I've got a 94 Dodge Grand Caravan 3.3L, front wheel drive.
I was going down the highway when the fuel pump fuse blew.
I immediatetly put in another fuse and it blew after turning
the ignition on, but before cranking the engine.
I towed it to the local Tuffy's and they swapped out the fuel pump
(I had them install an Airtex fuel pump ($160) instead of the
regular AC Delco fuel pump ($350) they normally install.) They
also replaced the 6ft(?) wiring harness that connects to the
pump assembly, and they swapped out the fuel pump relay. (They
normally replace the fp,relay, and harness, even if only one of
these is bad.)
It ran okay for about 6 hours then blew the fuel pump fuse again.
After about an hour, I installed another fuse and it ran fine.
I took it back to the shop to diagnose why the fuse blew though.
It ran fine for them for a while and then blew the fuse. They
mentioned that the new wiring harness also melted during testing.
So they again replaced the wiring harness and fuel pump with another
Airtex fuel pump.
It ran okay for about 4 hours out of the shop and then the fuel
pump fuse blew again.
One thing I have noticed and the mechanic noticed as well, if you
start the engine while it's cold, there isn't any problems. If you
turn the engine off and then restart it while it's still warm, the
fuel pump fuse will either burn out immediately upon turning on the
ignition, or it will usually be fine until you try to crank the
The mechanic also disassembled the fuse block under the hood but
didn't see any problems.
The guy I spoke with at O'Reilly Auto Parts was the one that suggested
the Airtex fp. He mentioned he had 5 years experience with Carter fp's
and 5 years experience with Airtex fp's and said he has had about half
as many returns with the Airtex units.
I've found a post by someone else that seems to be having the same
problem, with the same year model:
Any ideas would be appreciated.