Re: Replace 1994 Escort Fuel Pump at 200,000?

The Ford pumps also have the fuel pass through the pumps to cool them. However, even in this case chronically running the car with only a few gallons in the tank can cause problems. Older cars (Ford, Toyota, GMs, etc.) all had single speed pumps that were sized to provide excess fuel to the engine under all conditions. There is a pressure regulator at the engine with a return line back to the tank. Because you are circulating the excess gas through the system back to the tank, the gas in the tank can get quite warm, reducing its ability to cool the pump, particularly when driving on a hot day at a slow speed in stop and go traffic, or if the vehicle spends a lot of time idling. The more fuel in the tank, the bigger the heat sink, and the less effect the recirculated gas has on the temperature of the gas in the tank. But when you only have a few gallons in the tank, the fuel can get very hot.

In recent years most companies are making the switch to variable speed fuel pumps and returnless systems. These systems control the speed of the fuel pump (and therefore the volume of fuel being delivered) in order to eliminate the problem of "hot fuel." The variable speed pumps also require less power on average.

Ed

Thanks for the info. I learned something new today!

I replaced my still working fuel pump at 250,000 miles (in 2003) along with a few hoses and internal sock filter and sending unit. Around $500 when done.

Good Luck

Harryface