Yes, a fuel pump can fail from overheating due to lack of cooling. Fuel pumps use the fuel they pump to help cool and lubricate their internal parts like the motor and bearings. Without enough fuel in the tank, the pump will not be able to maintain flow and will start to overheat. That is like starting up a fuel tank when it is close to the way and running the gaseous system to the fuel pump, it will work at higher temperatures since it will pull in air as opposed to the liquid fuel. Running a fuel pump low on fuel can overheat it, according to the U.S. Department of Energy, which greatly shortens its life. In fact, research indicates pumps in low-fuel conditions can have a life reduced up to 40%.
Fuel pump(s) are also rated to work properly at temperature ranges. And as they overheat, the internal parts can start to wear out or seize. Overheating causes significant wear and tear within the pump, resulting in complete pump failure if the issue is not resolved. According to a report by the Automotive Maintenance Association, an estimated 15% of fuel pump failures are due to overheating, and running on low fuel is a major cause.
The pump works harder in cars with bad fuel quality or clogged fuel filters, so becomes strained further. According to the National Automotive Service Task Force (NASTF), a dirty fuel filter inhibits fuel flow, and as a result, the pump works under increased pressure and produces more heat. Likewise, if the vehicle’s cooling system such as radiator or coolant system is not working properly, it could contribute to higher than necessary temperatures inside the fuel pump as the whole engine temperature rises up.
Unattended and improper maintenance wholes up to this menace. The internals of fuel pumps may have degraded as they have aged, making them vie vulnerable to heat-related failure. According to a report by the Automotive News Agency, fuel pumps with over 100,000 miles are 30% more likely to fail due to overheating, especially if they do not have regular maintenance.
As automotive expert Michael Turner points out, “Fuel pumps rely on cooling from the fuel itself. (Overheating is a clear indication of stress, and a sustained overheating event will lead to failure.”)
The fuel tank should not be allowed to run low, and regular fuel filter changes should be kept up to prevent overheating and boiling of the Fuel Pump and to extend its lifespan, high-quality fuel should be used. However, these are also very minimal maintenance actions that can help reduce the risk of pump failure due to inadequate cooling.