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LID is a Mechanical Engineer, Engineering Manager, Automotive Steering Technology and Design Consultant, Automotive Product Engineering and Manufacturing Consultant with world-class expertise in automotive engineering, design and development of chassis components and systems, development of high-tech energy-efficient steering systems, electrical pumping product development, hybrid automotive vehicle transmissions, fuel cells, and automotive cooling systems.
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An automobile manufacturer received reports of numerous vehicles being grounded because of engine stalling. These were "fleet" vehicles, in several different rental fleets, and all were new vehicles. Rental fleet service personnel reported that the problem was caused by plugging of the fuel filters. In many cases, the cars stalled shortly after leaving the airport rental terminal, in their first rental.
Several fleet terminals were affected, all in the mid-western states. A review of the complaint vehicles indicated that all were produced at the same assembly plant. Their build dates were all within two weeks. It was confirmed that the fuel filters of the stalled vehicles were plugged, preventing flow of fuel to the engine. The rental fleet quickly developed a repair process of draining and purging the fuel tanks, replacing the fuel filters, and refilling the tanks with new fuel. This was 100% effective at resolving the problem. The rental fleets suffered significant financial losses from this problem, and demanded reimbursement by the manufacturer, as well as assurance that the problem would not recur. The manufacturer needed to know what had caused the problem, so that it could be avoided in the future.
Here are the findings of the investigation that followed:
- The plugged filters were all clogged by a whitish precipitate, which was characterized in the lab.
- The precipitate was not found in the fuel or the filters of cars that were built in the same assembly plant, but shipped to other customers.
- The precipitate was not found in the fuel storage tanks of the fleet locations with the problem.
- The precipitate was not found in the fuel tank manufacturing process, or in any of the individual fuel system components.
- An audit of the fuel tank manufacturing process revealed that a soap residue could remain in the tank after the post-welding cleaning operation.
- Analysis of the soap residue showed that one of the compounds of that residue was a part of the whitish precipitate found in the filters.
- Review of the source of the gasoline for the rental terminals showed that the fuel for which there was stalling complaints had all come from the same distribution center.
It was never determined what specific component in the gasoline was causing the soap residue in the fuel tanks to precipitate out. Indeed, even if it had been determined, there was nothing the manufacturer could have done to prevent the fuel industry from doing it again. Fuel specifications are strictly regulated, and vary significantly with region, climate, season and availability of additives. It is unlikely that the EPA or the fuel industry would be sympathetic to the auto manufacturer’s poor housekeeping. The auto manufacturer’s only recourse was to modify the tank manufacturing process to assure that no residue was left in the tank and that each tank was thoroughly rinsed with clean water and fully dried. That was done, and the problem never recurred.
Read other articles by this KKAI Associate:
Automobile Suspension Fastener Integrity
| Mechanical Engineer, Engineering Manager, Automotive Steering Technology and Design Consultant, Automotive Product Engineering and Manufacturing Consultant, automotive engineering, design and development of chassis components and systems, development of high-tech energy-efficient steering systems, electrical pumping product development, hybrid automotive vehicle transmissions, fuel cells, and automotive cooling systems. | |
| Resume of TWW | automotive electro-mechanical, hydraulic design expert consultant |
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| Resume of GEF | value analysis, value engineering, expert consultant |
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Kevin Kennedy & Associates, Inc.
Rapid Response Engineering® Solutions
3905 Vincennes Road, Suite 320
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