The Performance Suppression Fuel Pump is capable of indirectly or directly injuring the engine with problems such as insufficient fuel supply pressure and unsteady flow. According to SAE J2715 standard, when fuel pressure decreases by 10% of the nominal pressure (for example, from 4.0 Bar to 3.6 Bar), air-fuel ratio deviation can exceed ±0.5, leading to an increase of 32% in carbon deposit rate in the combustion chamber. The Volkswagen EA888 engine user case in 2022 shows that due to the fuel pump wear (the flow rate has decreased to 6.5 liters per minute, while the original factory demand was 8.2 liters per minute), the diameter of the atomized particles of the fuel injector increased from 20 microns to 45 microns, and the cylinder wall has experienced abnormal wear (the measured wear value is 0.08mm per 10,000 kilometers, while the normal value is 0.03mm). The lifespan of the piston rings is cut down by 41%.
Low-pressure fuel delivery can cause detonation and hot-spot hazards. Tests conducted by the Toyota Research Institute in 2023 revealed that whenever the Fuel pump pressure deviates by more than ±0.8 Bar, the ECU must retard the ignition Angle by 3-5°, elevating the maximum temperature inside the cylinder from 980 ° C to 1120 ° C, resulting in a rise in the likelihood of thermal fatigue cracks in the connecting rod bearing alloy layer by 5.7 times. The actual data of Ford EcoBoost 2.3T engine owners proves that the problem of Fuel diluting the engine oil caused by the poor quality fuel pump (the dilution rate increases from 0.8% to 3.5%) increases the risk of crankshaft bearing lubrication failure by 22%, and the maintenance cost is over 28,000 yuan.
The invasion of impurities aggravates mechanical damage. Faulty Fuel pumps not replaced on time, due to impeller wear (gap > 0.15mm), allow metal debris with a particle size of > 10 μm into the high-pressure oil rail. The teardown and test by the China Automotive Technology and Research Center (CATARC) show that the trash will make the needle valve of the fuel injector stuck (the probability of sticking rises from 1% to 17%), and even after repair, the uniformity of fuel flow remains at ±12%, and the recovery rate of engine power is only 78%. In the Chevrolet Silverado owner’s situation, due to the failure of the filter screen of the aftermarket Fuel pump (the aperture expanded from 25 μm to 80 μm), rust particles in the fuel tank penetrated into the cylinder and spoiled the piston ring bank. The repair cost totaled 45,000 yuan.
The extended impact reaches the emission and post-treatment systems. The dilution of the mixture gas caused by low Fuel pump (λ value > 1.05) will accelerate the peeling of precious metal coating of the three-way catalytic converter (the rate of peeling increases by 2.3 times). According to J.D. Power, these malfunctions increase the cost of replacement of the catalytic converter by 16,000 yuan and raise the chances of poisoning the oxygen sensor by 29%. When the fuel pressure of BMW B48 engine is less than 3.0 Bar, the particulate filter (GPF) regeneration cycle is cut down from 800 kilometers to 300 kilometers. The peak carbon load exceeds 6.5 g/L (the maximum is 5.0 g/L), resulting in 12 kPa of back pressure rise and 0.4 second retardation in turbine response.
Verify the correspondence of industry data. Based on the Frost & Sullivan report, in 2025 there will be 370,000 cases of engine damage around the world because of Fuel pump failure, and 64% of these are caused by under-pressure stability. The Fuel pump with intelligent diagnostic technologies (such as real-time detection via the Bosch CAN FD protocol) can give abnormal fuel supply notification 200 hours in advance and can eliminate 67% of related damage. The redundant pump system of Tesla Cybertruck switches automatically when the pressure deviation is more than ±0.3 Bar, to ensure fuel supply continuity in critical engine conditions (e.g., driving up a 35° slope). The measured damage rate is only 1/9 of that in traditional designs.