Get started with TÜV SÜD
Start your journey with fuel systems testing and cooling system testing tailored to your components, targets, and timelines.
What are fuel system testing and cooling system testing services?
Advances such as higher-efficiency combustion engines, alternative fuels and new drive concepts create fresh demands on fuel delivery components and on thermal management across the vehicle. To maintain safety, performance, and emissions over the full service life, components must operate reliably under real-world conditions.
TÜV SÜD’s services bring together fuel system testing and cooling system testing to validate function, durability and compliance across development and validation phases, helping manufacturers and suppliers meet evolving quality requirements.
How TÜV SÜD can help you with fuel system testing and cooling system testing services
For over 100 years, TÜV SÜD has partnered with automotive OEMs and suppliers worldwide. Our state-of-the-art facilities and global expert network provide end-to-end support from a single source. We verify components and systems against current industry standards and OEM specifications. Through targeted fuel system testing and cooling system testing, we help safeguard product safety and quality, support faster market entry, and reduce the risk of recalls and reputational damage.
We apply the right mix of test procedures to complete fuel tanks and cooling systems, as well as their individual components. Typical programmes assess fatigue strength, functional performance and responses to pressure, vibration and movement, temperature and flow. Where relevant, we also consider thermal management factors that influence component life and emissions.
Testing follows vehicle manufacturer requirements and international standards such as VDA, DIN, ISO and SAE. Media used include air, oil, coolant mixtures, water, AdBlue and real fuels. Many tests are conducted early in development to identify optimisation measures sooner, saving time and cost.
Typical scope
Components
Fuel tanks and modules, lines and hoses, pumps, valves, radiators, charge-air parts, SCR/AdBlue and water tanks, seals and connectors
Media
Real fuels, coolant mixtures, oil, air, water and AdBlue
Conditions
Pressure, temperature, flow, vibration and movement (including PVT and thermal cycling)
What our fuel system testing and cooling system testing services include
We offer the following tests for fuel tanks, cooling systems, and their components:
Ageing test
The components built into vehicles go through an ageing process which is influenced by factors such as temperature, different fluids, static pressure, and flow.
Climatic test
Components are exposed to specific temperatures. The benchmark values are -40 °C and +180 °C. The relative humidity, ranging from 0 to 98%, is also considered as an additional factor. TÜV SÜD uses ultra-modern climate chambers with a volume of 0.8 m³ to 3.5 m³. These chambers offer temperature gradients of up to 6 °C /min.
Durability testing
The component is exposed to several relevant external factors, such as internal pressure, temperature, and flow. The lifecycle of a component can be represented in time lapse. Our durability testing methods use the following fluids: coolant, fuel, oil, and air.
Erosion testing
Specific dirt particles are added to the fluid flowing through the cooling system’s components, thus allowing conclusions to be drawn about erosion behaviour.
Flow testing
This test tends to include the use of temperature, fluid (e.g. coolant, fuel, oil etc.), static pressure, and flow. Typical flow tests can include erosive flow testing as well as an internal corrosion test.
Freeze-thaw testing on 6 AP
The freezing and defrosting behaviour of SCR and water tanks is tested. The aim is to validate their quality and functionality under extreme climate conditions. The tanks and components are exposed to ambient temperatures ranging from -40 °C to +60 °C.
Homologation testing
Testing is based on international standards such as ECE R34 and EU Regulation 44/2014 Annex IX, and is designed to support the approval of vehicle components across various global markets and vehicle categories. TÜV SÜD has extensive experience with both European and international regulatory frameworks and can support you throughout the homologation process, ensuring compliance with relevant global requirements.
Internal corrosion testing
During this test, the cooling system components are flushed with a mixture containing specific salts to provide reliable data about the corrosion behaviour of the components.
Material testing
The test object is subjected to comprehensive leak tests, burst pressure tests, tensile tests, ball drop tests, cold impact tests, fire tests, and more. This allows the reliability, safety, and quality of the material to be determined and shows whether it meets legal requirements and standards.
Pressure cycle test
This test evaluates the long-term performance of components. They are exposed to dynamic pressure changes as well as impacted by temperature and flow. Fluids used in this test are coolant, fuel, oil, etc.
Pressure impulse testing
Testing exposes components to high-frequency, dynamic changes in pressure. Additional factors include temperature – both ambient and that of the component itself – and flowrate. Possible fluids here include coolant, fuel, oil, etc.
Pressure, vibration, and temperature (PVT) test
In this test, components are exposed to different loads at the same time: dynamic pressure changes, different temperatures, flow and vibration or motion. The PVT test simulates the actual situation of various parts when exposed to all factors. Furthermore, it provides reliable information on their durability.
PVT tests can be performed using fluids such as coolant, fuel, oil or air. Standard test procedures include SAE J2044, SAE J2045, DIN 73379 and numerous regulations from notable OEMs.
Refuelling test
These tests are designed to determine how well or poorly a fuel tank system performs under different conditions. A variety of different filling nozzles and different fuels are tested with the tank system. The tank system itself and the ambient temperature varies during refuelling tests.
Sealed housing for evaporative determination (SHED)
SHED systems reliably measure evaporative emissions from fuel tanks and their components. In addition, they can be used to determine hydrocarbon (HC) emissions from rubber and plastic materials, such as seals, hoses or tyres. Measurements during refueling procedures (ORVR tests) are also possible, allowing for a comprehensive evaluation of vapor recovery systems.
Simulation of dynamic driving conditions
Dynamic driving conditions such as ambient temperature, atmospheric pressure, fuel volatility, and driving behavior can significantly influence the performance and integrity of fuel tanks. Test procedures are designed to simulate these real-world conditions in a controlled environment to ensure the fuel tanks function reliably under all operating scenarios.
Static pressure and temperature test
This test calculates the ageing of components when influenced by temperature, pressure, and fluids such as coolant, fuel, oil, air, and others. It is often part of the ageing test.
Temperature change test
This test investigates the behaviour of a component under temperature ranges from -70 °C to +180 °C. To ensure the component’s operational reliability, it is constantly monitored as the temperature switches between the high and low values.
Temperature chambers with volumes ranging from 0.8 m³ to 3.5 m³, and temperature gradients up to 6 °C /min can be simulated. TÜV SÜD also has chambers that meet the requirements of the European Explosion Protection Directive ATEX for the testing of components with flammable fluids.
Temperature shock testing
In thermal shock tests with coolant as test medium, components are rapidly exposed to alternating high and low temperatures. These temperature changes occur within seconds and simulate extreme thermal stress conditions. The goal is to verify that the materials and connections withstand sudden temperature shifts and continue to function as intended.
Tests for charge air components
These tests are specially designed to investigate the endurance limit of a component when it is exposed to factors including temperature, pressure, and multi-axial motion. TÜV SÜD uses a specially designed robot to achieve the multi-axial motion for this test.
Frequently asked questions (FAQ)
Why are tests for automotive systems necessary?
To ensure that components function safely, reliably, and durably under real operating conditions.
What are the benefits of comprehensive testing of vehicle components?
Higher product quality, reduced risk of failure, clearer compliance with legal requirements, and improved customer satisfaction.
What is the difference between component testing and system testing?
Component testing focuses on individual parts, while system testing evaluates the interaction and performance of multiple components working together.
Are there differences in testing requirements?
Yes. For example, hydrogen systems require specific leak-tightness, material tests, overpressure safety checks and temperature resistance. In electric vehicles, testing focuses on the battery, electric motor, power electronics, and thermal management systems.
Which norms and standards apply to automotive system testing?
Environmental testing follows ISO and DIN specifications, SAE standards, specific OEM requirements, and, depending on the region, legal regulations.
