BRIEF INFORMATION about fuel pumps

➔ The fuel pump is an integral part of the fuel delivery system of a vehicle

➔ Supplies the fuel from the fuel tank to the engine

➔ It is located inside the fuel tank or under the chassis, depending on the application

➔ Performance: operates at higher speeds and draws less current than older style pumps

➔ Advantage: each fuel feed unit comes together with the gasket

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Full assembly

Fuel Feed Unit

When it comes to fuel pumps and feed modules, customers expect goods of the highest quality. With HELLA, workshops can rest assured that they will meet even the most discerning demands of their customers.

Swirl pot, fuel pump

In order to always ensure an optimum fuel supply, even on bends or on uneven roads, HELLA’s fuel tanks are equipped with a swirl pot. Thanks to its opening at the bottom, this cup-shaped tank ensures an uninterrupted flow of fuel.

Sub-components

Fuel pump

An engine is only as reliable as the fuel pump that supplies it with gas. The HELLA fuel pump is part of the fuel supply unit which operates in the tank. It ensures an absolutely reliable fuel supply at all times – and this is the case in a great number of widely differing vehicle makes and models.

Sender Unit, Fuel tank

The three most important parts of the fuel supply unit are the fuel pump itself, the fuel filter and the flange with its appropriate connections. The supply unit often has a lever sensor or it operates in conjunction with an immersion tube sensor. The unit can be fitted with a swirl pot.

TECHNICAL DETAILS

Technical Data
Operating voltage	12 V
Current	Between 5 A and 9 A
Delivery quantities (flow rate)	Between 60 and 250 l/h
Fuel-system pressure	Between 3 and 5 bar (300 to 500 kPa)

What are the most common causes of fuel pump failures?

One of the top causes of fuel pump failure is contamination. This can be caused by dirt and debris entering the system from re-fuelling or the use of poor quality fuel. Fuel pump overheating and wear can also cause failure.

Driving frequently on a low fuel tank can accelerate wear on the fuel pump due to debris in the bottom of the fuel tank being disturbed and entering the pump. It is interesting to note that over half of all fuel pump replacements are the result of misdiagnosis.

The complexity of modern vehicles leads to several systems that can disable the vehicle’s fuel pump. Systems that one would not normally associate with the fuel system now have the ability to render the fuel pump inactive (e.g. security, drive train, oil/fuel pressure switches, etc.), which can result in a misdiagnosis.

Vehicle symptoms that indicate the fuel pump may need to be replaced

➔ Difficult or non-starting

➔ Extended cranking

➔ Immediate or intermittent stalling

➔ Rough idle

➔ Poor acceleration

➔ Severe engine lag

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1 Some HELLA fuel pumps come with strainers and some do not. What determines whether a fuel pump is supplied with a strainer?

Usually, the design of the fuel pump units includes the fitting of a strainer. The fuel pump itself, can serve both as a subcomponent for the fuel pump unit, all though in most cases, it comes as a standalone element with various strainers and accessories suitable for multiple applications

2 What are the key design and performance features of HELLA fuel pumps?

HELLA fuel pumps are designed for high efficiency and reliability. They provide an optimal flow rate, stable fuel pressure, and low current consumption, ensuring smooth and consistent operation. HELLA fuel pumps meet rigorous performance standards, making them a dependable choice for the most demanding applications.

3 For those fuel pumps with strainers, will it be possible to use the same strainer in one country and a different one in another?

Yes, a fuel pump can be mounted on multiple applications / fuel feed units. Therefore, there are cases where one type of strainer is required for one country / market and a completely different strainer is required for another country / market.

4 What will be the main causes of fuel pump failure?

Contamination, dirt and debris caused by the use of poor quality fuel, as well as frequent driving with a low fuel tank.

5 Is a lower grade of fuel used in certain countries a concern when using a HELLA fuel pump? If so, what is the minimum fuel grade?

A lower fuel grad certainly has a direct negative effect on any fuel pump, including HELLA‘s. Experts recommend using the standard fuel grade as a reference:

➔ Minimum value for petrol is 95 MON (Motor Octane Number)

➔ Minimum value for diesel is 46 – 60 CN (Cetane Number

6 Is there a recommended service life for fuel pumps?

The life of a pump depends on many external factors. If they are observed in time, the pump itself can work up to 150,000 km or more. It is recommended:

➔ Not to drive frequently with a low fuel tank.

➔ Replace the fuel filter regularly. In general, the external ones are replaced every 20,000 km. The internal one is replaced every 90,000 – 100,000 km.

➔ When replacing the fuel pump, it is best to replace both gaskets and the filter at the same time.

➔ Clean the fuel tank before replacing the fuel pump.

BRIEF INFORMATION
Fuel Feed Units and component parts