1.

Petrol Injection Systems

✅ Definition and Purpose

Petrol injection systems deliver fuel into the intake manifold or directly into the combustion
chamber. Unlike carburetors, they use precise metering based on engine load, speed, and
temperature.

🧠 Types of Systems

Type Description Example

1. Lucas EFI (Electronic Fuel Injection)

 Operation: Uses sensors to monitor engine parameters (RPM,

throttle position, air temperature, etc.). The ECU calculates the
correct fuel quantity and activates injectors accordingly.

 Features:

o Closed-loop control using oxygen sensor

o Adaptive fuel delivery based on load and speed

o Idle speed and cold-start managed electronically

 Teaching Tip: Use diagrams showing sensor inputs to ECU and

injector timing. Emphasize diagnostic tools like scan readers.

🔹 2. Bosch KE-Jetronic (Mechanical Continuous Injection)

 Operation:
 It operates using a fuel distributor connected to a control plunger,
which meters fuel based on air intake volume measured by an airflow
sensor plate. As the engine draws in air, the sensor plate deflects
proportionally, moving the control plunger to adjust fuel flow through
calibrated nozzles. A mixture control unit fine-tunes the air-fuel ratio,
while an electro-hydraulic actuator provides limited electronic
correction for cold starts, acceleration, and emissions control.

 Components:

o Fuel distributor

o Warm-up regulator

o Cold-start valve

o Pressure regulator

 Features:

o No ECU—purely mechanical

o Cold-start enrichment via thermo-time switch

o Fuel pressure varies with engine vacuum

 Teaching Tip: Use cutaway diagrams of fuel distributor and

pressure regulator. Ideal for practical demonstrations of
mechanical control.

🔹 3. Bosch L-Jetronic (Hybrid System)

 Operation:

Airflow meter measures intake air. ECU uses this data along
with engine speed and temperature to control injectors.

The Bosch L-Jetronic is an electronically controlled fuel injection system

that blends mechanical fuel delivery with digital precision, making it a
hybrid system. It uses an electric fuel pump to maintain constant
pressure and an airflow meter to measure the volume of incoming air.
Based on this data, the electronic control unit (ECU) calculates the
required fuel quantity and signals solenoid-type injectors to deliver fuel
intermittently into the intake manifold. The system also integrates
sensors for engine temperature, throttle position, and oxygen content
to optimize fuel-air mixture under varying conditions.
 Components:

o Airflow sensor (flap type)

o ECU

o Injectors

o Cold-start valve

o Thermo-time switch

 Features:

o Combines mechanical airflow sensing with electronic

injector control

o Better fuel economy and emissions than KE-Jetronic

o Still relatively simple compared to full EFI systems

 Teaching Tip: Use airflow meter demonstration and ECU pinout

charts. Highlight how analog signals are converted to injector
pulses.
Components

 Fuel tank

 Electric fuel pump

 Fuel filter

 Injectors

 Sensors (MAP, TPS, RPM, O2)

 Electronic Control Unit (ECU)

operation

The operation begins with the electric fuel pump drawing fuel from the tank
and delivering it under high pressure through the fuel lines to the injectors.
Meanwhile, the Electronic Control Unit (ECU) continuously receives real-time
data from various sensors—such as the Manifold Absolute Pressure (MAP)
sensor, Throttle Position Sensor (TPS), engine speed (RPM) sensor, coolant
temperature sensor, and oxygen sensor—which provide critical information
about the engine’s operating conditions. Using this data, the ECU calculates
the optimal injector pulse width, which refers to the duration each injector
remains open to deliver the precise amount of fuel required for efficient
combustion. Once the ECU sends the command, the injectors open at the
correct timing and spray atomized fuel directly into the intake manifold, just
before the intake valves open, ensuring a well-mixed air-fuel ratio enters the
combustion chamber for ignition. This process is repeated rapidly and
continuously, adapting to changes in throttle input, engine load, and
temperature to maintain performance, fuel economy, and emissions control.

2. Pressure-Sensed Petrol Injection Systems

Principle

These systems use Manifold Absolute Pressure (MAP) to determine engine load. The MAP
sensor measures vacuum in the intake manifold and sends a voltage signal to the ECU.

🧠 MAP Sensor Operation

Engine Load Manifold Pressure MAP Voltage

Idle High vacuum ~0.5–1.5V

Full throttle Low vacuum ~4.0–4.5V

The ECU uses this signal to adjust fuel delivery dynamically.

🔧 Components

 MAP sensor
  ECU

 Injectors

 Throttle body

Diagnosis

 Use multimeter to test MAP voltage

 Check sensor wiring and vacuum hose

 Observe voltage change during acceleration

📊 Assessment

 Explain how MAP sensor affects injector timing.

 Diagnose a faulty MAP sensor using voltage readings.

📎 Teaching Aids

 MAP sensor samples

 Multimeter

 ECU wiring diagrams

🔹 3. Bosch L-Jetronic System

✅ Overview

A hybrid electronic system that uses airflow measurement to determine fuel needs. It was
widely used in 1980s vehicles.

🧠 Airflow Measurement

Type Principle Signal

Vane/Flap Mechanical flap moves with airflow Potentiometer voltage

Hot-wire Air cools heated wire Voltage drop across wire

🔧 Key Components

 Airflow meter (vane or hot-wire)

 Cold start injector

 Thermo-time switch
  ECU

 Injectors

Operation

fuel delivery begins as air enters the engine through an airflow meter, which can be either a
vane-type or hot-wire type. The vane-type uses a mechanical flap that moves in response to
airflow, generating a variable voltage via a potentiometer, while the hot-wire type detects
changes in electrical resistance as incoming air cools a heated wire. This airflow signal is sent to
the Electronic Control Unit (ECU), which also receives input from other sensors such as engine
speed (RPM), coolant temperature, and throttle position. Using these signals, the ECU calculates
the precise amount of fuel required and determines the injector pulse width—how long each
injector should remain open. During engine cranking, the system activates a cold start injector
controlled by a thermo-time switch, which enriches the mixture to ensure reliable ignition in
cold conditions. The injectors then spray atomized fuel into the intake manifold at the correct
timing, ensuring optimal combustion and engine performance.

Diagnosis

 Test airflow meter voltage output

 Check cold start injector resistance

 Inspect thermo-time switch operation

📊 Assessment

 Compare vane and hot-wire airflow meters.

 Explain cold start enrichment process.

📎 Teaching Aids

 Bosch L-Jetronic diagrams

 Airflow meter samples

 ECU test bench

🔹 4. Electronic Control Unit (ECU)

✅ Function

The ECU is the central processor of the injection system. It receives sensor inputs and controls
outputs like injectors, ignition, and idle speed.

🧠 Inputs and Outputs

Input Sensor Output Actuator

Engine load MAP Fuel delivery Injectors

Throttle position TPS Idle control IAC valve

RPM Crank sensor Ignition timing Coil

Oxygen level O2 sensor Mixture correction Injectors

🔧 Operation

The Electronic Control Unit (ECU) acts as the brain of the fuel injection system, constantly
reading signals from sensors like MAP, TPS, RPM, and oxygen sensors. It processes this data in
milliseconds to calculate the correct injector pulse width, adjust ignition timing, and apply fuel
enrichment based on engine conditions. The ECU then commands the injectors and other
actuators to deliver precise fuel amounts, ensuring efficient combustion, smooth idling, and
optimal performance across all driving situations

Diagnosis

 Use breakout box to trace signals.

 Retrieve fault codes using scan tool.

 Simulate sensor inputs and observe ECU response.

📊 Assessment

 List ECU inputs and outputs.

 Explain how ECU adjusts fuel delivery.

📎 Teaching Aids

 ECU block diagram

 Breakout box

 Scan tool

🔹 5. Extra Control Circuits in ECU

✅ Purpose

These circuits fine-tune fuel delivery under specific engine conditions to improve performance,
economy, and emissions.

🧠 Circuit Functions
Circuit Function Condition

Cranking enrichment Adds fuel during start Engine cranking

After-start enrichment Maintains rich mix First 30 sec

Hot-start enrichment Adjusts for heat soak Restart after hot shutdown

Full-load enrichment Max power Wide open throttle

Over-run fuel cut-off Saves fuel Deceleration

Idle speed control Stabilizes idle Varies with load/temp

🔧 Operation

 ECU monitors engine state.

 Activates enrichment or cut-off based on sensor inputs.

 Controls injector pulse width and idle valve.

Diagnosis

 Simulate engine conditions using scan tool.

 Observe injector pulse width changes.

 Test idle air control valve operation.

📊 Assessment

 Match enrichment modes to engine conditions.

 Diagnose idle control faults.

📎 Teaching Aids

 ECU simulation software

 Scan tool

 Engine test bench