A lot of various factors can cause a fuel pump failure, and knowing what those factors are might be in the better interest of avoiding tedious, costly repairs. A fuel pump will usually last from 100,000 to 150,000 miles; however, various circumstances can bring its useful life right down. The most common cause of premature failure of a fuel pump is driving with a low fuel level. The fuel pump uses gasoline during normal use as an agent of cooling. This makes the pump overheat and wear out sooner than it is supposed to. General Motors also suggests having at least a quarter of a tank of fuel in it at all times for the proper cooling of the pump. Running on low fuel regularly can reduce your pump's life up to 20% because of increased heat and wear.
Contaminated fuel is another common factor for its failure. Dirt, rust, or other debris inside the fuel can clog up the fuel filter, and that makes the pump work harder to get the fuel to the engine. Eventually, that extra strain on the pump can cause it to fail. Bosch reports that a dirty fuel filter can reduce fuel pump efficiency by as much as 30%, causing it to overheat-and fail. This can be prevented by changing the fuel filter every 20,000 to 40,000 miles, as this will increase the life of the pump.
Other potential problematic areas that may result in premature failure of the pump would include electrically-related problems such as a failing fuel pump relay or poor wiring. An electrical feed that is inconsistent within the fuel pump could cause it to work spastically, hence promoting increased wear of the pump. Another example of how electrical issues can take years off the life of a pump is that Ford recalled over 50,000 vehicles in 2018 due to faulty fuel pump relays; these situations cause stalled vehicles and premature failure. A lot of these can be prevented by ensuring regular inspections of the electrical components of the pump.
Fuel quality plays a major factor in the health of the fuel pump. Poor or dirty fuel introduces contaminants into the system, fostering wear on internal pump components. Chevron estimates that high-quality fuel, containing cleaning additives, can reduce fuel system wear by as much as 20%, improving performance and prolonging the life of the pump.
Other causes include faulty regulation of fuel pressure. When the regulator fails, it forces the pump to work harder than it should, which in turn can cause early failure. Replacing a faulty fuel pressure regulator, usually ranging from 150-300 dollars, serves as a precautionary measure that ensures the pump does not encounter excess strain due to unstable levels of pressure.
Another common issue is vibration: if the fuel pump-or any of its mounting components-is not correctly secured over time, constant heavy vibrations can shock internal parts enough to cause early failure. AAA reports that a leading cause of premature fuel pump replacement due to vibration failures-in particular with those vehicles that regularly drive on uneven roads or off-road.
Finally, fuel pump overheating is usually dominated by a number of cases in which the distance driven has been long with high speeds. This occurs because the car runs on low fuel or with a clogged fuel filter. Recently, in 2019, BMW recalled thousands of its cars for fuel pumps that tend to overheat and lead to stalling and other failures during high-speed traveling.
Conclusion Fuel pump failure is mostly due to running on low fuel, adulterated fuel, electrical problems, and poor regulation of fuel pressure. This can be properly maintained through replacement of the fuel filter and quality fuel in order to maximize the life cycle of the pump. For more information on fuel pumps and how to maintain them, visit Fuel Pump.