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So I bought this dual fuel pump system about 15years ago, right before I had to stop working on the car and start caring for family. Now that I can finally finish where I left off, I need to rebuild this system. I thought it was made by A&A, but they say no, Aeromotive says the same thing. Does anyone remember this?
I'm working on building AI models that are experts on repairing and modifying specific chassis, and I asked it, does this seem accurate?
Yep — that looks like the original RSI (Racing Solutions) dual in-tank pump hanger for the C5 (’97–’02/early ’03). A few tells in your photos match that first-gen RSI piece: Billet aluminum hat with four ports up top. RSI’s design used a big outlet, a small venturi feed, and two returns (one from the external regulator and one for the passenger-side saddle tank), exactly what their later write-ups describe. It reuses the GM level sender (your tan resistor card/float), which was a selling point of the RSI hanger. The rectangular venturi block at the bottom with two orange pickup/sock necks — RSI’s newer page explicitly says they “eliminated the old venturi block,” implying the earlier hanger (yours) had that block.
Period listings and forum posts show “RSI dual pump hanger (97-02)” for C5s; your hardware layout lines up with those. If you want to rebuild it, here’s the quick, safe path:
1. Pumps Direct-fit for this vintage is typically Walbro/TI 255 (GSS342). If you try to step up to 450/525 “Hellcat” style pumps, expect bracket/spacing tweaks because of the larger bodies; many owners just keep 255s on gasoline or move to a modern hat instead. (Modern options: Radium, Snow/Fore/NX hats.)
2. In-tank hose & clamps Replace every short section with SAE J30R10 submersible hose (e.g., Gates submersible) and use EFI liner or Oetiker clamps — not bare worm clamps inside the tank.
3. Strainers/socks New TI/Walbro strainers for each pump (match the orange neck style).
4. Hat seals & fittings Swap all O-rings for Viton; inspect/replace the bulkhead pass-through seal. Map the ports as: feed (-8AN), venturi/jet (-4AN), return from regulator (-6AN), return from passenger tank (-6AN) — that’s how RSI describes the later version and matches the four-port layout on yours.
5. Wiring Use a fresh high-current harness with relays and a Hobbs switch to stage the second pump under boost (RSI and Racetronix both sold kits set up this way). Keep runs short and use 10–12 AWG for power/ground.
6. Sender & safety Your sender face shows heat/discoloration; clean the wiper, check resistance sweep, and re-secure any pass-through wiring. Any epoxy or potting that’s gone gummy should be redone. If you’d rather not refurbish an early unit, the cleanest modern drop-ins that support dual pumps (and E85 compatibility) are the Radium 03–13 hanger or the Snow/Fore/NX billet hats; they replace the venturi plumbing with integrated passages and make service easier. Want me to sketch a parts checklist (pumps/hoses/strainers/O-rings) tailored to your fuel (gas vs. E85) and target WHP?
I'm working on building AI models that are experts on repairing and modifying specific chassis, and I asked it, does this seem accurate?
Yep — that looks like the original RSI (Racing Solutions) dual in-tank pump hanger for the C5 (’97–’02/early ’03). A few tells in your photos match that first-gen RSI piece: Billet aluminum hat with four ports up top. RSI’s design used a big outlet, a small venturi feed, and two returns (one from the external regulator and one for the passenger-side saddle tank), exactly what their later write-ups describe. It reuses the GM level sender (your tan resistor card/float), which was a selling point of the RSI hanger. The rectangular venturi block at the bottom with two orange pickup/sock necks — RSI’s newer page explicitly says they “eliminated the old venturi block,” implying the earlier hanger (yours) had that block.
Period listings and forum posts show “RSI dual pump hanger (97-02)” for C5s; your hardware layout lines up with those. If you want to rebuild it, here’s the quick, safe path:
1. Pumps Direct-fit for this vintage is typically Walbro/TI 255 (GSS342). If you try to step up to 450/525 “Hellcat” style pumps, expect bracket/spacing tweaks because of the larger bodies; many owners just keep 255s on gasoline or move to a modern hat instead. (Modern options: Radium, Snow/Fore/NX hats.)
2. In-tank hose & clamps Replace every short section with SAE J30R10 submersible hose (e.g., Gates submersible) and use EFI liner or Oetiker clamps — not bare worm clamps inside the tank.
3. Strainers/socks New TI/Walbro strainers for each pump (match the orange neck style).
4. Hat seals & fittings Swap all O-rings for Viton; inspect/replace the bulkhead pass-through seal. Map the ports as: feed (-8AN), venturi/jet (-4AN), return from regulator (-6AN), return from passenger tank (-6AN) — that’s how RSI describes the later version and matches the four-port layout on yours.
5. Wiring Use a fresh high-current harness with relays and a Hobbs switch to stage the second pump under boost (RSI and Racetronix both sold kits set up this way). Keep runs short and use 10–12 AWG for power/ground.
6. Sender & safety Your sender face shows heat/discoloration; clean the wiper, check resistance sweep, and re-secure any pass-through wiring. Any epoxy or potting that’s gone gummy should be redone. If you’d rather not refurbish an early unit, the cleanest modern drop-ins that support dual pumps (and E85 compatibility) are the Radium 03–13 hanger or the Snow/Fore/NX billet hats; they replace the venturi plumbing with integrated passages and make service easier. Want me to sketch a parts checklist (pumps/hoses/strainers/O-rings) tailored to your fuel (gas vs. E85) and target WHP?
I can confirm this is the RSI. I have their quad pump setup. I might be the only person that ever bought it lol.
Dual Fuel pump identification help needed
