MODULE TITLE: MAINTAINING FUEL SYSTEM

UNIT TITLE: SERVICING PETROL FUEL SYSTE

INTRODUCTION
A petrol fuel system stores and supplies fuel to the engine in the
correct quantity and pressure for proper combustion. Proper
servicing ensures:
• Efficient engine performance
• Reduced fuel consumption
• Lower emissions
• Longer engine life
Petrol engines mainly use two types of fuel supply systems:
• Carburetion system
• Electronic Fuel Injection (EFI) system
SERVICING CARBURATION FUEL SYSTEM

1.1 Definition
A carburetor is a mechanical device that mixes air and fuel in
the correct ratio before delivering it to the engine.
One example is the traditional carburetor used in older vehicles
like the Toyota Motor Corporation Corolla (older models).
1.2 MAIN COMPONENTS OF CARBURETOR FUEL
SYSTEM
1. Fuel Tank
Function:
The fuel tank stores petrol before it is supplied to the engine.
• It is usually made of steel or plastic.
• Located at the rear of the vehicle.
• Contains a fuel outlet, fuel gauge sender unit, and vent
system.
• Supplies fuel to the fuel pump through fuel lines.
Common Problems:
• Rust contamination
• Dirt and debris
• Fuel leakage
2. Mechanical Fuel Pump
Function:
Pumps fuel from the tank to the carburetor.
• Operates using engine motion (camshaft driven).
• Creates suction to draw fuel from the tank.
• Maintains low pressure (3–7 psi) suitable for carburetor
operation.
 • Usually mounted on the engine block.
Working Principle:
When the engine rotates, a cam pushes a lever in the pump,
moving a diaphragm up and down to draw and push fuel.
Common Problems:
• Weak diaphragm
• Fuel leakage
• Insufficient fuel pressure
3. Fuel Filter
Function:
Removes dirt and impurities from fuel before it enters the
carburetor.
• Installed between fuel pump and carburetor.
• Contains filter paper element.
• Prevents blockage of carburetor jets.
Importance:
A blocked filter can cause:
• Engine hesitation
• Hard starting
• Engine stalling
4. Carburetor
Function:
Mixes air and fuel in correct proportion (usually 14.7:1 air-fuel
ratio).
The carburetor works using Venturi principle:
• Air enters through air filter.
• Air passes through narrow section (venturi).
• Pressure drops.
• Fuel is sucked from jets into airflow.
• Mixture goes to intake manifold.
Main Internal Parts:
• Venturi
• Main jet
• Idle jet
• Float chamber
• Needle valve
Older vehicles from manufacturers like Nissan Motor
Corporation used carburetor systems before switching to EFI.
5. Throttle Valve
Function:
Controls engine speed by regulating amount of air-fuel mixture
entering engine.
Explanation:
• Located at lower part of carburetor.
• Connected to accelerator pedal.
• When pressed → valve opens → more mixture enters →
engine speed increases.
• When released → valve closes → engine speed decreases.
Fault Effects:
• Sticking throttle → unstable idle
• Worn linkage → poor acceleration

6. Choke Valve
Function:
Provides rich mixture during cold starting.
Explanation:
• Located at upper part of carburetor.
• Restricts air flow.
• Increases fuel quantity in mixture.
• Used when engine is cold.
Types:
• Manual choke
 • Automatic choke
Why Needed:
Cold engines need more fuel because petrol does not vaporize
easily at low temperature.

7. Float Chamber
Function:
Maintains constant fuel level inside carburetor.
Explanation:
• Contains a float and needle valve.
• When fuel level drops → float goes down → needle opens
→ more fuel enters.
• When fuel level rises → float rises → needle closes → fuel
stops.
Importance:
Correct fuel level ensures proper air-fuel ratio.
Common Problems:
• Stuck float → flooding
• Worn needle valve → fuel overflow
• High fuel level → black smoke
SUMMARY OF WORKING PROCESS
1. Fuel stored in tank.
2. Fuel pump draws fuel.
3. Fuel passes through filter.
4. Fuel enters float chamber.
5. Air enters carburetor.
6. Venturi effect mixes fuel and air.
7. Throttle controls mixture flow to engine.
8. Choke assists during cold start.
1.3 Functions of a Carburetor
• Mixes air and fuel
• Regulates engine speed
• Controls fuel supply according to load
• Assists in cold starting
1.4 Servicing Procedures
A. Preliminary Inspection
• Check for fuel leaks
• Inspect fuel hoses and connections
• Check air filter condition
•
B. Cleaning the Carburetor
• Remove carburetor carefully
• Dismantle components
• Clean jets using compressed air
• Remove dirt from float chamber
• Reassemble properly
C. Adjustment
• Adjust idle speed screw
• Adjust air-fuel mixture screw
• Check float level
• 1.5 Common Faults and Remedies
Fault Possible Cause Remedy
Engine hard to start Blocked jet Clean jet
Engine stalls Incorrect mixture Adjust mixture screw
Black smoke Rich mixture Reduce fuel supply
Poor fuel economy Leaking float Replace float

1.6 Safety Precautions

• Work in a well-ventilated area
• Avoid open flames
• Wear protective gloves
• Disconnect battery before servicing
SERVICING ELECTRONIC FUEL INJECTION (EFI)
SYSTEM
2.1 Definition
Electronic Fuel Injection (EFI) is a computer-controlled system
that delivers fuel directly into the engine using fuel injectors.
Modern vehicles like the Toyota Corolla use EFI systems.
2.2 MAIN COMPONENTS OF EFI SYSTEM
EFI is a computer-controlled fuel system that ensures precise
fuel delivery to the engine for efficient combustion.
Modern vehicles such as the Toyota Hilux and Honda Civic use
EFI systems instead of carburetors.

1. Fuel Tank
Function:
Stores petrol safely until needed by the engine.
• Made of metal or high-density plastic.
• Contains fuel pump (in most modern vehicles).
• Includes fuel level sensor (fuel gauge).
• Has ventilation system to control pressure.
Important Note:
In EFI systems, the fuel tank usually contains an electric fuel
pump inside it.

2. Electric Fuel Pump

Function:
Pumps fuel from tank to engine at high pressure.
• Located inside or near the fuel tank.
• Powered electrically.
• Produces higher pressure (30–60 psi or more) compared to
carburetor system.
• Controlled by ECU.
Why High Pressure?
Injectors require high pressure to spray fuel as fine mist for
proper combustion.
Common Problems:
• Weak pump → engine hard to start
• Pump failure → engine does not start
• Noisy pump → possible wear

3. Fuel Pressure Regulator

Function:
Maintains constant fuel pressure in the fuel rail.
• Controls excess fuel.
• Returns extra fuel back to tank.
• Ensures injectors receive correct pressure.
Why Important?
If pressure is:
• Too high → engine runs rich (black smoke)
• Too low → engine runs lean (poor power)

4. Fuel Injectors
Function:
Spray fuel directly into intake manifold or combustion chamber.
• Electrically controlled valves.
• Open and close rapidly.
• Spray fuel in fine mist form.
• Controlled by ECU signals.
Types:
• Single-point injection
• Multi-point injection
• Direct injection
Common Problems:
• Clogged injector → engine misfire
• Leaking injector → high fuel consumption
• Electrical failure → no fuel delivery

5. Electronic Control Unit (ECU)

Function:
The “brain” of the EFI system.
• Receives signals from sensors.
• Calculates correct fuel quantity.
• Sends signal to injectors.
• Controls fuel pump and ignition timing.
How It Works:
1. Sensors send data (temperature, air pressure, oxygen level).
2. ECU processes data.
3. ECU commands injectors to spray correct fuel amount.
Without ECU, EFI cannot operate.
6. Sensors
Sensors provide information to ECU to ensure proper fuel
control.
A. Oxygen Sensor (O2 Sensor)
Measures oxygen level in exhaust gases.
Location:
Mounted in exhaust system.
Purpose:
Helps ECU adjust air-fuel ratio.
If faulty:
• High fuel consumption
• Poor emissions

B. MAP Sensor (Manifold Absolute Pressure Sensor)

Function:
Measures pressure inside intake manifold.
Purpose:
Determines engine load.
If faulty:
• Poor acceleration
 • Engine hesitation

C. TPS (Throttle Position Sensor)

Function:
Detects throttle opening position.
Purpose:
Tells ECU how much driver is pressing accelerator.
If faulty:
• Sudden jerking
• Poor acceleration

D. Engine Coolant Temperature Sensor (ECT)

Function:
Measures engine temperature.
Purpose:
Helps provide rich mixture during cold start.
If faulty:
• Hard starting
• Poor fuel economy
7. Throttle Body
Function:
Controls amount of air entering engine.
• Contains throttle plate.
• Connected to accelerator pedal.
• Modern systems may have electronic throttle control.
Difference from Carburetor:
• Throttle body controls only air.
• Fuel is injected separately by injectors.

COMPLETE WORKING PROCESS OF EFI SYSTEM

1. Driver turns ignition ON.
2. ECU activates fuel pump.
3. Fuel pump builds pressure.
4. Sensors send engine condition data.
5. ECU calculates fuel amount.
6. Injectors spray fuel.
7. Air enters through throttle body.
8. Air and fuel mix and enter engine.
9. Combustion occurs.
 10. Oxygen sensor checks exhaust and sends feedback to
ECU.
This continuous process ensures:
• Maximum power
• Minimum fuel consumption
• Reduced emissions

ADVANTAGES OF EFI OVER CARBURETOR

• Better fuel economy
• Easier cold starting
• Lower pollution
• More accurate fuel control
• Improved engine performance
2.3 Functions of EFI
• Precise fuel delivery
• Improved fuel economy
• Reduced emissions
• Better engine performance
• Automatic adjustment to conditions
2.4 Servicing Procedures
A. System Diagnosis
• Use diagnostic scanner
• Check ECU fault codes
• Inspect warning lights
B. Fuel System Inspection
• Check fuel pressure
• Inspect fuel lines
• Check fuel pump operation
C. Injector Servicing
• Remove injectors carefully
• Clean using injector cleaning machine
• Replace damaged O-rings
• Reinstall and test
D. Sensor Testing
• Test oxygen sensor
• Test throttle position sensor
• Check wiring connections

2.5 Common Faults and Remedies

Fault Possible Cause Remedy
Clean or replace
Engine misfire Faulty injector
injector
Poor acceleration Faulty TPS Replace TPS
High fuel Faulty oxygen
Replace sensor
consumption sensor
Engine not starting Fuel pump failure Replace fuel pump

2.6 Safety Precautions

• Relieve fuel pressure before servicing
• Disconnect battery
• Avoid sparks
• Use proper diagnostic tools

COMPARISON: CARBURETOR VS EFI

Carburetor EFI
Mechanical system Electronic system
Less fuel efficient More fuel efficient
More emissions Lower emissions
Carburetor EFI
Simple to repair Requires diagnostic tools
Used in older vehicles Used in modern vehicles

CONCLUSION
Servicing petrol fuel systems is essential for maintaining engine
performance and fuel efficiency. While carburetor systems are
simpler and mostly found in older vehicles, EFI systems provide
better control, efficiency, and reduced emissions but require
advanced diagnostic skills.
 MODULE TITLE: MAINTAINING FUEL SYSTEMS
UNIT TITLE: SERVICING NATURAL GAS FUEL
SYSTEMS
INTRODUCTION
Natural gas fuel systems use gaseous fuels instead of petrol or
diesel. The two main types are:
1. LPG (Liquefied Petroleum Gas)
2. CNG (Compressed Natural Gas)
These systems are used because they:
• Reduce fuel costs
• Produce lower emissions
• Improve engine cleanliness
• Are environmentally friendly
Many modern vehicles from companies like Toyota Motor
Corporation and Hyundai Motor Company have LPG and CNG
variants.
SERVICING LPG SYSTEM COMPONENTS
1.1 Definition of LPG
LPG (Liquefied Petroleum Gas) is a mixture of propane and
butane stored in liquid form under moderate pressure.
1.2 Main Components of LPG System
• LPG cylinder (tank)
• Multivalve
• High-pressure fuel lines
• Regulator/Vaporizer
• LPG filter
• Mixer or Injectors
• ECU (for sequential systems)
• Changeover switch
1.3 Explanation of LPG Components

1. LPG Cylinder
Function:
Stores LPG in liquid form.
Features:
• Made of strong steel.
• Equipped with safety valve.
• Must be periodically inspected.
Safety Note:
Cylinder must never be exposed to excessive heat.
2. Multivalve
Function:
Controls filling, fuel supply, and safety shut-off.
Includes:
• Fill valve
• Service valve
• Pressure relief valve
• Level indicator

3. High-Pressure Lines
Function:
Carry LPG from tank to regulator.
Servicing:
• Check for cracks or leaks.
• Ensure fittings are tight.

4. Regulator / Vaporizer
Function:
• Reduces LPG pressure.
 • Converts liquid LPG into gas form.
How It Works:
Engine coolant heats the regulator to help vaporize LPG.
If faulty:
• Engine may stall.
• Poor acceleration.

5. LPG Filter
Function:
Removes dirt and oil residues.
Maintenance:
Replace after recommended mileage.

6. Mixer or LPG Injectors

Function:
Delivers LPG into intake manifold.
• Older systems use mixer.
• Modern systems use injectors controlled by ECU.
Example of LPG vehicles include the Hyundai Elantra LPG
variant.
1.4 LPG Servicing Procedures
A. Visual Inspection
• Check tank condition.
• Inspect mounting brackets.
• Look for corrosion or damage.
B. Leak Test
• Use soap solution to detect leaks.
• Never use open flame.
C. Filter Replacement
• Remove old filter.
• Install new filter.
D. Regulator Inspection
• Check diaphragm condition.
• Inspect coolant connections.
E. ECU Diagnosis (if equipped)
• Scan for fault codes.
• Check injector performance.

1.5 Safety Precautions (LPG)

 • Work in well-ventilated area.
• No smoking.
• Disconnect battery before servicing.
• Use approved tools.
• Wear safety gloves and goggles.
SERVICING CNG SYSTEM COMPONENTS
2.1 Definition of CNG
CNG (Compressed Natural Gas) is methane gas stored at very
high pressure (200–250 bar).
CNG vehicles are popular in public transport systems in many
countries including models from Tata Motors.

2.2 Main Components of CNG System

• CNG cylinder
• High-pressure regulator
• Pressure gauge
• Solenoid valves
• CNG injectors
• ECU
• Fuel lines
• Filling valve
2.3 Explanation of CNG Components
1. CNG Cylinder
Function:
Stores compressed natural gas.
Characteristics:
• Very strong (steel or composite material).
• Designed to handle high pressure.
• Requires periodic hydrostatic testing.
Important: CNG cylinders operate at much higher pressure than
LPG.

2. High-Pressure Regulator
Function:
Reduces high cylinder pressure to usable engine pressure.
Operation:
• First stage reduces pressure.
• Second stage regulates to engine requirement.

3. Solenoid Valves
Function:
Electrically control gas flow.
When ignition is OFF → valve closes automatically.

4. CNG Injectors
Function:
Inject gas into intake manifold.
Controlled electronically by ECU.
If faulty:
• Engine misfire
• Power loss

5. Pressure Gauge
Function:
Indicates gas pressure level.
Helps monitor fuel quantity.
2.4 CNG Servicing Procedures
A. System Inspection
• Check cylinder mounting.
• Inspect for corrosion or damage.
 B. Leak Detection
• Use gas detector or soap solution.
C. Regulator Testing
• Check pressure output.
• Inspect diaphragm condition.
D. Injector Cleaning
• Remove and clean injectors.
• Check electrical connections.
E. ECU Diagnosis
• Scan system for errors.
• Check sensor readings.
2.5 Safety Precautions (CNG)
• Always release pressure before servicing.
• Use certified pressure-rated tools.
• Never weld near CNG cylinder.
• Ensure workshop ventilation.
DIFFERENCE BETWEEN LPG AND CNG
LPG CNG
Stored as liquid Stored as compressed gas
LPG CNG
Lower pressure (5–15 bar) Very high pressure (200–250 bar)
Heavier than air Lighter than air
Moderate cylinder strength Very strong cylinder required
Higher energy density Lower energy density

ADVANTAGES OF NATURAL GAS SYSTEMS

• Cleaner combustion
• Lower emissions
• Reduced engine wear
• Lower fuel cost
• Environmentally friendly
CONCLUSION
Servicing LPG and CNG systems requires technical knowledge
and strict safety precautions because these fuels are highly
flammable and stored under pressure. Regular inspection, leak
testing, filter replacement, and regulator servicing ensure safe
and efficient vehicle operation.