UGANDA TECHNICAL COLLEGE-KICHWAMBA
AUTOMOTIVE ENGINE TECHNOLOGYII
SUBMODULE4: DIESEL FUEL INJECTION SYSTEMS
LECTURE V
DIESEL FUEL INJECTION
A diesel fuel injection system is the mechanism that delivers, meters, and injects diesel
fuel into the engine cylinders at the correct time, pressure, and quantity for efficient
combustion.
Main Functions
❖ Supply fuel to the engine cylinders.
❖ Meter the correct quantity of fuel.
❖ Inject fuel at the correct time.
❖ Atomize the fuel into fine droplets.
❖ Distribute fuel evenly to each cylinder.
Main Components
❖ Fuel tank
❖ Fuel lines
❖ Fuel filter
❖ Injection pump
❖ High pressure pipes
❖ Fuel injectors (nozzles)
❖ Governor
❖ Fuel return line.
TYPES OF DIESEL FUEL INJECTION SYSTEM
1. Inline pump fuel injection system
2. Rotary pump fuel injection system.
3. Unit injection system
4. Electronic control injection system
1. INLINE PUMP DIESEL INJECTION SYSTE
Definition
An inline injection pump system is a fuel injection system where each engine cylinder
has its own pumping element arranged in a straight line within a single pump housing.
Main Components
❖ Pump housing
❖ Plunger and barrel assembly
❖ Camshaft
❖ Delivery valves
❖ Fuel rack
❖ Governor
Working Principle
➢ Fuel from the fuel tank passes through filters.
➢ Fuel enters the injection pump gallery.
➢ The camshaft pushes the plunger upward.
➢ The plunger compresses the fuel to very high pressure.
➢ The delivery valve opens.
➢ Fuel flows through the high-pressure pipe to the injector.
➢ The injector sprays fuel into the combustion chamber.
Advantages
➢ Accurate fuel metering
➢ High pressure fuel delivery
➢ Reliable for heavy duty engines
➢ Long service life
➢ Disadvantages
➢ Large and heavy
➢ Expensive to manufacture
➢ Requires precise maintenance
Applications
➢ Heavy trucks
➢ Buses
➢ Agricultural tractors
➢ Industrial diesel engines
[Link] PUMP DIESEL FUEL INJECTION SYSTEM
Definition
A rotary injection pump is a system where one pumping unit distributes fuel to all
cylinders sequentially using a rotating distributor.
Main Components
➢ Distributor rotor
➢ Pumping plunger
➢ Cam ring
➢ Transfer pump
➢ Governor
➢ Fuel control valve
Working Principle
• Fuel enters the pump through a transfer pump.
• The rotor rotates inside the distributor head.
• The pumping plunger pressurizes fuel.
• Fuel is delivered to each cylinder one at a time through the distributor.
• Injectors spray fuel into the cylinders.
Advantages
➢ Compact design
➢ Lightweight
➢ Less expensive
➢ Suitable for small engines
Disadvantages
➢ Limited pressure capacity
➢ Less durable for heavy-duty engines
➢ Sensitive to fuel contamination
Applications
➢ Small trucks
➢ Passenger vehicles
➢ Light diesel engines
3. UNIT INJECTOR DIESEL FUEL INJECTION SYSTEM
Definition
A unit injector system is a diesel fuel injection system where the injection pump and
injector are combined into a single unit for each cylinder.
Main Components
➢ Unit injector
➢ Plunger
➢ Camshaft
➢ Rocker arm
➢ Fuel supply system
Working Principle
➢ Fuel flows into the unit injector.
➢ The camshaft moves the rocker arm.
➢ The plunger compresses fuel inside the injector.
➢ Fuel is injected directly into the cylinder.
Advantages
➢ Very high injection pressure
➢ Accurate fuel control
➢ Improved fuel efficiency
➢ Reduced fuel lines
➢ Disadvantages
➢ Expensive
➢ Complex servicing
➢ Requires precise adjustment
Applications (Used in):
➢ Heavy duty diesel engines
➢ Marine engines
➢ Large trucks
5. ELECTRONIC CONTROL OF DIESEL FUEL INJECTION
Modern diesel engines use Electronic Diesel Control (EDC) systems.
Definition
Electronic control of diesel injection is the use of electronic sensors and a computer
(ECU) to control fuel injection timing, pressure, and quantity.
Main Components
➢ Engine Control Unit (ECU)
➢ Sensors (temperature, speed, pressure)
➢ Electronic injectors
➢ Wiring harness
➢ Fuel pump
Working Principle
• Sensors monitor engine conditions.
• Signals are sent to the ECU.
• The ECU calculates the correct fuel quantity and timing.
• Injectors are electronically controlled.
• Fuel is injected precisely for optimal combustion.
Advantages
➢ Better fuel economy
➢ Lower emissions
➢ Improved engine performance
➢ Automatic adjust
➢ Disadvantages
➢ High cost
➢ Requires electronic diagnostic tools
➢ Sensitive to electrical faults
SERVICING OF DIESEL FUEL INJECTION SYSTEMS
Proper servicing ensures efficient engine performance and long service life.
Routine Servicing
➢ Replace fuel filters regularly.
➢ Check fuel lines for leaks.
➢ Clean injectors.
➢ Check injection pump timing.
➢ Bleed air from the fuel system.
Injector Servicing
➢ Remove injector carefully.
➢ Clean nozzle tip.
➢ Test spray pattern.
➢ Check opening pressure.
➢ Injection Pump Servicing
Check pump timing.
➢ Inspect plungers and barrels.
➢ Lubricate moving parts.
➢ Calibrate pump if necessary.
ENGINE TESTING
Engine testing is done to evaluate engine performance and detect faults.
TYPES OF ENGINE TESTS
1. Compression Test
• Measures cylinder compression pressure.
2. Fuel Consumption Test
• Determines engine fuel efficiency.
3. Power Output Test
• Measures engine power using a dynamometer.
4. Smoke Test
• Checks exhaust emissions.
5. Injector Test
• Tests spray pattern and injection pressure.
COMMON DIESEL INJECTION FAULTS
➢ Hard starting
➢ Excessive smoke
➢ Poor fuel economy
➢ Engine knocking
➢ Loss of power.