FPMC Meeting
Bosch Chicago
March 3 & 4, 2008
Mike Wilinski
March 3 & 4, 2008
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Special THANKS
to
Nosa and Bosch
March 3 & 4, 2008
March 3 & 4, 2008
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Agenda
• March 3, 3:00 – 5:30 PM
– Media Articles & Exposure - Wilinski
– Website Status & Discussion - Wilinski
• March 4, 8:00AM – 3:30PM
Lunch Noon – 1:00 PM
– Website Status & Discussion cont’d - Wilinski
– Generic Procedures – Thompson/Dent
– Pressure/Flow Tester Specs – Wilinski
– Test Equipment Endorsement – Wilinski
March 3 & 4, 2008
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Agenda cont’d
• March 4, 8:00AM – 3:30PM cont’d
– Council Expansion – Wilinski/Gardner
– Customer Warranty Experiences - WDs
– Future Meeting Locations - Gardner
– AASA Warranty Council - Gardner
March 3 & 4, 2008
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Media Articles & Exposure
• Larry Carley Article
– Fuel Pump Warranty Returns Still An Issue
• Published In February 2008 Brake & Front End,
Underhood Service & Import Car
– High Rate of Returns
– FM In-Store Tester
– Upcoming fuelpumpinfo.org Website
March 3 & 4, 2008
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Media Articles & Exposure
• Jacques Gordon/Advanstar
– FPMC Phone Interview Dec 2007
– Untitled
– Draft Due May/Jun
– FPMC to edit/proof
– Publish Sep 2008
– Publications?
March 3 & 4, 2008
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2008 Meetings
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Mar 3 & 4
May 22 & 23
Sep 11 & 12
Dec 9 & 10
Bosch Chicago
March 3 & 4, 2008
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Website
Web Development Team
• Richard Dent
• Steve Gonzales
• Jeff Richardson
• Tom Thompson
• Mike Wilinski
March 3 & 4, 2008
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Website
URL: www.fuelpumpinfo.org
• Home Page
– Logo or FPMC Identifier (fuel pump module?)
– About FPMC, history and mission statement
– Tabs
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Members Only
News
FAQs
Spanish
Contact Us
Consumers
Technician Installers
March 3 & 4, 2008
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Website
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Members Only Page
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All member logos and links
Short intro
Sign-on and links
FTP Site
News Page (Do you know)
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FAQs Page
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Where is fuel pump located?
How long does it take to change a fuel pump?
What do I do with the gas I removed?
How do I know the pump is bad?
Do I need any special tools?
Rust
Contamination
Water
Etc.
March 3 & 4, 2008
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Website
• Link to Spanish Version Site
• Contact Us Page
– Email address to webmaster
• Who is designate and how will questions be answered?
• Should we list a turnaround time?
• Should manufacturer specific emails be forwarded, How?
• Consumer Page
– Safety
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Fuel Volatility
Danger of fire and explosion
Keep fire extinguisher nearby
Fighting gasoline fires????
– Education
• DIYer elementary training videos
• Do’s and don’ts
– E85
– What else???
March 3 & 4, 2008
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Website
• Technician/Installer Page
– Safety
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Fuel Volatility
Danger of fire and explosion
Keep fire extinguisher nearby
Fighting gasoline fires????
– Education
• Links to manufacturer training information
• Videos, etc.
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TSBs
Test Specs
Test Procedures
Test Equipment
Wiring diagrams
March 3 & 4, 2008
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FPMC ftp site
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Used for posting and downloading docs for review - pdfs
Once accepted, docs are transferred to applicable web page
To access use FTP client
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Via FileZilla
File: Site Manager
Click on New Site
Host: dev.mema.org
Change Logon type to: Normal
Username: fpmc
Password: efpiemci
Click on the “Transfer Settings” tab
Click on the “Active” radio button
Click on “Connect”
Help Contact: Zoltan Borsodi (919-406-8848 or zborsodi@mema.org)
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Proposed Logos
March 3 & 4, 2008
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Proposed Logo Usage
March 3 & 4, 2008
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Generic Procedure
March 3 & 4, 2008
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Fuel Delivery System Tester Specs
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Product Description
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A fuel system tester is a combination of components for connecting
into and inline with an automotive fuel delivery system to
simultaneously confirm fuel pressure and flow volume, and to provide
a means of performing tests upon the fuel delivery system to
diagnose system performance and pinpoint common malfunctions as
required.
This product is intended to be hung under the hood of a vehicle. The
inlet hose is connected to the fuel supply line extending from the fuel
tank/pump, and the outlet hose is connected to the fuel rail inlet.
When the engine is operating, fuel will flow uninterrupted through the
tester.
A 3-way valve is integrated into the flow of fuel at a location
subsequent to the measurement of fuel flow and pressure. The valve
has the capability to fully restrict fuel flow for the purpose of testing
the maximum pressure output of the fuel pump (deadhead test). It
also has the capability to direct some or all of the flow of fuel through
a bypass port for the purpose of simulating an engine’s use of fuel
under a “heavy load” condition.
March 3 & 4, 2008
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Fuel Delivery System Tester Specs
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cont’d
Product Specifications
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Performance objectives
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Fuel pressure measurement to 120 PSI
Fuel flow measurement to 1 gallon/minute in increments of
0.2 gallon/minute
Minimum unrestricted fuel flow of 1 gallon/minute through
tester
Capability to fully restrict flow for deadhead test
Capability to bypass fuel away from the engine at a
controlled, measured rate up to an unrestricted flow of 1
gallon/minute
Temperature Ranges
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32°F to 115 °F
March 3 & 4, 2008
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Fuel Delivery System Tester Specs cont’d
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Product Specifications cont’d
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Installation requirements
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Fuel system connections with 3/8” SAE J2044 endforms for maximum
automobile make/model compatibility
Push-to-connect fuel system couplers with push button release
Specific features
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Interchangeable scales of flow measurement calibrated for varying
specific gravities of alternative fuels, including but not limited to:
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Gasoline
Diesel
E85
Interchangeable scales of flow measurement calibrated for varying units
of measure, including but not limited to:
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Gallons/minute
Liters/minute
Gallons/hour
Liters/hour
March 3 & 4, 2008
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Fuel Delivery System Tester Specs cont’d
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Product Specifications cont’d
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Safety requirements
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Fuel line connections manufactured to SAE J2044 specifications
Flow tube manufactured of tempered borosilicate glass for
chemical resistance to fuels and additives, and pressure tested to
200 psi
Shatter resistance shield surrounding flow tube
Complete materials and component compatibility with gasoline
and diesel fuel and their common additives
Pressure relief valve located prior to the 3-way flow control valve
Customer requirements
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Serviceable components for convenient field maintenance
Adapters for connection to most makes and model of
automobiles
Custom case capable of housing all components for protection
and ease of storage
March 3 & 4, 2008
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Fuel Delivery System Tester Specs
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cont’d
User’s Manuals
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A detailed user’s manual is required
describing applications and procedures, and
including information critical to making an
accurate diagnosis.
Methods of Inspection and Testing
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Testers should be 100% inspected and
pressure tested by the manufacturer.
3rd party approval and CE certification N/A
March 3 & 4, 2008
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Lincoln Tester Endorsement
March 3, 2008
Typical testing of an automotive fuel delivery system
usually begins and ends with a simple pressure test.
To accurately diagnose fuel pump and other fuel
system related component issues, voltage and voltage
drop testing and more accurate fuel flow or volume
testing is required. The Fuel Pump Manufacturers
Council has endorsed the Lincoln MityVac FSTPRO
fuel delivery system tester as a must have tool to
properly and accurately diagnose fuel delivery system
and related component faults.
March 3 & 4, 2008
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Typical testing of an automotive fuel delivery system consists
only of a simple pressure test. However, to accurately diagnose
fuel pump and other fuel system related component issues,
voltage/voltage drop testing and more accurate fuel flow or
volume testing is required.
The Fuel Pump Manufacturers Council recommends a fuel
delivery system tester as a must have tool to properly diagnose
fuel delivery systems for pressure and flow.
The Fuel Pump Manufacturers Council recommends the following
testers.
Lincoln FSTPRZO
Carter CV1000
Legal disclaimer here
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Fuel Delivery System Testing
• Lincoln MityVac FSTPRO Spec
– Baseline Tester Spec
• Endorse FSTPRO
• Invite Other Testers for Endorsement
March 3 & 4, 2008
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Max Fuel Flow Formula
• Generic, Based on Max Fuel Required For
Engine Size & Max RPM @ Lambda 1
X = (YxZ/2) x A/B/6
– X = Max Engine Fuel Volume Reqd (Gallons Per
Minute)
– Y = Engine Size (Cubic Inches)
– Z = Max Engine Speed (RPM) (Redline)
– A = 0.00004419 = Specific Weight of Air @ 60 Deg F
Air (Lbs Per Cubic Inch)
– B = 14.7 = Lambda 1 = Stoichiometric Air Fuel Ratio
– C = 6 = Est Weight of Gasoline (Lbs/Gallon)
March 3 & 4, 2008
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Fuel Volume Calculator
March 3 & 4, 2008
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Council Expansion
• Open Discussion
– Additional Fuel Pump Mfrs
– Fuel Tank Mfrs
– Fuel Mfrs/Suppliers
– Fuel Filter Mfrs
– Fuel Additive Mfrs
– Educators/Schools
March 3 & 4, 2008
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Fuel Pump test Data Sheet
March 3 & 4, 2008
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2008 Important Dates
• Mar 4
• Apr 1
• Apr 1
Endorse FSTPRO
Website IO
Invite Test Equipment For
Endorsement
• May 22 Generic Procedure Due
• May 22 Endorse Pressure/Flow Testing
• Jun 1
Motorage Draft Due
• Sep 1
Motorage Article Published
• Sep 15 Website Content Complete
• Sep 16 Promote Website
March 3 & 4, 2008
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FPMC Standard Warranty Claim
FPMC STANDARDIZED FUEL PUMP WARRANTY CLAIM
SUBMIT COMPLETED CLAIM FORM, COPIES OF ORIGINAL AND REPLACEMENT
FUEL PUMP RECEIPTS AND ALLEDGED DEFECTIVE UNIT TO ORIGINAL INSTALLER OR PLACE OF PURCHASE. Refer to Manufacturer’s specific Warranty Policy
And Procedure for detailed instructions.
Date ____________ Cust Ref #__________ Mfr Ref #____________
Vehicle Owner Name ________________________________________
Address ___________________________________________________
City/State/Zip code __________________________________________
Phone No __________________________________________________
Vehicle, Year, Make, Model, Engine ______________________________
VIN ___________________________
Date Original Installed _________ Date Replacement Installed_________
Fuel Pump Mfr_____________________ Fuel Pump Part # ___________
Installer Name ______________________________________________
Address____________________________________________________
City/State/Zip code____________________________________________
Phone No __________________________________________________
Installer Signature ____________________________________________
Jobber/Supplier_____________________________________________
Address ____________________________________________________
City/State/Zip code____________________________________________
Distributor Name _____________________________________________
Address_____________________________________________________
City/State/Zip code_____________________________________________
REASON FOR RETURN ________________________________________
____________________________________________________________
Mfr Disposition
Accepted
Not Accepted __________________
March 3 & 4, 2008
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Generic Installation Instructions
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Air Filter
Carburetion
Fuel Filter
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Fuel Pump
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Turbo and Supercharger
Description: A mechanical fuel pump is most often used on cars with carburetors. This type of pump produces low pressure and is usually driven by the
engine. Cars all use electric fuel pumps nowadays because of the universal application of fuel injection and its need for higher pressures. Electric fuel
pumps are almost always located inside the gas tank, but there are some applications where the pump may be located along the frame or unibody
channel. The pump has a strainer at its pickup to filter out contaminants and uses an electric motor for power. Fuel is used as a lubricant and coolant for
the motor. The electric fuel pump has its own electrical control circuit, typically consisting of wiring, a fuse and a relay. This circuit interacts with the
car?s powertrain control module (PCM), which governs and monitors fuel pump operation.
Purpose: The fuel pump provides fuel with the proper pressure and volume for delivery by the carburetor or fuel injection system. The electric fuel
pump circuit also employs various safeties that stop the pump from running in the event of an accident.
Maintenance Tips/Suggestions: Mechanical fuel pumps require no maintenance, but should be replaced at the first sign of a problem. Pressure or
volume may drop off, giving an early warning sign of impending pump failure. A professional service technician can usually identify a pump problem
quickly. With fuel-injected vehicles, regular fuel filter changes can help extend the life of the electric fuel pump. It's best to replace the filter every two
years or 24,000 miles. A contaminated filter can restrict fuel flow from the electric fuel pump, eventually taking a toll on its life. You can also help protect
the pump by keeping the tank at least ? full at all times. Since fuel cools the pump, having plenty of fuel in the tank helps keep the pump from getting too
warm, which could damage it. Another good reason to keep the gas tank at least ? full is to reduce the chances of sediment pick-up at the fuel pump
inlet strainer. A restricted strainer can starve the pump, causing it to overheat and fail. If you own a Ford or Lincoln-Mercury vehicle, check your owner?s
manual for the location of the fuel pump shut-off switch. This switch is designed to electrically disconnect the fuel pump in the event of an accident.
Sometimes, an abrupt jarring of your car may be enough to cause this switch to open. It?s good to know where the switch is so you can try resetting it if
your car does not start. A faulty electric fuel pump can cause various symptoms including a loud pump whine, engine no-start, hesitation, poor
performance and stalling. If your car demonstrates any of these performance problems, have it checked out by a qualified service technician. Replacing
the fuel pump generally involves removal of the fuel tank.
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Fuel Delivery System Test Sheet
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Date
Customer
Customer Complaint
Repair Order No.
Fuel Pump Brand
Battery Voltage, Key Off
System Voltage, Engine Running
Voltage at Fuel Pump
System Operating Fuel Pressure
System Rest Pressure
System Volume
March 3 & 4, 2008
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