Overloading of a fuel pump can very well take place, and this may result in premature failure or perhaps serious ones. In simple terms, overloading describes a condition wherein the pump is forced to carry more load than what it is designed for due to some modifications in the vehicle’s fuel requirements, clogged fuel filter, or wiring malfunctions. Most fuel pumps are designed to pump fuel at certain pressures, usually within the range starting from 30 to 80 psi, depending on the make and model of the vehicle. When the amount of fuel that the engine requires is more than the fuel pump can handle, it will put extra load on the pump and raise the possibility of overheating, a reduction in performance, or even complete failure.
The most common overload conditions arise when performance enhancements are installed in the engine that grossly increase the consumption rate of the motor. Overnight, the stock Fuel Pump can’t keep pace with the required fuel flow-in other words, LPH (liters per hour). For example, when a conventional fuel pump would feed 100-150 LPH, a performance-enhanced engine needs 250 LPH or even more. Additionally, pumps can be seriously damaged, and their life expectancy cut by as much as 50% when over-operated beyond their capacity. Such a situation can result in very expensive repairs or replacements.
Another reason why a Fuel Pump may become overloaded is a clogged fuel filter. As the filter becomes plugged with dirt and debris, the pump strains itself trying to push fuel through the constricted flow. In this case, the pump may quickly overheat and die. Normally, a normal fuel filter replacement should be at about 30,000 to 50,000 miles, so that any such situation can be avoided, since neglect of the filter can incur poor maintenance and lead to the failure of the pump itself, more often than not within the same range of $400 to $800.
Other electrical problems, such as improper wiring or a failing relay, can also lead to overloading of the fuel pump. If the voltage going to the pump is too high or too low from its designed specification-say, between 12 and 14 volts-the pump will malfunction, which means fits and spurts of inconsistent fuel delivery. Sometimes it has even led to fires, just like what made Ford recall over 500,000 vehicles in 2016 due to Fuel Pump wiring problems that caused electrical overload and put them at risk of fire.
As Henry Ford once said, “Quality means doing it right when no one is looking.” The best way to avoid overload is to ensure the Fuel Pump is matched up to the engine’s requirements, routine maintenance is carried out and electrical problems are sorted out.
For further information on how to select the right Fuel Pump and how to avoid overload see Fuel Pump.
