Molly Ayala
Bench testing an electric fuel pump is a simple process that can be done in a variety of ways. The most common method involves using two cans of gasoline, pumping from one to the other, and measuring the amount pumped over a short period to confirm the flow rate. This is done outside to avoid vapour risk. Other methods include using a battery to power the pump, measuring the voltage, and listening for a buzzing sound. It is important to note that fuel pumps are rated at litres or gallons per hour, so pumping a gallon or more into a container and timing it can help determine if the pump is functioning correctly. Additionally, it is crucial to prioritise safety when working with gasoline and electricity to avoid potential hazards.
| Characteristics | Values |
|---|---|
| Fluids to use | Water, gasoline, treated kerosene, isopropanol, methyl hydrate (gas line antifreeze) |
| Testing procedure | Pump fluid from one can to another and measure the amount pumped over a short period of time, test flow rate at 0psi, test pressure with a gauge, test volume on the return line |
| Safety precautions | Avoid sparks, perform the test outdoors in a well-ventilated area, keep a bucket of water or a fire extinguisher nearby |
| Common issues | No familiar buzz when turning the key, no pressure in the fuel rail, voltage pulse at the pump on ignition, debris lodged in the pump |
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What You'll Learn
Testing the flow rate
Firstly, it is important to note that fuel pumps are typically rated in litres or gallons per hour, so measuring the flow rate involves pumping a certain volume of fluid (usually a gallon or more) and timing how long it takes. This can be done by pumping the fluid into a container and using a stopwatch or timer to measure the duration.
One simple method is to use two cans of gasoline, pumping from one to the other and measuring the amount pumped over a short period. This method is quick and easy but may not provide the most accurate results as it does not take into account factors such as pressure and viscosity. It is also important to perform this test outdoors to avoid vapour risk.
For a more accurate test, it is recommended to use a treated kerosene that closely resembles the density and viscosity of gasoline. This can provide a more realistic simulation of how the pump will perform with gasoline. However, this method may be more complex and require additional equipment.
Another factor to consider is the pressure at which the pump is rated to operate. For example, a pump may be rated to deliver a certain flow rate at 3.3 psi. To test this, you can set up an outlet held at a specific height above the pump, as per the manufacturer's specifications. This will help determine if the pump can deliver the expected flow rate at the required pressure.
Additionally, it is important to ensure that the pump is securely clamped down during testing, as these pumps tend to move around a lot while running. It is also crucial to minimise sparks and perform the test in a well-ventilated area to reduce the risk of igniting gasoline fumes.
Finally, it is worth noting that while these tests can provide valuable insights into the performance of the electric fuel pump, they may not capture all potential issues. More comprehensive testing setups may be required to identify internal issues or problems that only occur under specific conditions, such as high RPM in a vehicle.
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Using water as a testing fluid
If you do decide to use water, you must be extremely careful to remove all residual moisture from the pump before reinstalling it. This is because water can damage the pump, and it is essential to ensure that the pump is completely dry before using it with gasoline. One way to remove moisture is to use methyl hydrate (gas line antifreeze).
It is worth noting that some people have used water to test their electric fuel pumps and have not reported any problems. However, it is generally advised to avoid using water as a testing fluid for electric fuel pumps due to the potential risks involved.
Instead of water, you could use a treated kerosene that is close to gasoline in density and viscosity. This will give you a more accurate test and help you identify any potential issues with the pump. Another option is to use an old can of gasoline and pump it from one container to another, measuring the amount pumped over a short period to confirm the flow rate. This method should be done outside to avoid vapour risk.
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Using gasoline as a testing fluid
Before beginning the test, ensure that you have clamped the pump securely to your bench to prevent it from moving around during operation. Additionally, minimise any potential sources of sparks when connecting the power source. Installing a simple 12V on/off switch can help secure all wires and reduce the risk of sparks. Keep a fire extinguisher nearby as a safety precaution.
For the test setup, you will need a container that can hold gasoline. A milk jug or a pretzel jar with a large open top can be used for this purpose. Fill the container halfway with gasoline. Ensure that your gas source can gravity-feed the pump, as electric fuel pumps are typically "push" pumps rather than "pull" pumps. Secure the output hose to prevent any accidental spills or leaks during the test.
Connect the electric fuel pump to a suitable power supply, such as a battery charger or a battery. You can then proceed to measure the flow rate by timing how long it takes to fill a measured bucket or container. Alternatively, you can connect a hose to the Schrader valve and measure the time and output to determine the system volume under pressure.
It is important to note that using gasoline for testing electric fuel pumps may not be the safest option. Some alternatives suggested by professionals include treated kerosene, which has similar properties to gasoline but is less flammable, and Stoddard solvent, which has reduced flammability compared to gasoline. Always prioritise safety when working with flammable substances and electrical equipment.
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Testing for debris
To test for debris, start by removing the fuel filter from the vehicle. Drain any excess fuel from the filter using a short piece of rubber hose attached to the filter inlet. This step is crucial for safety, as gasoline is highly flammable and working with minimal fuel reduces the risk of accidents.
Once the filter is drained, you can begin inspecting for debris. Use your breath to blow through the filter inlet, paying attention to any resistance. A properly functioning filter should offer minimal resistance. If you encounter significant resistance, it could be due to debris clogging the filter.
After assessing the resistance, inspect the screen of the filter for any debris buildup. This can include sediment, dirt, or other particles that may have found their way into the fuel system. If the screen appears dirty or clogged, it's likely that the filter needs to be replaced.
To confirm the presence of debris, you can also try blowing through the outlet side of the filter into a white rag or towel. This will help you visualize any dislodged debris that may have been trapped in the filter.
In addition to inspecting the fuel filter, it's important to note that debris can also become lodged directly in the fuel pump itself. If the filter appears clean and undamaged, consider performing further inspections or tests on the fuel pump to identify any debris that may be impacting its performance.
Remember to exercise extreme caution when working with gasoline and electrical systems. Always work in a well-ventilated area and have a fire extinguisher nearby in case of emergencies.
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Testing with a battery
To test an electric fuel pump with a battery, you will need a suitable power supply, either a battery charger and battery or a bench-type (lab) supply with adequate current. You will also need a suitable container and a way to secure the pump.
Firstly, find a graph or table of pump flow vs pressure. Then, mount the pump and submerge it in a suitable container, such as a milk jug or a pretzel jar, ensuring that the pump is securely clamped down to your bench before connecting the power source. If using gasoline, remember that these pumps are ''push'' pumps, not ''pull'' pumps, so you will need your gas source to be able to gravity-feed the pump. Also, make sure the output hose is safely secured as these are high-pressure, high-volume pumps.
Next, connect the battery to the pump using test leads, grounding it first. You can also install a simple 12V on/off switch and secure all the wires to minimise sparks. Once the pump is powered, you can measure the flow rate by timing how long it takes to fill up a measured bucket or by pumping between two cans of gas and measuring the amount pumped over a short period of time.
It is important to exercise caution when testing an electric fuel pump with a battery. Gas fumes are at least as flammable as the liquid, so ensure that you work in a well-ventilated area and have a fire extinguisher nearby. Additionally, do not run the pump for an extended period, as they are cooled by the gas in the tank and can overheat if run for too long.
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