Fuel pump burning in tank

[Evan33]

Hey i have a toyota kluger grande 2003 which was driving perfectly come home yesterday woke up this morning and wouldn't start. Cut a long story short it was a fuel issue after pulling out the orginal internal fuel pump assembly this is what i found. The pump motor connection to the plunger had burt out so bad that it melted the connection as showen in the pictures. And didn't even blow the fuse.

[campbeam]

Do not know too much about the fuel pump assembly except that the fuel in the tank is supposed to help cool the fuel pump. This is the main reason why it is not a good idea to be driving around too much on an empty tank.

Would this have been a contributing factor or is there another explanation for this melted electrical connection?

[trentmeyer23]

Replace the pump and hanger. Odds are, the pump has had a short circuit or drawn a large current due to a blockage.

[Evan33]

Yeah im replacing the pump and filter and plunger seal and wiring for pump toyota said they have seen this happen before but not this bad one of the mechanics said loose connection but this is the original pump never touched. Also as this connection is right at the very top of the tank so unless the tank is on full 100% all the time to the motor over heating i dont think the fuel level would affect the prime power connection to the pump if so it should short the fuse when it overheating.

 

[trentmeyer23]

17 minutes ago, Evan33 said:

Yeah im replacing the pump and filter and plunger seal and wiring for pump toyota said they have seen this happen before but not this bad one of the mechanics said loose connection but this is the original pump never touched. Also as this connection is right at the very top of the tank so unless the tank is on full 100% all the time to the motor over heating i dont think the fuel level would affect the prime power connection to the pump if so it should short the fuse when it overheating.

Nope, I have seen fuse boxes burnt out on many occasions without popped fuses. Fuel pumps are bad for burning out wiring.

The fuel does indeed cool the pump, continuous drawing from the bottom of the tank will reduce the life of the pump.

Most dealership mechanics won't see cars older than 3-5 years old, so take that with a grain of salt. "Old Kev" down at "Bob's Mechanical" would have a better knowledge of these kinds of faults.