While many complaints related to a blown fuel pump fuse due to an over-drawing electrical system, yes, the fuel pump can cause a blown fuse. For example a fuel pump requires 12 volts and with the current being drawn of say 4 to 6 amps. As the pump starts to fail, it can either heat up or take more current—it may even draw as much as 10 amps or more. This overcurrent can blow the fuse that safeguards the fuel pump circuit resulting in the fuel pump not engaging and making it so your vehicle would not start or run properly.
Short circuit This is a very common cause for a blown fuse in regard to the fuel pump. The motor or internal wires within the pump as they waste away and these create an electrical short, which in turn overloads the circuit. This became apparent in a 2019 auto recall, when multiple car models had problems with blown fuses because their fuel pump wiring was flawed and the engines died without warning. The improper wiring in this case caused an electrical failure, which drew too many AMPS from the pump and used more current than the fuse could withstand.
Also when fuel filters are clogged or fuel lines are blocked, the pump has to work even harder to maintain pressure which can add increased electrical load and cause heat both of which lead to premature failure. By some estimates, a clogged filter will reduce fuel flow to the engine by as much as 25 per cent and the extra demand placed on the pump can cause it to overheat and, of course a burnt-out electric fuel pump may in turn pop a fuse. By replacing your fuel filter every 30,000 miles, you can minimize the chances of this happening by assuring that the pump is able to function at full capacity without straining.
Fuel system wiring problems, on the other hand, may be another cause. Worn or corroded wiring has a greater resistance, so the pump will attempt to pull more current through your vehicle. Because an additional 10% voltage drop due to less-than-perfect wiring (or crimps) can cause the pump to overheat, and this new resistance could overload the fuse. For instance, in 2016 when some automakers put a stop on various vehicles for the recall to repair bad wiring connections affect fuel pump functionality or causing an electric malfunction that could blow fuses and result in the worst case scenario as a direct cause of no-drive with failure of the fuel pump.
For further information on diagnosing and repairing Fuel Pump problems please see our Fuel Pump page.