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Why is 40 gph not enough? The flow information I have seen indicates that 70% of what flows to the injection pump is returned to the tank, this implies that the engine is using the remaining 30%. If I assume that my truck is getting 10 miles to the gallon and traveling at 100 mph then the engine is using 10 gph. If 10 gph represents 30% of total fuel flow then the remaing 70% equates to 23. 33 gph, for a total flow of 33. 33 gph.
Flow rates are usually quoted at free-flow - no back pressure, and are significantly reduced at rated OPERATING pressure. At maximum demand on the VP-44 in *normal* usage, you might see a demand rate of as much as 40-45 gph if engine demand and VP-44 cooling are properly applied - add power enhancements, and that GPH figure increases even higher. It becomes a matter of whether you want to provide "insurance" with a pusher operating WELL within it's operating parameters - or out at the ragged edge...
Because the 70% that is returned is used to cool the injection pump. It is cooled and lubed by the diesel that flows through it.
The other 30% that goes towards the injectors... well some of it gets burned and some of it even goes back to the tank through a return passage way in the cyl head.
It is not safe to consider only fuel used to run the engine. The return line picks up cooling/lube fuel straight from the VP44 and "T"'s into the line coming from the cyl head.
AFAIK it's rated at 15 psi, 100 gph. I can only find 4 different electric carter pumps, 15 psi 100gph, 7 psi 100gph, 7 psi 72gph, and 5 psi 72gph. BTW, I now have ~60,000 miles on the current 7 psi pusher inline with the stock pump (both were new at that point) with no pressure problems - went through 4 stock pumps in the 60,000 miles before that.
I am thinking of running this pump in series with the stock lift pump. Having the stock lift pump in series, ahead of the pusher pump back at the tank will reduce the head pressure the pusher pump sees, right?
If I do a baseline check and then add the pusher, I can verify the fuel pressures at the VP44 at Idle and WOT?
A "pusher pump" goes back at the tank. The point of the pusher pumps is to reduce the load on the stock pump. If your going to move the stock pump back to the tank why not just do that? If you do that you'll probably be fine. The specs on the stock pump (data from carter/federal mogul) call for it to be within 3 feet of the fuel source. Regardless you do not want a pump that's only rated for 40 gph. The pump you are looking at is over twice as expensive as the 7 psi 100 gph Carter. The way you are talking about hooking it up your stock pump would be working harder than it is now because it would be trying to force 100 gph worth of fuel through a 40 gph pump - certainly not an ideal situation. There are many people running alternative pumps out there, so far the two with the most promise reliability wise is running a 7 psi 100 gph carter at the tank feeding the stock pump at the tank and the PE pumps (running by themselves). There are others that are happy with other pumps (holly black is one for example) but AFAIK all of the others that have been tried have had failures and there aren't as many running those as the options listed above. JMHO