Ford's Easy Fuel system takes the guesswork out of filling up

When Rudolph Diesel devised a more efficient engine in 1892, he probably did not envision the situation that exists today: petrol and diesel sold next to each other from look-alike pumps, sometimes three or four in a row. But for anyone who accidentally fills their diesel-powered car with petrol, it can be a €4,000-€5,000 (Lm1,700-Lm2,150) case of mistaken identity.

Ford of Europe has now come up with a solution for the misfuelling of cars, a problem that affects hundreds of thousands of people in Europe each year. It's called Easy Fuel, and it is a simple device that prevents a petrol nozzle from being inserted into a car with a diesel engine.

"Ford's intention is to isolate the danger of engine damage to all customers," Ford Fuel Systems engineer Stefan Buro said. "With the Easy Fuel system, we have developed a method for error-free handling, especially for the coming generation of quietly running diesel engines, where the only things customers notice are good performance and excellent fuel economy."

The Easy Fuel system, with a patented misfuelling inhibitor, consists of a sealed filler pipe insert and fuel nozzle locator that guides the nozzle to the tank opening. The insert contains a mechanically operated diameter detector that only allows the larger diesel fuel nozzle to be inserted into the filler pipe, and locks out the thinner petrol nozzles. The system will begin appearing on Ford vehicles within two years, following final testing.

Unlike a petrol engine, which compresses a mixture of petrol and air, diesel engines compress just air before diesel fuel is injected into the cylinder and the fuel is ignited. Pouring petrol into a diesel engine can cause damage to the fuel pump, the high-pressure injection system, as well as other serious engine problems.

Today's modern diesel engines, with their sophisticated high-pressure injection systems, typically have a low tolerance against misfuelling. Even after a short driving distance, parts of the fuel pump may seize, requiring parts or the total injection system to be replaced.

With the European diesel market growing - approximately 50 per cent of Ford's car sales in Europe have diesel engines - misfuelling is an ever increasing problem.

In the UK, for example, where diesel fuelled family cars are relatively new, the Automobile Association reported 43,000 breakdowns as a result of an estimated 120,000 cases of unintended misfuelling in 2003, with approximately the same proportion expected for the following years.

Other European countries, such as Germany and France, have a longer tradition of diesel powered cars and a somewhat lower proportion of misfuelling. But, as has been indicated by car industry trade magazines, misfuelling happens to very experienced drivers as well.

Depending on the amount of damage sustained, engine repairs can cost from €120 to €4,000-€5,000 for a major overhaul.

The Easy Fuel system is catching the attention of others. Autocar magazine presented the Easy Fuel system with its 'Idea Of The Year Award'.

Autocar editor Rob Aherne said: "If simplicity is the essence of a great invention then Ford's Easy Fuel Concept must be one of the best. It has the potential to prevent the inconvenience and expensive repair bills associated with filling a diesel car with petrol.

"We think it is ingeniously designed and a worthy winner of the Autocar idea of the year."

On collecting the award, Ford's Buro said: "We are delighted to accept this Autocar award.

"We at Ford are keen to make motoring as problem free as we can by constantly evolving our product design and integrating ideas such as the Easy Fuel Concept."