PressureWorx 3bar PWM kit for Pontiac G8 CTS-V and ZL1 fuel module conversions.
The PressureWorx fuel module control system has everything needed to provide a stand-alone, OE-type returnless fuel system. When used with the GM CTS-V2 or Gen5 Camaro ZL1 fuel modules, the system can provide a constant pressure or any base pressure with a 1:1 manifold referenced (MAP sensor based) fuel pressure. It will act just like a mechanical fuel pressure regulator would with the ECM tuned in the same manner. The fuel injector does not know if the fuel supplied is pumped by a return or returnless system. If manifold referenced fuel pressure is to be used, the standard PressureWorx G8 option is tuned for the GM LSA 3bar 12592525 sensor. Other sensor tunes are available at no charge. The MAP sensor tune in the PressureWorx controller must match the MAP sensor so that the proper 1:1 pressure rate change can occur.
Suggestion: If your car is already running with a constant pressure tune and all you need is a larger volume fuel system, changing to MAP referenced fuel pressure is usually not needed or worth the extra expense to retune the fuel maps in the ECM.
Base fuel pressures at idle are typically between 42-60psi, but the VaporWorx controller has much greater range if needed. For a constant fuel pressure system, like that for all GM naturally aspirated LS and LT series engines, a 60psi pressure is typically used. For supercharged applications either a constant or MAP referenced fuel pressure can be used depending on how the ECM is tuned. VaporWorx recommends using a MAP referenced fuel pressure on large fuel injected systems to allow injector duty cycles to be increased at idle/cruise, hence allowing greater tuning capability. MAP referenced fuel pressure also reduces the at idle power requirements by 2/3 vs traditional return type fuel systems.
Fuel pressure for the CTS-V2 fuel module should be limited to 65psi maximum. Above this pressure the internal safety valve that limits overpressure will start to open, hence limiting further pressure increase.
When combined with the Gen5 Camaro ZL1 fuel module, a 750hp naturally aspirated / 650hp supercharged fuel pumping system is easily obtained. The CTS-V2 module with stock pumps is 900hp naturally aspirated / 750hp supercharged capable on gasoline. This setup has been used in hundreds of G8’s with good success, easier fitment, and low overall cost.
The PressureWorx Fuel Module Controller system includes these standard features:
- Everything needed electrically to drive the fuel pump module. No relays, external regulators, or return lines needed.
- Unmatched low fuel level capability when matched with an OEM style fuel module.
- Up to 2/3 reduction in power to the fuel module during idle and cruise vs traditional systems.
- Intended only for stock/OEM pumps. Not for use with DW300 or AEM aftermarket pumps. See here for DW300/AEM upgrades: https://www.vaporworx.com/shop/product/pressureworx-dw300c-returnless-pwm-kit/
- OEM G8 fuel level sensor can be re-used on ACDELCO M10235 CTS-V2 module. ZL1 module must use ZL1 fuel level sensor included on ACDELCO MU2101 fuel module.
- 40A minimum continuous power rating in a compact controller package. Total size 4”L x 2.1”W x 1-5/8”H.
- Over-temperature shutdown with automatic reset that will operate indefinitely without damage.
- Short circuit protection that will operate indefinitely without damage.
- OEM Delphi/Aptive connections for terminals, seals, and connector bodies where appropriate.
- All cross-linked polyethylene wiring.
- 20′ wiring harness from the controller to the fuel module.
- UL94 rated components used throughout.
- Integrates into the OE ECM to allow all safety systems to remain functional.
- 10-22v operating capacity. Can be used with voltage boosters. The preferred booster is the JMS FuelMax. Lower than 10v applied to the turn on circuit will cause controller shutdown to protect from an AFR lean condition.
- Can be used in constant or manifold referenced fuel pressure modes. Manifold referenced suggested to further reduce electrical demand and for vehicles with large, 100#/hr+, injectors.
The basic connections and wiring layout is shown below: