Fuel pumps typically last between 100,000 and 150,000 miles, but this number can vary widely based on maintenance, driving habits, and fuel quality. Changing the fuel filter every 20,000-30,000 miles ensures clogs don’t make the pump work harder; this can shorten the life of a pump by as much as 20%. Fuel pumps are asked to run at a certain fuel pressure (usually between 40–60 PSI for most cars, and sometimes over 100 PSI for high-performance models). Usually, when the pump operates consistently at the upper end of its life cycle, it is efficiently delivering this seal without a strain.
Keeping the gas tank low means the pump works harder to get gasoline to the engine since gas acts as a coolant for many in-tank pumps. Anything below a quarter tank runs the risk of exposing the pump to air, raising internal temperatures 20-30 degrees Fahrenheit and increasing wear by as much as 30%96. Having a full tank is one of those car features that mechanics swear by that reduces the risk of overheating, which is one of the leading causes of premature fuel pump failure.
An unfortunate downside of the great advantages of E85 or other ethanol-composed fuels is that the substance is naturally corrosive, leading to a shorter service life for fuel pumps on high-demand vehicles, since the material in the pumps can degrade more rapidly. According to research, even a low percentage of ethanol-blended fuels may shorten the lifespan of a fuel pump by nearly 25% if they are commonly used within a system not designed to handle the risks of ethanol.
If properly maintained, a good Fuel Pump should be able to perform reliably within the range of miles you can expect it to last. By adhering to recommended maintenance schedules and avoiding high-strain conditions, drivers can achieve a longer lifespan of their fuel pump, allowing it to provide adequate fuel delivery with minimal risk of sudden failure.