The answer is yes, fuel pumps can leak fuel, especially if they contain worn seals, corrosion at the fittings, or any sort of crack in the pump housing. Such leaks not only compromise the fuel efficiency of vehicles but also become a safety hazard as leaking fuel raises the fire risk. All fuel pumps are inherently pressurized (about 40-70 PSI in a fuel-injected system), so any leaks due to weak seals or weak connections can lose fuel. In high-mileage vehicles, seals break down naturally as time passes, thus, impeding the seal of pressurized fuel as expected, which makes up for almost 15% of the fuel leaks of older cars.
Another frequent reason for leaking fuel pumps is the corrosion of fittings. Metal parts and connectors can corrode (especially in vehicles that are exposed to road salt or humid environments). This leads to weak points in the system that allows fuel to leak. Since corrosion on fuel lines and fittings can result in the loss of 1 gallon or more of fuel an hour (and more than $200–400 in damage), mechanics recommend that those line and fittings be checked annually for early signs of rust.
Cracks in the fuel pump itself in the housing are less frequent, but can also contribute to a leak. High temperature and pressure can induce stress in the pump housing, especially of plastic elements. If the pump-housing is cracked, all the fuel will start leaking out, and it will also cause less pressure to be maintained by the pump as a workable pressure so the engine is maintained and thus performance. Indeed, the American Automobile Association (AAA) claims that this kind of leakage is responsible for roughly 10 percent of documented fuel system problems but even more in cars used in extreme environments.
Ed China, fuel system specialist, explains: “Fuel pumps leaking do not only impact performance but endanger safety. Fuel leaks should be addressed immediately in order to get the most out of your fuel and to keep the vehicle operating safely.
Investing in a quality built durable Fuel Pump will reduce the chances of leaks with the right constructional material used to build the pump to give corrosion resistance and seals to hold the fuel to avoid any safety and performance issues.