Fuel tank testing, hoses, and cooling system services

Innovations such as increasingly efficient combustion engines, different fuels, and alternative drive concepts pose new challenges for vehicle cooling and refuelling systems. These systems and components must function reliably throughout their entire service life.

Manufacturers and suppliers therefore face correspondingly high quality requirements. TÜV SÜD’s comprehensive testing services support you in the individual development and validation phases so you effortlessly meet ever-evolving quality requirements.

TÜV SÜD has successfully partnered automotive manufacturers and suppliers worldwide for over 100 years. Our state-of-the-art test facilities and worldwide network of specialists deliver comprehensive solutions from a single source.

We verify compliance of components and systems with current industry standards and manufacturer specifications. Our tests ensure optimum safety and quality, both of which are basic prerequisites for successful marketing, and minimise the risk of recalls and reputational damage.

Different test procedures are applicable to complete tank and cooling systems, and their components. They ensure that products meet vehicle manufacturers’ current standards and requirements.

The tests include aspects such as fatigue strength, quality and function, as well as the reactions of the components to pressure, vibrations/movements, temperature, flow and other influences, and loads. These tests are performed according to various vehicle manufacturer specifications, international standards and specifications such as VDA, DIN, ISO, and SAE.

All media within the vehicle are used, including air, oil, coolant mixtures, water, AdBlue, and real fuels. We carry out many of these tests in the development phase. This allows any optimisation measures to be taken at an early stage, saving time and money.

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, coolant, oil, static pressure, and flow. These tests calculate how much each factor influences the ageing of the cooling system and fuel tank components.

Calculating the ammonia concentration in diesel exhaust fluid (DEF) systems

Photoacoustic measurements are taken to calculate the ammonia concentration in SCR systems and components.

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 4 °C /min.

Durability testing

Testing calculates how long a component can safely and reliably perform its function. 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 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 calculate their quality and functionality under extreme climate conditions. The tanks are exposed to ambient temperatures ranging from -40 °C to +60 °C.

Homologation testing

Testing are based on ECE R34 and Reg. EU 44/2014 Annex IX and have been designed to allow for the European-wide approval of vehicle components for different vehicle categories. TÜV SÜD is familiar with the requirements of the EU and ECE regulations and can advise you on the homologation process and compliance.

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, bursting pressure tests, tension-compression tests, ball drop tests, cold impact tests, and fire tests. 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, and air.

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 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 reliably measures evaporative emissions from a fuel tank and its components, and the hydrocarbon concentration (HC) in rubber and plastic components and tyres.

Simulation of dynamic driving conditions

Dynamic driving conditions are factors such as the ambient temperature, pressure, fuel, and driving conditions. They can all influence the components being tested. These tests accurately simulate the influencing factors to demonstrate their effects.

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

Components are exposed to certain fluids such as coolant, fuel, oil, and more. Parts of the fuel system are heated to a specific pre-defined temperature. The temperature switches between high and low temperatures within just a few seconds. This is known as temperature shock due to the extreme speed and change in temperature.

Testing of complete tank systems

In addition to individual tank components, TÜV SÜD also regularly tests complete tank systems. Starting testing early in the development phase means we can identify and resolve any weak spots early to cut costs.

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.