel Aftermarket Industries 200 micron fuel filters.
  • Fuel level sender NOT included - OEM sender to be attached to FS1000-V2 surge tank as per illustrations - may require calibration
  • ​Note: Fuel Pressure Regulator, Wire Harness, Hobbs Switch and Fuel Pumps ARE NOT INCLUDED in this package and can be added to your order; see 'AVAILABLE OPTIONS'.


Is all this too overwhelming? Don't worry, you're not alone!


Fuel System Advice (FREE)

*These products must be correctly fitted by "Certified Installer" workshops and partners. Aftermarket Industries is not liable for personal injury, death or for any damaged whatsoever arising from any accident or incident where these conditions are not satisfied.

*It is your responsibility to ensure that the Product is sufficient and suitable for your purposes and meet your individual requirements. We do not warrant that the Products will meet your individual requirements. You acknowledge that the Products are standard and not made bespoke to fit any particular requirements that you may have.

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