Fuel Pump Overheating: Fact or Fiction?

*Some*

My TDI isn't. Compression generates heat. You can watch the fuel temp climb the longer you drive it. It climbs higher the lower the fuel level gets in the tank.

Not every car on the road is brand new or the same.
Ya, stupid diesels. ;)

This is why when the HPFP fails on BMWs, we have to replace EVERYTHING the fuel touches. Right from the tank to the injectors.
 
Ya, stupid diesels. ;)

This is why when the HPFP fails on BMWs, we have to replace EVERYTHING the fuel touches. Right from the tank to the injectors.
Same. I think the system could be cleaned properly, but it would be too labor intensive for a shop and would end up costing more.

For a customer performing his/her own repairs, I think it is doable.
 
I suspect pump cavitation occurs more when fuel level is extremely low and depending on driving style and conditions is what causes the failures.
I've used the fuel pump to pump down tanks and anything past an 1/8 of a tank is also pumping air.

That being said I run mine to empty every time. Maybe it's the people who only put a couple twenty bucks in at a time?
 
Electric fuel pumps are lubricated and kept cool in the fuel tanks. Fuel tanks are less likely to heat up unless in rare condition you park on a surface that is already exceeding 160f+ radiated heat. Running a fuel tank for long periods often bellow 1/4 effect the life of fuel pumps and also other fuel supply parts.

I hate dead head systems and often convert to live to run a cooler fuel to the injectors .
 
I put 200k miles on my vehicle with a tank mounted pump, and never knew of this until recently. I'd say probably 50% of those miles were under 1/4 tank, and at least 100 times I was driving with less than 1-2 gallons. A few times I coasted into the gas station on fumes. I never had a fuel pump failure on this (or any other) vehicle.

But since I've learned of this, I do keep at least 1/4 tank in my tanks. And there's generally smart reasoning to do so anyway.
 
Should be able to read it with the appropriate software then.

Just do a quick google search:

p4WMhXL.png


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Anyone want to show us the data with the tank full and also with it almost empty?

I'd almost bet there's little to no difference. The only exception I'm aware of are some
Diesel cars that have a return line (e.g. Pumpedüse), but these use to come along with a
underbottom mounted Diesel fuel kind of radiator/heat sink.
I use to fill up when I have a remaining range between 50 and 100 km left, with the only
exception being on track. Slicks or semislicks along with high-µ pavement makes for high
g forces up to 1.5 g and that's why it's better having at least 25 % in the tank. Never had
any issues with fuel supply or a fuel pump on street. It's the last thing I'd worry about.

.
 
Should be able to read it with the appropriate software then. Anyone want to show us the data with the tank full and also with it almost empty?
Before filling, after sitting for 4 hours after my 35 mile commute, then the lowest the temp fell after filling with 24 gallons. (~5mi), then the ending temp after the remains 30 miles home.

I'll do it again tomorrow from ambient.

Screenshot_20210907-114117.webp

Screenshot_20210907-115009.webp

Screenshot_20210907-121711.webp
 
What is a "dead head" system? How is it converted to a live system?
Simply a non-return system where the fuel goes from pump to injectors and that's where it stops. Most cars use a system where the fuel goes from pump, to injectors, to a fuel pressure regulator which bypasses fuel back to the tank in order to maintain pressure. This requires 2 hoses, one up and one back.
 
The fuel pump relies on surrounding fuel to keep it cool in operation. Run it low, it's above the level of the fuel, starts getting hot, prone to excessive wear or even seizing. It doesn't cost any more to just keep the tank full, or close. Less condensation in the tank that way too!
 
The fuel pump relies on surrounding fuel to keep it cool in operation. Run it low, it's above the level of the fuel, starts getting hot, prone to excessive wear or even seizing. It doesn't cost any more to just keep the tank full, or close. Less condensation in the tank that way too!
If you are getting condensation in the tank, you have bigger issues. It is a sealed system.
 
If you are getting condensation in the tank, you have bigger issues. It is a sealed system.
Not in diesels-many of the issues we had with diesels were caused by running them low & freezing fuel lines or growing fungus in the tank. Fuel gets hot from return fuel or ambient temps, cools overnight-how does the tank not collapse? Most fuel systems have a one-way valve somewhere, to allow air IN.
 
I always thought it was bogus until I had my Mk6 GTI for about three or four years (bought new) , I used to always run the tank right down to nothing about once a week, and the fuel pump died really early, at like 45-50k miles or something. So it's an anecdote but I certainly believe it more now.

Don't tell my fuel pump, at 110k and 8 years of running until the fuel gauge is pegged to the stop it's still fine.
 
Not in diesels-many of the issues we had with diesels were caused by running them low & freezing fuel lines or growing fungus in the tank. Fuel gets hot from return fuel or ambient temps, cools overnight-how does the tank not collapse? Most fuel systems have a one-way valve somewhere, to allow air IN.

Diesel tanks are vented, no valves.
 
Meh, maybe it's a problem with certain pumps and not others. In over a million miles combined I run all of my cars down to near empty every tank and even my 25 year old Accord and my 22 year-old Sienna (with over 450,000 miles at this point) have their original fuel pumps.

I also never use any sort of aftermarket fuel additive nor do I watch when the tanker truck is at the station.
I only run my cars with mechanical pumps low on fuel. When I worked in the auto service industry it seemed like almost every fuel pump failure was either on an almost empty tank or 100% full as they just filled it up. I was told it often happened immediately when the cold fuel hit the overheated pump.
If I do end up below 1/4 with my truck I try to corner more gently as that's when the pump supposedly ends up uncovered and overheating.
 
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