According to the statistics of the National Highway Traffic Safety Administration (NHTSA) of the United States in 2023, engine stalling accidents caused by Fuel Pump failures accounted for 23.6% of the total vehicle failure rate, among which 82% of the cases were related to fluctuations in fuel pressure. Take the LTG engines recalled by General Motors on a large scale in 2022 as an example. The original low-pressure fuel pump (part number 12669731) frequently dropped below 2.5bar (the standard requirement is ≥3.0bar±5%) at idle speed, causing the air-fuel ratio to deviate from the threshold within 1.3 seconds and resulting in engine stalling. After replacing the improved high-pressure Fuel Pump (with a pressure range adjustable from 4 to 6bar), the failure rate decreased from 18% to 0.7%, and the ECU data record showed that the stability of fuel flow increased by 94%.
In terms of technological innovation, the Bosch HDP5 series Fuel Pump adopts a two-stage turbine design and has passed the ISO 16750-3 vibration test (amplitude ±2mm, frequency 10-2000Hz), controlling the fuel delivery fluctuation within ±0.8L/h on bumpy roads. Volvo verified in the Arctic Circle test that the B5 series hybrid models equipped with this pump have reduced the fuel pressure establishment time to 1.2 seconds during a cold start at -30°C (while the traditional pump requires 3.8 seconds), successfully eliminating 97% of the low-temperature idle stalling problem. Its intelligent pressure sensor feeds back the data to the ECU in real time, compressing the fuel rail pressure deviation from ±4.5% to ±0.9%, and the matching accuracy reaches the highest level of the ASAM XCP protocol.
Cost-benefit analysis shows that replacing the high-performance Fuel Pump can reduce the comprehensive maintenance cost by 38%-65%. Taking the common low-speed stalling fault of Nissan CVT models as an example, the traditional solution requires the simultaneous replacement of the throttle (420) and the oxygen sensor (310). However, after upgrading the Denso DENSO 950-0111 fuel pump ($185), by improving the fuel injection accuracy (±0.1ml/stroke), the idle speed stability is increased by 82%. The success rate of the single-piece solution reached 91%. The 2024 report of J.D. Power indicates that the Fuel Pump with a modular design reduces the replacement time from 2.5 hours to 45 minutes, and the return rate within the warranty period is less than 0.3%.
In the field of new energy, the Fuel Pump of Toyota’s THS-II hybrid system innovatively integrates an electric supercharging module. When the engine starts and stops, it can restore the fuel pressure from 0 to 4.2bar within 0.05 seconds, eliminating 87% of the risk of engine stalling during condition switching. The measured data shows that at the critical state of SOC (battery charge) of 15%, the fuel supply response speed of this pump is 3.2 times that of the traditional pump, ensuring the smoothness of engine engagement (vibration intensity ≤0.3m/s²). The ECE R83 regulation of the European Union requires that the new Fuel Pump must pass 100,000 start-stop cycle tests with a pressure attenuation rate of ≤0.02%/cycle. This standard extends the fuel system life of hybrid vehicle models to 250,000 kilometers.
Market cases show that the intelligent diagnostic Fuel Pump developed by Continental AG of Germany is equipped with 32 sets of fault prediction algorithms. It transmits 500 sets of parameters per second through the CAN FD bus and predicts 92% of the potential stalling risk 15-30 seconds in advance. In the actual test conducted by the New York taxi fleet, this technology reduced sudden road stalling accidents by 89% and cut towing rescue costs by 63%. Frost & Sullivan predicts that the global market size of intelligent fuel pumps will reach 7.4 billion US dollars by 2026. Among them, 83% of the products will integrate real-time health monitoring functions, completely reconstructing the solution paradigm of vehicle stalling problems.