Wiring that connects to the fuel pump can burn out as a result of several larger forces which affect such electrical performance. One common reason behind this is the current gets flown more than needed. A fuel pump that goes bad, will draw up to as much as 30% worse current than specified and those wires will overheat. Increased current — as cited by the National Institute for Automotive Service Excellence, which is achieved via increased resistance or just shift of an uncontrollable number — can break down the insulation on a wire and end in burnout.
Variety of weak connections as well contribute significantly. If connections are corroded or loose, this will put resistance on the wires and they may heat up. According to a study by the Electrical Safety Foundation International, almost 25% of electrical fires in vehicles are caused by poor connections. The British unit works as the electrical power flows between two points of high resistance, with these points becoming hot due to said resistance and eventually damaging wire insulation causing a meltdown.
Voltage spikes are another factor. What happens is that sudden changes in voltage, or pwm duty cycle are quite literally forced upon the wiring. According to studies done by the Society of Automotive Engineers, voltage spikes are 1.5 times more than permissible which significantly increases the likelihood of insulation failure and burning wire.
The only problem is that now we also have to deal with environmental conditions in order to keep the wiring durable. Excessive heat, especially in the 100°F (38°C) plus air temps can erode wire insulators. According to automotive expert Mike Johnson, “If you put wiring in an environment which is consistently as hot as the Mojave Desert with virtually no moisture, ends of wires will dry out; solder make take on a crystalline structure and connectors become brittle… Preventing rust is one thing; preventing failure due to heat — it is not always as easy. Heated paths from running equipment can harm-virtually anything by example.” In tight engine compartments, this is especially important due to the potential for heat build up.
Furthermore, wiring integrity can also be compromised by age and wear. The insulation on wiring will get brittle and crack with age leaving the wires open to being wrecked. Wiring over 10 years old is shown to be 40% more prone to insulation failure. Periodic checks will reveal symptoms of wear and burnout being avoided.
Finally, a wiring loss can be due to poor installation. Although it is not difficult, the truth is that due to incorrect installation wires can overheat if they are too close to a heat source or have a wrong size for the application. The National Highway Traffic Safety Administration (NHTSA), for instance, has estimated that as much as 20% of vehicle electrical failures can be traced back to poor wiring.
To sum up, fuel pump wiring can be damaged by going over current draw, loose connections, voltage spikes from various external sources, environmental conditions like heat and cold, age and even from an improper installation. Preventing wiring failures requires a deep understanding of these factors. You can find Fuel Pump for all your fuel pump solutions, or fuelal.