1 FPMC Meeting Bosch Chicago March 3 & 4, 2008 March 3 & 4, 2008 Mike Wilinski

2 Special THANKS to Nosa and Bosch March 3 & 4, 2008 March 3 & 4, 2008

3 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 Agenda March 3 & 4, 2008

4 March 4, 8:00AM – 3:30PM cont’d –Council Expansion – Wilinski/Gardner –Customer Warranty Experiences - WDs –Future Meeting Locations - Gardner –AASA Warranty Council - Gardner Agenda cont’d March 3 & 4, 2008

5 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 Media Articles & Exposure March 3 & 4, 2008

6 Jacques Gordon/Advanstar –FPMC Phone Interview Dec 2007 –Untitled –Draft Due May/Jun –FPMC to edit/proof –Publish Sep 2008 –Publications? Media Articles & Exposure March 3 & 4, 2008

7 Mar 3 & 4Bosch Chicago May 22 & 23 Sep 11 & 12 Dec 9 & Meetings March 3 & 4, 2008

8 Web Development Team Richard Dent Steve Gonzales Jeff Richardson Tom Thompson Mike Wilinski Website March 3 & 4, 2008

9 URL: Home Page –Logo or FPMC Identifier (fuel pump module?) –About FPMC, history and mission statement –Tabs Members Only News FAQs Spanish Contact Us Consumers Technician Installers Website March 3 & 4, 2008

10 Website March 3 & 4, 2008 Members Only Page –All member logos and links –Short intro –Sign-on and links –FTP Site News Page (Do you know) –??????????? FAQs Page –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.

11 Link to Spanish Version Site Contact Us Page – address to webmaster Who is designate and how will questions be answered? Should we list a turnaround time? Should manufacturer specific s be forwarded, How? Consumer Page –Safety 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??? Website March 3 & 4, 2008

12 Technician/Installer Page –Safety Fuel Volatility Danger of fire and explosion Keep fire extinguisher nearby Fighting gasoline fires???? –Education Links to manufacturer training information Videos, etc. –TSBs –Test Specs –Test Procedures –Test Equipment –Wiring diagrams Website March 3 & 4, 2008

13 FPMC ftp site Used for posting and downloading docs for review - pdfs Once accepted, docs are transferred to applicable web page To access use FTP client –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 ( or

14 Proposed Logos March 3 & 4, 2008

15 Proposed Logo Usage March 3 & 4, 2008

16 Generic Procedure March 3 & 4, 2008

17 Product Description –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. Fuel Delivery System Tester Specs March 3 & 4, 2008

18 Product Specifications –Performance objectives 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 32°F to 115 °F March 3 & 4, 2008 Fuel Delivery System Tester Specs cont’d

19 Product Specifications cont’d –Installation requirements 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 Interchangeable scales of flow measurement calibrated for varying specific gravities of alternative fuels, including but not limited to: –Gasoline –Diesel –E85 Interchangeable scales of flow measurement calibrated for varying units of measure, including but not limited to: –Gallons/minute –Liters/minute –Gallons/hour –Liters/hour Fuel Delivery System Tester Specs cont’d March 3 & 4, 2008

20 Product Specifications cont’d –Safety requirements 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 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 Fuel Delivery System Tester Specs cont’d March 3 & 4, 2008

21 User’s Manuals –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 –Testers should be 100% inspected and pressure tested by the manufacturer. –3rd party approval and CE certification N/A Fuel Delivery System Tester Specs cont’d March 3 & 4, 2008

22 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. Lincoln Tester Endorsement March 3 & 4, 2008

23 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

24 Lincoln MityVac FSTPRO Spec –Baseline Tester Spec Endorse FSTPRO Invite Other Testers for Endorsement Fuel Delivery System Testing March 3 & 4, 2008

25 Generic, Based on Max Fuel Required For Engine Size & Max 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 = = Specific Weight of 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) Max Fuel Flow Formula March 3 & 4, 2008

26 Fuel Volume Calculator March 3 & 4, 2008

27 Open Discussion –Additional Fuel Pump Mfrs –Fuel Tank Mfrs –Fuel Mfrs/Suppliers –Fuel Filter Mfrs –Fuel Additive Mfrs –Educators/Schools Council Expansion March 3 & 4, 2008

28 March 3 & 4, 2008 Fuel Pump test Data Sheet

29 Mar 4Endorse FSTPRO Apr 1Website IO Apr 1Invite Test Equipment For Endorsement May 22Generic Procedure Due May 22Endorse Pressure/Flow Testing Jun 1Motorage Draft Due Sep 1Motorage Article Published Sep 15Website Content Complete Sep 16Promote Website 2008 Important Dates March 3 & 4, 2008

30 FPMC Standard Warranty Claim March 3 & 4, 2008 FPMC STANDARDIZED FUEL PUMP WARRANTY CLAIM SUBMIT COMPLETED CLAIM FORM, COPIES OF ORIGINAL AND REPLACEMENT FUEL PUMP RECEIPTS AND ALLEDGED DEFECTIVE UNIT TO ORIGINAL INSTAL- LER 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 __________________

31 Generic Installation Instructions

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34 Find a PartShop/Store FinderRepowered EnginesRoad Trip PrepService ScheduleCar Care ArticlesHelpful Stats & InfoCollision RepairAccessoriesTools for DIYersNews SupplementC.A.R. Radio ShowNtl. Car Care MonthSite Search Find a PartShop/Store FinderRepowered EnginesRoad Trip PrepService ScheduleCar Care ArticlesHelpful Stats & InfoCollision RepairAccessoriesTools for DIYersNews SupplementC.A.R. Radio ShowNtl. Car Care MonthSite Search Air Filter Carburetion Fuel Filter Fuel Injection Fuel Pump Fuel Storage Turbo and SuperchargerAir Filter Carburetion Fuel Filter Fuel Injection Fuel Pump Fuel Storage 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. Home | Contact Us | About Campaign| SearchHomeContact UsAbout CampaignSearch Copyright 2007, Car Care Council. All rights reserved.

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39 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 Fuel Delivery System Test Sheet March 3 & 4, 2008