An overloaded Fuel Pump is forced beyond the designed capacity, creating excessive mechanical strain and generation of much heat. Usually, the Fuel Pumps are designed to deliver fuel within a pressure range of 30 to 80 psi depending on the specification of the vehicle. Due to this, when demand for fuel exceeds the capacity of the pump-such as in high-performance vehicles or because of a blocked fuel filter-it has to work harder and can often draw more current than it was designed for. Overheating from an overload can lead to the early wear or complete failure of the internal parts of the pump.
Commonly, the very first symptoms of overload in the Fuel Pump are decreased fuel efficiency and poor performance of the engine. It may hesitate when accelerating or cannot sustain its power due to the fact that the pump cannot provide a sufficient amount of fuel needed by the engine. There is even stalling or misfiring under load or high-speed conditions where more fuel is needed.
Yet another effect that may be related to overload conditions from a Fuel Pump is with an electrical failure. When the pump is overloading with too much current, fuel pump relay failure occurs where there is a complete cut off of power to the pump. The replacement cost for a fuel pump relay costs in a range of $20 to $50. However, the cost for replacing the Fuel Pump alone ranges between $400 to $800 if it gets damaged due to overload conditions.
Besides that, overloading can result in long-term damage due to the increased heat generation inside the Fuel Pump. If excessive heat inside the pump is continuously experienced, seals, bearings, and other internal parts may be degraded, which results in reducing the lifespan of the pump by up to 50%. However, in extreme conditions, the resultant excessive heating might even result in seizing of the pump and complete failure of the fuel system.
In 2016, Ford recalled several models due to overloads in the Fuel Pump that caused the vehicles to stall and shut down unexpectedly. Events of this kind have shown how serious proper fuel system maintenance can be to avoid overloads and their ensuing hazards.
As Henry Ford, one of the founders of the automotive industry, once said, "You can't build a reputation on what you are going to do." Performing regular preventive maintenance, such as replacing clogged fuel filters and making sure the Fuel Pump is sized to supply the engine with what it needs and nothing more, will prevent overloads from happening in the first place and ensure longevity.
To get all the information you need about how to avoid Fuel Pump overload and maintain your car's fuel system, head to Fuel Pump.