In automotive PEM fuel cell systems, one of the most important targets is to reduce the parasitic power of balance of plant components, e.g. the air supply. This can be achieved for example by decreasing air stoichiometry. However, this could lead to bad flow sharing in the fuel cell stack. Therefore the fluid distribution in the flow field has to be evaluated, understood and optimized. This work evaluates the effect of GDL intrusion on the pressure drop via ex-situ determination of GDL intrusion using CFD simulation. The intruded GDL geometries, evaluated by an optical microscope with 200 times enlargement, are transferred to pressure drop behaviors by a numerical CFD model. These results are compared to the results of the differential pressure method of mapping the pressure distribution, described in [43]. The intrusion of the GDL leads to homogeneous flow distribution up to clamping pressures of 2.5 MPa. The inhomogeneous intrusion, induced by cracked fibers that extend into the channel, dominates the flow at higher clamping pressures and leads to the exponential increase in pressure drop in the differential pressure method. For clamping pressures used in typical fuel cell applications, the results of both methods show homogeneous flow through the channels. (C) 2015 Elsevier B.V. All rights reserved.