Running a car with low fuel can indeed burn out a fuel pump, because when operating, this component needs to be submerged in fuel to keep its temperature down. Operating on a low tank makes the Fuel Pump prone to higher temperatures because it loses the natural cooling effect provided by the surrounding fuel. Prolonged overheating of the pump brings extra wear to it and may decrease its usual life service from 100 000 to 150 000 miles for as much as 20-30%, provided that low-level fuel happens quite often.
Another risk of running on low fuel is sediment buildup at the bottom of the tank. Over time, the dirt, rust, and other contaminants that build up and settle at the very bottom of your tank mean, in those conditions, the low level of fuel means the pump is required to draw from fuel that contains a lot of sediment, raising the risk of clogging. A clogged fuel filter-which is supposed to stop contaminants-makes the pump fight harder to push fuel through, further increasing the strain. Regular replacements of every 30,000 miles help prevent these contaminants from ever entering the pump, but avoiding low fuel levels minimizes this risk from the outset.
Another problem that low fuel levels contribute to is called vapor lock, which occurs when the fuel vaporizes inside the lines because of high temperatures, causing some sort of blockage. As a rule, this sort of problem occurs more often in cases when the fuel pump has been exposed to air, which usually happens when fuel is running low. The effect of vapor lock is disruption in fuel flow, which causes various problems: sputtering, hard starts, or even stalling. In extreme cases, vapor lock can even cause total pump failure when the incoming fuel is not sufficient to maintain the pressurization of the system.
Globally renowned automotive expert Carroll Shelby said once, “Performance and reliability are not an accident.” The automotive fuel pump requires routine preventative care. Keeping the fuel tank above 1/4 full ensures that the pump stays constantly cooled and protected from sediment, extends the life, and decreases the cost of repair. A good investment in a Fuel Pump coupled with proper maintenance of sufficient fuel levels are the quintessential ways to keep the pump healthy, ensuring continuity of performance without developing any unnecessary problems with the engine due to running low on fuel. Mindful fuel management secures the fuel pump and maintains long-term vehicle reliability.