3 dead fuel pumps in a matter of weeks

[02FRTJ]

After replacing two short-lived Delphi fuel pumps from Summit Racing with a third from AutoZone (same model), I am now back to having a dead fuel pump for the third time in less than two months with maybe 3 miles of total driving. All three times the pumps worked when the Jeep was turned off only to not turn back on days later.

4a test light at the pump connector shows good power to that point when the key is turned on. And providing 12v power and ground directly to the fuel pump does nothing.

Either I am a very unlucky person, or something is killing them. But what could it be?

 

[Chris]

After replacing two short-lived Delphi fuel pumps from Summit Racing with a third from AutoZone (same model), I am now back to having a dead fuel pump for the third time in less than two months with maybe 3 miles of total driving. All three times the pumps worked when the Jeep was turned off only to not turn back on days later.

4a test light at the pump connector shows good power to that point when the key is turned on. And providing 12v power and ground directly to the fuel pump does nothing.

Either I am a very unlucky person, or something is killing them. But what could it be?

Given that you've tested for power at the pump connector and still face the same issue, there are a few possibilities to consider that could be causing early failures of the pumps:

Electrical Issues: Since you're getting power to the connector, check for voltage drops or bad grounds in the wiring harness. Poor ground connections can lead to increased resistance, which can cause the pump to overheat and fail prematurely.

Fuel Quality: Contaminated fuel can be harsh on fuel pumps. If there's debris or water in your fuel tank, it can lead to pump failure. Consider replacing the fuel filter and inspecting the tank for any foreign substances.

Fuel Pump Relay/Fuse: A malfunctioning relay or fuse could be causing intermittent power issues, which can lead to pump failure. Make sure these components are in good shape.

Overheating: Ensure that the fuel pump is getting adequate fuel supply, as pumps rely on fuel for cooling. If the tank is low or there's an issue with the fuel lines causing improper flow, it could lead to overheating and failure.

Voltage Regulation Problems: If your vehicle's voltage regulator is malfunctioning, it could be sending higher than normal voltages to the fuel pump, which can shorten its lifespan.

Default Mode: Some electronic problems may leave the pump in a default mode that runs it continuously even if it should be off, leading to burnout.

It might be worth taking a closer look at the complete fuel delivery system, including the wiring, connectors, and any potential performance issues. Also, consulting a professional mechanic could help in diagnosing underlying issues causing the failures. Best of luck!

 

[DuckNut]

Voltage Regulation Problems: If your vehicle's voltage regulator is malfunctioning, it could be sending higher than normal voltages to the fuel pump, which can shorten its lifespan.

Most, not all, but most DC electric motors will work in excess of their stated value. A vast majority of 12v will work with 18 and many will work with 24.

Not very many will live long at 11 and real short life at 10.

But you would be onto something with the regulator issue.

 

[JKP]

The YJ fuel pump assembly I got from MTS had a US Motor Works pump in it. It's been running since 2020.

It seems a lot of Delphi are reported to be failing.

 

[Jeepoftheseus]

I agree with what folks have been saying about looking for an issue with power supply to the pump. Double check the connector to make sure you didn't damage it when removing the pump the first time, maybe hit it with some electronic cleaning spray or replace it altogether. Trace the wires all the back to the battery from the tank and look for issues. Luckily TJs are pretty easy when it comes to tracing electronic issues. Also, I imagine this isn't the issue, but double check you're installing it correctly.

 

[ColoJeep]

Given that you've tested for power at the pump connector and still face the same issue, there are a few possibilities to consider that could be causing early failures of the pumps:

Electrical Issues: Since you're getting power to the connector, check for voltage drops or bad grounds in the wiring harness. Poor ground connections can lead to increased resistance, which can cause the pump to overheat and fail prematurely.

Fuel Quality: Contaminated fuel can be harsh on fuel pumps. If there's debris or water in your fuel tank, it can lead to pump failure. Consider replacing the fuel filter and inspecting the tank for any foreign substances.

Fuel Pump Relay/Fuse: A malfunctioning relay or fuse could be causing intermittent power issues, which can lead to pump failure. Make sure these components are in good shape.

Overheating: Ensure that the fuel pump is getting adequate fuel supply, as pumps rely on fuel for cooling. If the tank is low or there's an issue with the fuel lines causing improper flow, it could lead to overheating and failure.

Voltage Regulation Problems: If your vehicle's voltage regulator is malfunctioning, it could be sending higher than normal voltages to the fuel pump, which can shorten its lifespan.

Default Mode: Some electronic problems may leave the pump in a default mode that runs it continuously even if it should be off, leading to burnout.

It might be worth taking a closer look at the complete fuel delivery system, including the wiring, connectors, and any potential performance issues. Also, consulting a professional mechanic could help in diagnosing underlying issues causing the failures. Best of luck!

Chris , is this an AI answer ? Seems like the 800 lb. Gorilla in the room. Thanks man .

 

[02FRTJ]

Would an issue with power not rear its ugly head while the Jeep is running? None of the three pumps died while running.

 

[macleanflood]

In any of these fuel pump swaps have you tipped over the tank and completely poured out all the gas? Gotten a clean towel and some brake cleaner or something to wipe down the inside of the tank...look in there with a flashlight?

I'd be monitoring fuel pressure and voltage/amperage to the next pump real time.

My Brute Power $85 Rock Auto pump is doing great.

-Mac

 

[02FRTJ]

I have not drained the fuel tank. I inspected the fuel and tank with a flashlight on the first pump replacement and it looked fine. And when I removed that same pump shortly thereafter when it died, the filter bag (or whatever it is called at the base of the pump) was clean.

 

[Moglocker]

You really need to go to the trouble of installing a fuel access panel.it will guarantee success (lol)no if I were you,I would get this pump out and hook it straight to a 12 volt battery test it off the car.i don’t know if you can tear into it and see what’s going on,or like Mac said find away to monitor the voltage to the pump,try to catch it overl or underloading it?one thing is for sure,the second time it went out,I’m all access panel bound.

 

[macleanflood]

You really need to go to the trouble of installing a fuel access panel.it will guarantee success...

I spent more money on a Racetronix 5/16 QD adapter and a fuel pressure gauge for my rail than I did for my cheap ass pump. Another way to guarantee success.

-Mac

 

[Jeepoftheseus]

Chris , is this an AI answer ? Seems like the 800 lb. Gorilla in the room. Thanks man .

Yeah 100% that's chat gpt, there are nonetheless some insights there lol

 

[jonny jeep]

Reading this has reminded me, I did have a no start issue shortly after fitting my delphi unit.

I found the cause was that the pins on the connector of new unit were ever so slightly thinner than the pins of the OEM fuel pump connector.
The solution was to disassemble the loom side connector and squeeze the receiving terminals to close them up a touch. The difference the tighter terminals made could be felt as more resistance when pushing the connector together. No issues since then.

 

[Weasellee]

Given that you've tested for power at the pump connector and still face the same issue, there are a few possibilities to consider that could be causing early failures of the pumps:

Electrical Issues: Since you're getting power to the connector, check for voltage drops or bad grounds in the wiring harness. Poor ground connections can lead to increased resistance, which can cause the pump to overheat and fail prematurely.

Fuel Quality: Contaminated fuel can be harsh on fuel pumps. If there's debris or water in your fuel tank, it can lead to pump failure. Consider replacing the fuel filter and inspecting the tank for any foreign substances.

Fuel Pump Relay/Fuse: A malfunctioning relay or fuse could be causing intermittent power issues, which can lead to pump failure. Make sure these components are in good shape.

Overheating: Ensure that the fuel pump is getting adequate fuel supply, as pumps rely on fuel for cooling. If the tank is low or there's an issue with the fuel lines causing improper flow, it could lead to overheating and failure.

Voltage Regulation Problems: If your vehicle's voltage regulator is malfunctioning, it could be sending higher than normal voltages to the fuel pump, which can shorten its lifespan.

Default Mode: Some electronic problems may leave the pump in a default mode that runs it continuously even if it should be off, leading to burnout.

It might be worth taking a closer look at the complete fuel delivery system, including the wiring, connectors, and any potential performance issues. Also, consulting a professional mechanic could help in diagnosing underlying issues causing the failures. Best of luck!

Is this an AI response?

 

[dwprice]

Did you ever find the cause on this? I have a 2017 dodge caravan doing the same thing. 3 fuel pumps in a 3 month span. Voltage at the fuel pump while running is 13.4 volts.

 

[Gilaguy23]

Did you ever find the cause on this? I have a 2017 dodge caravan doing the same thing. 3 fuel pumps in a 3 month span. Voltage at the fuel pump while running is 13.4 volts.

FYI, the caravan, durango and a few other Chrysler products do have an issue with the F/P not shutting down after its turned off and burning up the pump. There are a few fixes for this. https://verticalvisions.com/en/127-...Sufc5esV_1zRbr4Sx4DXGdxm_fMrWRZ6t_dGQbfrc8WRx This link is where I got the kit to get the neighbors mini van fixed. Unfortunately its not as easy as a new relay because chrysler in their infinite wisdom made the FP relay non removable. The bypass or complete new fuse/relay panel is the only fix IIRC.

 

[dwprice]

Due to the ongoing issues we already did a fuel pump relay bypass. Still having issues. Thanks for the info and quick reply.

 

[macleanflood]

Most new parts are crap these days. Just as simple as that. I'm having to replace parts 3-4 times to find something that works.

On a whim I threw a Brute Power fuel pump assembly in my 97. Almost cheapest one on Rock Auto. I didn't expect much...but it's perfect two years in. And I have not been kind to it. Road trip to Canada, two trips to the Rubicon. Moab. Beat in the gas tank skid several times. YMMV.

-Mac