AUTOMOBILE ENGINEERING

FUEL SYSTEM

CIJIL B. JOHN
Asst. Professor
Dept. of ME, JECC
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Fuel System: Functions

1. To store fuel in the fuel tank.

2. To supply fuel in the required amount and proper condition

3. To indicate the driver about the fuel level in the fuel tank

Components of fuel feed system :- PETROL ENGINE

Fuel Tank - Fuel Pump - Fuel Filter - Carburetor - Intake

Manifold - Fuel tubes for connections - Fuel Gauge
 2.1 Fuel systems: Fuel feed systems petrol

 In petrol engine, the petrol from the fuel tank reaches

through the fuel pump, filter and carburettor to the
engine cylinder.
Fuel tank
 1. Gravity system :
 In this system the fuel tank is mounted at a place
higher than that of the carburettor. Fuel filter
 The fuel flows from the tank to carburettor through
the filter due to gravitational force.
Carburettor
 It does not require any fuel pump.
 It is a simple and cheap system.
 This system is used in Scooters, Mopeds and motor Engine
cycles.

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Gravity Fuel feed system - Motorcycles

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 Fuel feed systems (petrol)
 2. Air Pressure system
 In this system, a pressure sealed tank is used.
 The pressure is created in the tank by means of a separate air
pump.
 For starting, the pump is primed by cam which produces pressure
in the tank and the fuel flows to the carburettor.
 [Link] system
 In this system the engine suction is used for sucking the fuel from
the main tank to auxiliary fuel tank then it flows by gravity to the
carburettor.

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 Fuel feed systems (petrol)
 4. Pump system
 In pump system , a fuel pump is used to feed the fuel from the fuel
tank to the carburettor. The pump is driven either by the camshaft
or electrically.

 In this system fuel tank can be placed at any suitable position in

the vehicle.
Engine
 This system is used in car, jeep, bus and lorries.

Storage tank Fuel Filter

pump Carburettor

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 Fuel feed systems (petrol)
 5. Fuel Injection System
 A fuel injection pump is used in place of a Carburetor. Fuel is
atomized by means of a nozzle & sprayed into an air stream.

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 Fuel feed pumps

 Fuel pump is used in fuel system to deliver fuel from the fuel
tank to the carburettor.

 1.) Mechanical fuel pump (Diaphragm type)

 2.) Electrical fuel pump

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 Mechanical (Diaphragm) fuel pump

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 In-tank electric fuel pump

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 Fuel filters for petrol
 All carburetors have a no. of passages and small holes through
which petrol must flow. Tiny pieces of dirt or blobs of water
can obstruct the flow and prevent the correct functioning of
the carburettor
 Filters may be fitted in one or more of the following positions.
1. Around the outlet from the fuel tank
2. At the fuel pump inlet
3. At the carburettor inlet
4. At any convenient point in the pipe line connecting tank to
carburettor,

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 Fuel Filter

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 It’s a filter in the fuel line that screens out dirt and rust particles from
the fuel, normally made into cartridges containing a filter paper.

 Unfiltered fuel may contain several kinds of contamination, for eg;

paint chips and dirt that has been knocked into the tank while filling,
or rust caused by moisture in a steel tank.

 If these substances are not removed before the fuel enters the
system, they will cause rapid wear and failure of the fuel pump and
injectors, due to the abrasive action of the particles on the high-
precision components used in modern injection systems.

 Fuel filters also improve performance, as the fewer contaminants

present in the fuel, the more efficiently it can be burnt.

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 Fuel filter in a motorcycle

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 Carburetors
 The carburetor is a device for atomizing and vapourizing the fuel
and mixing it with the air in varying proportions to suit the
changing conditions of petrol engines.
 The process of mixing the petrol with air to obtain the combustible
mixture before admission to the e/n cylinder is called carburetion.
 The air fuel mixture obtained from the carburettor is called the
combustible mixture.
 Vapourization is the change of state of the fuel from liquid to vapour.
 Atomization is the mechanical breaking-up of the liquid fuel in to
small particles, so that every particle of the fuel is surrounded by air.
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 Simple Carburetor

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 Drawback of a Carburetor
 The gasoline may move to the end of the inlet manifold &
accumulate there, which enriches the mixture going to the end
cylinders.

 The central cylinders, which are very close to the carburetor get the
leanest mixture.

 Thus, the various cylinders receive air-fuel mixture in varying

quantities & richness – Maldistribution

 Modern Injection s/ms injects the same quantity of fuel at each inlet
manifolds.

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 ELECTRONIC FUEL INJECTION
SYSTEMS

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 What is Electronic Fuel Injection??
 Modern gasoline injection s/ms use engine sensors, a computer &
solenoid operated fuel injectors to meter & inject the right amount of
fuel into the engine cylinders.

 Makes use of electrical & electronic devices to monitor & control

engine operation.

 The ECU receives electrical signals in the form of current or voltage

signals from various engine sensors.

 It then uses the stored data to operate the injectors, ignition system &
other engine related devices.

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 Benefits of EFI
1. It can provide precise and accurate amount of fuel under a
wide range of engine operating conditions.
2. Easy engine starting.
3. Smoother and more consistent throttle response.
4. Better adaptation to altitudes and ambient temperatures
5. Can operate properly regardless of vehicle orientation
6. Smoother idling
7. Helps reduce knocking/detonation
8. Lower maintenance needs
9. Better fuel efficiency
10. Cleaner exhaust.

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 Typical Sensors for an EFI
 Exhaust gas or Oxygen sensor – senses the amount of Oxygen in
the exhaust gas & calculates the air fuel ratio.

 Engine Temperature Sensor – Senses the T of engine coolant & the

ECU adjusts the mixture strength for hot or cold starting

 Air flow sensor – monitors mass of air flowing into the intake
manifold for adjusting the quantity of fuel.

 Air Inlet Temperature Sensor – checks the T of ambient air entering

for fine tuning the mixture strength

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 Typical Sensors for an EFI
 Throttle Position Sensor – senses the movement of the throttle plate
to adjust the mixture.

 Manifold Pressure Sensor – monitors vacuum in the intake manifold

to adjust the mixture strength

 Camshaft Position Sensor – senses the rotation of

camshaft/crankshaft for speed & timing of injection.

 Knock Sensor – microphone type sensor that detects pre ignition

noise so that ignition timing can be retarded.

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 Components of a Fuel Injection System
1. Pumping element: moves fuel from fuel tank to injector.

2. Metering element: measures & supplies the fuel at the rate demanded by
the speed & load conditions of the engine

3. Mixing element: atomizes the fuel & mixes it with air.

4. Metering Control: adjusts the metering according to e/n speed & load

5. Mixture Control: adjusts the air-fuel ratio as per engine’s demand

6. Distributing element: divides the metered fuel equally among all cylinders

7. Timing Control: fixes the start & stop of air fuel mixing process

8. Ambient Control: compensates for changes in T & P of either fuel or air.

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 PETROL INJECTION SYSTEM

Necessity
 Petrol injection system is used in most of the modern cars. Some of
the cylinders may not get regular supply of the mixture by a single
carburetor.

 So, every cylinder is provided with an injection nozzle receiving the

petrol from a pump.

 Petrol may injected directly into the cylinder or into the inlet
manifold.

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 Petrol Injection

Advantages Drawbacks

1. higher power 1. Higher initial cost

2. Low specific fuel 2. Higher maintenance cost
consumption 3. Complicated design
3. Quick starting & warm-up 4. Difficulty in servicing &
4. Avoidance of acceleration operation
disturbances during
cornering & braking.

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 Petrol Injection systems
1. Port Injection System (multi point fuel injection system)
2. Throttle Body Injection system (Single Point Injection)
3. Gasoline Direct Injection (GDI)

1. Port Injection System (multi point fuel injection system)

The injector is fitted in the inlet manifold near the inlet
valve. The uniform mixture formed enters into the engine
cylinder. Every cylinder is provided with a separate injector in
multi-cylinder engine.

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 MPFI

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 Multi Point (Port) Fuel Injection

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 D- MPFI

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 L-MPFI

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 Petrol Injection systems
2. Throttle Body Injection system (SPFI)

In this system, a single injector is used like a single carburetor.

The throttle valve controls the amount of air entering into the intake
manifold. The injector located above the throat of the throttle body
injects the fuel and it mixes with air in the intake manifold. The mixture
passes into the intake manifold. The injected fuel quantity is controlled
as per the speed and load on the engine.

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Throttle Body (Manifold) Injection System

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 Gasoline Direct Injection

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 GDI – BMW Engine

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 Gasoline Direct Injection (GDI)

 Fuel is injected directly into the engine cylinder at a much higher

pressure, by means of the fuel injector located at the cylinder head.

 The pump compresses fuel upto 350 bar, depending upon the speed
and load of the engine. The pressure is generally limited to 20MPa,
to prevent excessive wear on the injectors.

 GDI enables two charge modes based on how the fuel is distributed
throughout the combustion chamber.

1. Homogeneous charge mode

2. Stratified charge mode

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 GDI - Advantages

1. 10-15% better fuel economy.

2. 10% greater output and torque than MPFI at all engine

speeds.

3. Offers outstanding acceleration.

4. Burns leaner than MPFI, 40:1 versus 14.7:1 A/F ratio.

5. Torque delivery can be increased by as much as 50%.

6. Helps increase engine efficiency and specific power output as

well as reduce exhaust emissions.

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 Ford Ecoboost Engine (3.5L) - GDI

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 Kia Seltos 1.4 Turbo GDI with DCT

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 Hyundai Venue 1.0 Turbo GDI

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 Volkswagen Polo 1.0 TSI

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 Petrol EFI S/m Carbureted Fuel Supply S/m

1. High quality fuel distribution 1. Maldistribution of fuel to

2. High Volumetric efficiency individual cylinders.
due to absence of Carb 2. Low Volumetric efficiency due
Venturi. to the presence of Venturi.
3. Low fuel consumption
3. High fuel consumption.
4. Suitable for Supercharged
engines. 4. Not preferred for
supercharged engines.
5. Improves engine
performance & reduce 5. Higher emission & lower
emission. performance than EFI
6. Much complicated 6. Simple assembly, less no. of
mechanism- pump, injectors parts.
& fuel lines.
7. Not widely used today.
7. Extensively used in luxury &
racing cars
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 Fuel supply in CI engines
It consists of :
[Link] Tank
2. Fuel filter
[Link] pump
4. Injectors
5. Fuel lines
6. Fuel gauges

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 CRDI

 Direct fuel injection system for diesel engines.

 Diesel is injected at very high pressures (about 2000 – 2500 bar).

 Injecting fuel at a much higher pressure improves the atomization

and vaporization of high density diesel fuel, leading to more
complete combustion, better power delivery, increased fuel
efficiency and reduced emissions.

 Piezoelectric injectors are used nowadays, for increased precision.

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 CRDi
 Most commonly used in Diesel engines.
 CRDI consists of a ‘common fuel rail’ to supply fuel to injectors.
 With CRDI, the quantity, timing and injection pressures are controlled
separately.
 Allows more fine-tuning of engine performance than with petrol EFI
Systems.
 In CRDI, commencement of combustion takes place directly into the
main Combustion chamber located in a cavity on top of the piston
crown.
 Works in tandem with the engine ECU which gets input from various
sensors to calculate precious quantity & inj. timing
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 Common Rail Direct Injection

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 Bosch Piezo-electric CRDI Injector

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Diesel fuel injector as installed in a MAN
V8 Diesel engine

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 Benefits of CRDI

 High torque at low engine speed.

 Applicable to a variety of cylinder configurations.

 Better power & engine refinement than conventional system.

 Longer life & lower maintenance.

 Could be easily coupled with turbochargers.

 Delivers quiet, high torque, low emission & efficient diesel

engine performance to the consumer.

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