1996 Chevy Tahoe Fuel Pump Relay

JSTIL99

MEMBER
1996 CHEVROLET TAHOE
V8
4WD
AUTOMATIC
164,995 MILES

I have replaced 3 fuel pump relays in the last year (2009)

My question to you is:
Why does it keep burning out the fuel pump relays?

96 tahoe
5.7L vortec

Friday, October 30th, 2009 AT 6:42 PM

2 Replies

JDL

MECHANIC
16,098 POSTS

Welcome to the forum, how many gas tanks? 5.7l engine? Use a gage and check fuel pressure, key on engine off, 60-66 psi on spider fuel system. There is an oil pressure switch in the fuel pump circuit, redundant power supply to the pump. Once you crank it enough to bring up oil pressure and the switch closes, the pump should run regardless of the relay, as long as the o/p circuit is functional.

How long since the last tune-up? A clogged fuel filter-- fuel supply line-- clogged return line, can cause the pump to draw more amps. Have you tried a different relay brand? Some manufacturers have their own web sites. You can ask them about their parts. I talk to them ever once in a while, I always get an answer.

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Friday, October 30th, 2009 AT 7:17 PM

JSTIL99

MEMBER
1 POST

Tahnks for the quick reply, I changed the fuel filter today, hope it helps.

I have tried several brands of relays, all made in china of course.

I spent $600.00 in parts and labor for genuine GM factory fuel lines (I know big mistake) fuel tank was removed to replace the lines, and the ground for the pump was repaired. Fuel pump was working fine, and still seems to be. I wanted to replace the fuel pump and sender when the tank was out, but the mechanic said I did not need to. An additional $350-$400!
This tahoe has been a money pit since day one, thought I was getting a good seal at $3500, but a few months later the tranny went caput. Arrrgh $2200 later, now the abs sensors are acting up!
About ready to drive it into a wall!

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Saturday, October 31st, 2009 AT 3:36 PM