Chapter V

The petrol injection

Gasoline injection should not be confused with diesel engine injection, or

with direct gasoline injection (into the cylinder). Modern injections are the evolution
of carburetors, they inject a mist of gasoline outside the chamber of
combustion.

1- Operation :
Whatever the type of injection, the basic principle is the same.
The dosage of the engine power is done by a throttle that brakes the intake of air.
The fuel is injected in the form of a mist just before the intake valve.

The injections differ mainly by the principle of fuel dosage or by the

air flow measurement method, but apart from these differences, the operation is very
resembling one brand to another.
We will not see Bosch's mechanical injection 'K', but the electronic injection 'L'.
and its improvements, as well as the single point.

Injection « L » : Le principe :

The injection can be broken down into three parts:

The fuel circuit, which brings, distributes and doses the fuel.
The sensors that inform the electronic unit of the operating conditions of
engine.
The electronic housing, which according to the information from the sensors, calculates the quantity
fuel to inject, and controls the opening of the injectors.
Dosage :

Mechanically, it is very difficult to design and control an opening valve.

proportional. For this injection, we have therefore chosen to use a sectional opening
constant, subjected to a constant pressure difference, are the injectors. That one
whether at full throttle or idling, when the injector is open, the flow rate (l/min) that passes through it is
always the same. What varies the amount of fuel injected is the time during
which the injectors remain open.

1 2 3 4

Injector
5- Constitution :

Landmarks Designations Landmarks Designations

1 tank 13 Oxygen sensor (Lambda)
2 Fuel pump 14 Knock sensor
3 Fuel filter 15 Water temperature sensor
4 Injector 16 Air temperature sensor
5 Pressure regulator 17 Idle regulator
6 Injection ramp 18 Canister solenoid valve
7 Gas butterfly 19 Tank canister
8 Intake manifold 20 Injection witness
9 Calculator 21 Diagnostic price
10 Pressure sensor 22 Power relay
11 Throttle position sensor 23 Starter contactor
Speed and position sensor
12 24 Battery
engine
System overview:

The main parameters: They allow the measurement of the amount of air that will be used.
based on fuel dosage
The adaptation parameters: They allow to adjust the base dosage in
adapting it to different driving conditions (examples: cold engine, foot to the floor
etc.) in order to make the engine's operation as optimal as possible
Secondary information: They allow for dosage adjustment based on the
different systems used by the driver or the vehicle.

2- The power supply circuit:

a- Different montages:
Pumps immerse Submersible pump and regulator External pumps
 Landmarks Designations
1 Reservoir
2 Lift pump
3 Fuel filter
4 Feeding ramp
5 Injectors
6 Pressure regulator

3- Constitutive elements:

a- The lift pump:

➢ It provides a constant fuel flow to the supply circuit.

Submersible pump Submersible pump and regulator

Landmarks Designations Landmarks Designations

1 Reservoir 4 Fuel level sensor
2 Fuel transfer pump 5 Gauge well
3 Strainer 6 Pressure regulator

Constitution :
Landmarks Designations
A Pumping element
B Electric motor
C Connecting cover
1 Arrival of fuel
2 Safety valve
3 Indigenous
4 Inductors (magnets)
5 Check valve
6 Fuel outage
 b- The pressure regulator:
It limits the pressure after the distribution ramp, and it is influenced by the pressure in the
tubing in such a way as to always ensure the same pressure difference at the injectors.
The pump only pushes the fuel towards the regulator when the pressure
desired is achieved, the spring compresses and the excess fuel returns to the tank.
Arrival from
the pump Return to
reservoir

Ball and plate

support

membrane

Spring locked
Depression of the
tubing

Thanks to the influence of the depression of the tubing on the membrane, the pressure
The fuel supply to the injectors is continuously regulated to always be 2.5 bar.
higher than the pressure in the tubing. Thus, regardless of the size of the opening of the
butterfly, the strangler (the nozzle) located in the injector is always subject to the same
pressure difference.
 Landmarks Designations
1 Intake manifold connector
2 Spring
3 Flap door
4 Membrane
5 Valve
6 Fuel arrival
7 Fuel exit (return)

Its function is to maintain a constant pressure in the supply circuit and to

Allow the return of the surplus fuel.

The injectors: Situation setup:

Constitution

Nipple injector Flooded injector

 Landmarks Designations Landmarks Designations
1 Filter 5 Magnetic core
2 Connector 6 Needle
3 Magnetic winding 7 Nipple
4 Return spring 8 Fuel Arrival

Operation:

➢ The injectors spray the fuel

➢ They are ordered by the calculator that decides on their grounding.
➢ When there is current flow in the magnetic winding, a ... is created.
magnetic field that attracts the magnetic core. The latter being connected to
the needle rises and allows the fuel to flow out.
➢ As soon as the excitement ends, the return spring pushes back and keeps the needle on
his seat. There is no more injection

The needle is pushed onto its seat by

the spring and closes the passage of
fuel.

When powered, the electromagnet

lifts from its seat by 0.1 mm and
thus freeing an annular slot
calibrated.

The nipple placed at the tip of the needle

ensures the spraying of gasoline
in the tubing.

It is the injector itself that determines the amount of fuel injected.

In order for the principle explained on the first page to work, the injector must, when it
is open, always allows the same flow rate, in all usage situations.

In order to reduce clutter and improve the cooling of the injectors, the
Modern injections increasingly use radial flow injectors.
 Improvements have also been made regarding the dosing. The injectors
using the needle's run to release a ring slot at the conical seat location,
have been replaced by injectors whose section released upon opening is given by
a few calibrated holes located just at the exit of the injector:

In order to improve the spraying at idle, when the airflow in the manifold
is low, and especially with the aim of reducing harmful emissions from the exhaust, we
uses air sweep injectors.
 The idle airflow passes
directly in front of the exit of
the injector, the mixing is good
best.

To draw in air and concentrate the airflow in front of the injector, the depression of the
intake manifold (between the throttle and the engine) and we draw in air upstream of the throttle
(between the butterfly and the flow meter). This volume of air comes from the bypass passage of the
Butterfly valve for idle adjustment. On fuel injection systems with an idle actuator, air is taken in.
upon its release.

Air flow meter:

A shutter, held by a spring, is lifted by the passage of air.

He commands a potentiometer whose resistance varies according to the amount of air drawn in.
by the engine.
 The measuring flap is coupled with a compensation flap that serves as a damper, and which
thanks to its 'L' shape, it avoids the potentiometer vibrations by canceling out influences
due to pressure pulsations caused by the opening and closing of the valves. Without
This, the panel would vibrate so much that the potentiometer would wear out very quickly.
There is usually a valve on the main panel that allows the passage of air.
in case of 'return'.

Engine temperature sensor:

Variable resistance
depending on the
temperature
 + 5V
Probe of
températur

Signal

Throttle switch:

It includes: Afulchargecontact

Acontactofderalenti(Gazlâchés)
 Cold start injector:

As its name indicates, the cold start injector injects a quantity of fuel
additional to enrich the fuel mixture during engine start-up,
only at low temperatures. It is powered by the supply pressure, and is
always under pressure. It consists of a solenoid valve and a spray nozzle with effect
roundabout.

Timed thermocontact:
He commands the cold start injector, he is subject to the influence of
the engine temperature, and an electric heating that
limit the operating time.

Example: at -20° interruption after 8

seconds (2 s. at 20°) OPEN at 35°
Bosch Idle Actuator (Regulating Valve) (Doc Dubath-Gisler)

The two windings are alternately subjected over a period of 10 ms to a

12 volts tension.
When the duration of current flow in a winding is longer than in
the other the bushel takes, due to its inertia a well-defined position.
The percentage of current passage duration is called Cycle Ratio
Opening. (RCO)
The order frequency is not very important; it is the cyclical relationship.
who determines the opening of the idle valve.

Hitachi throttle actuator (regulating valve) (Doc Dubath-Gisler)

 In this variant, the valve has only one winding that acts on a core.
himself connected to the valve.
At rest, winding 3 is not powered, the core is kept in contact with the drawer.
4 by the small spring 1. Drawer 4 is pushed back onto its seat by spring 5. It thus closes the
air circuit. When winding 3 is powered, the core is drawn to the right and the drawer 4
moves and opens the valve.

The valve is also controlled by a cyclic opening ratio (COR).

Idle speed control stepper motor

It is directly mounted on the throttle body, the engine drives a piston that
more or less close the air bypass passage.

The stepper motor is powered by pulses. With each pulse, the motor turns.
from a certain fixed angle, called 'step'.

This rotational movement is transformed by a worm screw that allows for movement.
of the bushing.
Electronic housing:

It determines the opening time of the injectors, therefore the amount of gasoline introduced.
this, it uses 'maps' stored in its read-only memory (ROM = 'chip') in
which all the opening time values for all possible situations of
the engine operation is recorded.
A first mapping allows, thanks to the main parameters, to determine a time
basis opening which will then be slightly modified through the mappings
of adaptation.
Main parameters:
According to the airflow rate and the regime, we calculate the amount of air inhaled per stroke (state of
charge) and therefore the amount of gasoline to introduce.
the case is simply to look in the memory for the value corresponding to
two parameters.

Simplified example: Table representing

the content of the
7V 10 9 memory of the case
6V 10 9 8
5V 10 9 8 7 Duration of the sent impulse
4V 10 9 8 7 6 to the injectors
Quantity of gasoline introduced
3V 10 9 8 7 6 5
2 V 10 9 8 7 6 5 4
1V9 8 7 6 5 4 3 Number of impulses
500 1000 1500 2000 2500 3000 3500 per minute ignition

Tension obtained from the

variable resistance of the flowmeter
d’air

Adaptation parameters:

The injection duration determined by the baseline mapping is modified based on

different parameters. These parameters and their adaptations are also recorded by a
cartographies.

Adaptation : Information coming from:

Cold start enrichment Engine temperature sensor

Enrichment at full load Throttle switch at full load

 Enrichment during sudden accelerations Flow meter speed

Adaptation of wealth
Barometric probe in the case
to atmospheric pressure.
CoUpUred's injection to limit the regime
Regime (ignition pulses)
Cata

Deceleration cut-off ● Contact of butterfly

● Superior Regimes at approximately 1500 RPM
Regulation Probe
Correction of the injected urea
Edge tension
depending on the board voltage.
Mouillage des cylindres Terminal 50 (starter)

For the lambda regulation and the idle actuator, it is not possible to use a
mapping, as the accuracy of the output values can only be achieved through a loop adjustment and
UnevaleUrcible (the target value is stored in a map).

Example:
The target idle value in hot condition is 750 rpm, the case measures the speed, if it is in
below the target value, it opens the actuator a little more. After a certain delay, it
restart the measurement, and make a correction, etc... If the regime exceeds the target value, the
the housing slightly closes the actuator. The idle speed is thus constantly monitored and
adapted, it oscillates within a very narrow range around the desired regime, even if, by
for example, the air conditioning compressor starts...

Exit:

Simultaneous injection: The injection is done twice per cycle with half the volume.
for all the injectors at the same time, and unrelated to the valve opening
of admission. The injectors are controlled by mass, in groups of 2 or 3.
Grouped injection: The injection occurs once per cycle, in groups of two injectors.

Sequential injection: The injection is done independently for each cylinder, a little
before the opening of the intake valve.

Example of connection: