The fuel pump relay might burn out for several reasons, and electrical overload might be at the very top of the list. Most fuel pump relays have a specified quantity of current that they are rated for, such as 15 to 20 amps. When an amperage draw is taking place in the relay higher than what it was originally rated for, overheating will occur, and the energy source inside the relay may fail. This would most likely happen in high-performance vehicles where modifications to the fuel system also involve increasing power consumption. This can increase the risk of burnout when the fuel pump draws more current than the relay is designed for, especially when not designed for high-load conditions.
Another factor contributing to this is poor electrical connections. When these connections are corroded or loose, this adds resistance to the circuit and makes the relay work even harder to keep up power to the fuel pump. The higher the resistance, the higher the heat generated, and if the relay operates under such conditions constantly, it will lead to its premature failure. Maintenance on the electrical connections should be carried out regularly, as this may start to appear first on vehicles with over 100,000 miles.
One of the most critical enemies of fuel pump relays involves heat. The temperatures in an engine bay can easily exceed 200°F, or 93°C. Fuel pump relays positioned in the vicinity of high temperatures are more prone to burnout, especially if they do not have proper shielding or insulation. In hot countries, this effect can be greatly magnified, reducing their overall lifespan to an extreme extent. Many mechanics usually recommend relocating the relays or using a heat-resistant model for applications where high temperatures remain a concern.
The quality of the relay counts for a lot in its durability. Poor quality relays may not hold out to operational demands, especially for high-load conditions of the fuel pump system. Therefore, higher quality relays reduce this kind of risk since the materials and internal structures used for building those components are surely much stronger. Fewer replacements of relays result in generally more reliability with fuel systems over time.
As Henry Ford, one of the pioneers in the automobile world, once said, “Quality means doing it right when no one is looking.” A correct selection of quality Fuel Pump relay will ensure reliable vehicle operation. For high-quality fuel pump relays and more information, visit Fuel Pump.