What Causes Fuel Pump Rust?

Most of the time, rust in the Fuel Pump is due to the condensation of water inside the fuel tank and may eventually corrode it. Since water is heavier than fuel, it usually sits at the bottom of the tank where the fuel pump resides, especially when the temperatures are cold outside or condensation builds up because of temperature changes. Even less than 1% water content of the fuel volume can initiate the corrosion process, which over time progressively degrades the metallic parts in the pump and reduces its efficiency and life:.

Ethanol-blended fuels, such as E10 and E85, increase the risk of rust since ethanol is more hygroscopic than gasoline. Tests indicate that vehicles using ethanol fuels will have a greater potential for internal rust formation inside the fuel system, especially in areas where there is high humidity or where temperature fluctuations are more frequent. Indeed, tests indicate that ethanol may increase corrosion rates by a factor of up to 50% over pure gasoline.

There have been quite a number of real-world incidents attributed to fuel tank rust. For example, in Texas alone, one batch of contaminated fuel caused wide-ranging rust issues in Fuel Pumps across many different vehicle models in 2017, resulting in high-dollar repairs and overhauls of the fuel system. Repair of the Fuel Pump may require anything between $400 to $800 for models that could either minimize damage or sustain more serious damage.

Also, keeping a full tank of fuel would help to reduce the condensation that may arise, thereby reducing the chances of rust. Additionally, pouring fuel stabilizers which help in preventing moisture accumulation in the tank can also extend the life of the Fuel Pump. Owners of vehicles that normally have to run ethanol-based fuels should go for regular checks of their fuel system for signs of corrosion.

As Henry Ford once said, “Before everything else, getting ready is the secret of success.” The prevention of rust in the Fuel Pump starts by understanding those factors leading toward its creation, as well as taking steps to diminish those risks.

To learn more about protecting your Fuel Pump from rust, visit the Fuel Pump website.

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