It’s pretty common to see fuel pumps fail as a result of overheating because several interconnected issues arise. Overheating destroys the internal components, and once the internal components go bad, failure sets in to the prime function-the pumping of fuel at proper pressure. The fuel pump for your vehicle is usually the more modern kinds working between pressures of 40 psi to 70 psi. In most cases, the temperature exceeds 100°C (212°F), which can result in the breakdown of the insulation in the motor windings, leading to short circuits or open circuits that disrupt its functioning.
For instance, a study done in 2020 by the Society of Automotive Engineers revealed that overheating-related fuel pump failures account for over 20% of mechanical failures in high-mileage engine vehicles. In such instances, the failure of the fuel pump can be because the thermal expansion of materials within the pump results in loss of structural integrity. This is particularly so in the case of a brushless DC fuel pump, which generates a lot of heat to such an extent that it can cause the rotor to bind with the stator-a sure recipe for motor failure. “Excessive heat exposure accelerates wear and tear, reducing the pump’s operational life by up to 40%,” said Lisa Green, an automotive technician with more than 15 years of experience.
The leading cause of overheating usually involves low fuel levels inside the tank. When the fuel level is too low, the pump has to work harder, often running dry, which increases its internal temperature. According to a 2019 report by the National Highway Traffic Safety Administration, fuel pumps operating without sufficient cooling from fuel circulation are prone to a 24% higher risk of overheating and failure. This happens because the fuel pump relies on the fuel passing through it to absorb heat and prevent the motor from becoming too hot. Without sufficient fuel, this critical cooling mechanism is lacking.
Poor electrical connections that increase resistance and build additional heat also cause heat damage to the pump. Bosch automotive engineers indicate that voltage spikes, usually due to poor grounding or a malfunctioning relay, can lead to overheating. Such voltage fluctuations may cause the fuel pump relay to fail, which may cause the pump to overheat and stop working.
It can overheat and stop working completely, which may lead to engine sputtering, stalling, or a complete loss of power in the vehicle. According to AAA, “fuel pump failures are in the top 5 most common causes of breakdowns on highways” and are especially common with older vehicles. The regular servicing of the fuel system through checking the level of fuel in the tank and inspection of the electrical components of the pump is very important in averting these kinds of failures. If the fuel pump continues to overheat, replacing it with a high-quality replacement fuel pump ensures better performance and longevity. For reliable products, consider visiting Fuel Pump for advanced solutions designed to withstand extreme conditions.