Fuelab 496 In-Tank Brushless Fuel Pump w/3/8 SAE Outlet - 500 LPH

500 LPH of brushless fuel delivery in a package that drops straight into your existing hanger

The Fuelab 496 series brings brushless motor technology into the in-tank space at a size that fits most factory and aftermarket fuel pump hangers without modification. The 49613 flows 500 LPH at 3 bar on 13.5 volts, with a maximum operating pressure of 125 PSI, making it a capable foundation for builds targeting up to 1,500 horsepower. Unlike brush-style pumps that wear over time and generate heat through friction, the brushless motor in this pump draws less current, runs cooler, and lasts significantly longer under sustained high-load operation. Every unit leaves the factory individually flow and current draw tested, and comes with a copy of that report in the box.

3/8" SAE Outlet Configuration

The 49613 uses a 3/8" SAE outlet fitting, which matches common aftermarket fuel line and AN adapter configurations for EFI builds. The compact 41.5mm diameter body is sized to drop into standard OEM-style pump baskets and most universal hangers without needing to open up the basket diameter. The pump is designed for in-tank use only and requires an external brushless pump controller to operate. Fuelab's 72004 brushless controller is the recommended companion for single-pump setups, providing variable speed control and soft-start functionality that extends pump life further. A bypass regulator or relief valve is required in any application to prevent over-pressure conditions.

Fuel Compatibility

This pump is fully compatible with gasoline, E85, and methanol. Whether you are building a pump gas street car, an E85 flex-fuel setup, or a dedicated methanol drag application, the internal components handle all three without degradation or compatibility concerns. The included pre-filter protects the pump internals during initial startup and normal operation.

Specifications

What's Included

• 1x Fuelab 496 series in-tank brushless fuel pump, 3/8" SAE outlet (49613)
• Pre-filter strainer
• Wire lead harness
• Individual flow and current draw test report

Frequently Asked Questions

Yes. All 496 series brushless pumps require an external brushless controller to operate. The pump uses a three-phase DC brushless motor that cannot be driven directly from a standard fuel pump relay. Fuelab's 72004 PWM controller is the recommended option for most builds.

Fuelab rates the 496 series at up to 1,500 horsepower on gasoline. E85 and methanol require more fuel volume for the same power level, so supported horsepower on those fuels will be lower. For builds above 1,000 horsepower on E85, a dual-pump setup is worth considering.

Both pumps flow 500 LPH and share the same brushless motor and housing. The 49612 uses a 5/16" SAE outlet while the 49613 uses a 3/8" SAE outlet. Choose based on the fuel line size in your application.

The 41.5mm pump diameter fits most OEM-style pump baskets and aftermarket universal hangers without modification. Verify your basket's inner diameter before ordering if you are fitting the pump into an OEM module rather than a standalone hanger.

Yes. Fuelab specifies that all 496 series pumps must be used with a bypass regulator or relief valve. Running without one can lead to over-pressure conditions that damage the pump and fuel system components. This applies to both carbureted and EFI setups.

Fuelab backs the 496 series with a Limited Lifetime Warranty against defects in materials and workmanship. Individual flow and current draw test documentation is included in the box. Under the Magnuson-Moss Warranty Act, installing an aftermarket fuel pump cannot void your vehicle's factory warranty unless a dealer can directly link the pump to a specific failure.

Yes, the pump is compatible with carbureted setups. A bypass regulator is still required to control outlet pressure to the carburetor's specification, typically in the 6 to 9 PSI range for most carb applications. The external controller will need to be tuned to produce the appropriate flow for the lower pressure requirement.

The sending unit is not included with this pump. You will need to source a compatible sending unit or use your existing factory unit if your hanger accommodates it. Fuelab does not include a sending unit with any standalone 496 series pump.

Installation Overview

• Disconnect the negative battery terminal and relieve fuel system pressure before beginning work.
• Remove the factory fuel pump module or hanger from the tank following the OEM service procedure for your vehicle.
• Remove the factory pump from the basket or hanger and transfer any reusable components such as the sending unit and outlet fitting.
• Seat the pump body into the basket, confirming the 41.5mm diameter clears the basket walls.
• Connect the wire lead harness from the pump to the external brushless controller output leads.
• Wire the brushless controller per the 72004 controller instructions, including the fuse and relay requirements.
• Reinstall the hanger or module into the fuel tank and torque the locking ring to OEM specification.
• Reconnect the fuel feed line and any return or vent lines removed during disassembly.
• Reconnect the negative battery terminal and prime the fuel system before starting the engine.
• Verify there are no fuel leaks at all connections before driving the vehicle.

WARNING: This product can expose you to chemicals including lead and phthalates, which are known to the State of California to cause cancer and reproductive harm. For more information go to www.P65Warnings.ca.gov.