Internal Combustion Engine

FUEL SYSTEM

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 Fuel System in Vehicle

Types of fuel generally using in automotive vehicles.

•Gasoline (Petrol)
•Diesel
•LPG (Liquid petroleum Gas)
•CNG (Compressed Natural Gas)
 Fuel System in Vehicle
Gasoline is a term used to
describe a complex mixture of
various hydrocarbons refined
from crude petroleum oil for use
as a fuel in engines.
When combustion occurs,
carbon dioxide and water are
produced if the process is
perfect and all of the air and all
C8H18 + O2 ==> CO2 + H2O
of the fuel are consumed in the
process.
 Fuel System in Vehicle

Diesel fuel must meet an entirely different set of standards

than gasoline. Diesel fuel contains 12% more heat energy than
the same amount (volume) of gasoline. The fuel in a diesel
engine is not ignited with a spark, but is ignited by the heat
generated by high compression.

Diesel Load Carrying Vehicle

 Fuel System in Vehicle
LPG (Liquid petroleum Gas) or Propane is the LPG Cylinder
most widely used of all of the alternative fuels.
Propane is normally a gas but is easily
compressed into a liquid and stored in
containers.

•Propane is a by-product of petroleum refining.

•The pressure of storage is about 300 PSI
(2,000kPa).
Welded two
•Propane is often mixed with about 10% of other piece
gases It is Colorless and Odorless,
 Fuel System in Vehicle
Compressed Natural Gas, Or CNG, and vehicles using this
fuel are often referred to as natural gas vehicles (NGVs).
•Natural gas has to be compressed to about 3,000 PSI
(20,000 kPa) or more.
•The weight and the cost of the storage container is a major
factor when it comes to preparing a vehicle to run on CNG

One piece cylinder (Capable to bear 3000 PSI)

Fuel Supply System in Vehicle

Air Cleaner

Fuel Pump

Carburetor
Fuel Supply System in Vehicle
Vehicle with Carburetor
 Fuel Tank

Creating and maintaining a

correct air fuel mixture requires
a properly functioning fuel and
air delivery system.
•A vehicle fuel tank is made of
corrosion-resistant steel or
polyethylene plastic.
•A vertical baffle in fuel tanks
limits fuel sloshing as the
vehicle moves.
 Fuel Tank
Fuel tanks must be vented to prevent a vacuum lock as fuel is
drawn from the tank. Venting the tank allows outside air to
enter as the fuel level drops, preventing a vacuum from
developing.
An EVAP system vents gasoline vapors from the fuel tank
directly to a charcoal-filled vapor storage canister, and uses an
unvented filler cap.
Fuel System
 Fuel Tank
Fuel Filler Cap is a type of safety
valve mounted on a fuel tank.
Fuel Filler cap is generally flexible,
corrosion resistant and offers
better grip every time whenever
the tank is filled with fuel. Steel,
aluminum, polyamide resins, zinc,
copper, brass, iron and other
metals are used for
manufacturing automobile fuel
tank cap.
 Fuel Tank
Fuel Level Gauge
The fuel level gauge indicates the
fuel level in the fuel tank. The
fuel sending unit is combined
with the fuel pump assembly and
consists of a variable resistor
controlled by the level of an
attached float in the fuel tank
Fuel Tank
 Fuel Lines and Filter

Fuel filters remove dirt, rust,

water, and other contamination
from the gasoline before it can
reach the fuel injectors. Most
fuel filters are designed to filter
particles that are 10 to 20
microns or larger in size.
 Fuel Pump
The fuel pump sends fuel
from the fuel tank to the
carburetor or fuel common
rail.
There are two types of
automotive fuel pump .

Mechanical Fuel Pump

Electrical Fuel Pump

 Fuel Pump

Most carbureted fuel systems

use a mechanical fuel pump. It
usually mounts on the side of
the cylinder block. An
eccentric on the camshaft
operates the pump. The
Fuel Pump
rotating eccentric (or a push
rod riding on it)rocks the
rocker arm up and down. The
flexes a diaphragm to produce
the pumping action.
Fuel Pump
 Fuel Pump

The electric fuel pump is a pusher

unit. When the pump is mounted
in the tank, the entire fuel supply
line to the engine can be
pressurized. All electrical pumps
are driven by a small electric
motor,
Fuel Pump
 Fuel Pump

Electric fuel pump with sender in the fuel tank

Air Cleaner Assembly
 Carburetor System
Purpose of Carburetor
1. It combines gasoline and
air creating a highly
combustible mixture
2. It regulates the ratio of air
and fuel
3. It controls the engine's
 Carburetor System
A Venturi is a streamlined
restriction in any passage. This
restriction causes an increase in
air velocity and a lowering of
pressure of the air passing
through it. The greater the air
velocity, the lower the air
pressure at the venturi. This
lower pressure is the basic force
under which carburetors
function.
Main Parts of Carburetor
 Main Parts of Carburetor

The float system

Maintaining Fuel standard level on
float chamber by means of float
and needle valve.
•Higher fuel level then standard,
cause rich mixture.
•Lower fuel level then standard,
cause lean mixture.
•Perfect Air and fuel mixture for
maximum efficiency is 14.7:1
Main Parts of Carburetor
 Types of Carburetor

Variable Venturi Type carburetor

A variable venturi varies the

venturi diameter at the depression
by raising or lowering an
obstruction. This obstruction is
called a slide.
 Types of Carburetor

Variable Venturi depression

Type carburetor
The depression at the
venturi is transmitted up
through the holes in the slide
to the closed chamber above
the diaphragm. This lowers
the density of the air in that
chamber.
 Types of Carburetor

Single Fixed venturi type

Carburetor

Double Fixed venturi type

Carburetor
 Gasoline Combustion Process
Chemical Reactions The combustion process involves the
chemical combination of oxygen (O 2 ) from the air (about 21%
of the atmosphere) with the hydrogen and carbon from the fuel.
In a gasoline engine, a spark starts the combustion process,
which takes about 3 ms (0.003 sec) to be completed inside the
cylinder of an engine.
The chemical reaction that takes place can be summarized as
follows:
H + C + O 2 + N + Spark = Heat + CO 2 + HC + NOX
 Gasoline Combustion Process
The air-fuel ratio is the proportion by weight of air and
gasoline that the injection system mixes as needed for engine
combustion. The mixtures, with which an engine can operate
without stalling, range from 8 to 1 to 18.5 to 1.

•These ratios are usually stated by weight, such as: 8 parts of

air by weight combined with 1 part of gasoline by weight (8:1),
which is the richest mixture that an engine can tolerate and
still fire reliably.
•18.5 parts of air mixed with 1 part of gasoline (18.5:1), which
is the leanest practical ratio. Richer or leaner air-fuel ratios
cause the engine to misfire badly or not run at all.
 Gasoline Combustion Process

Stoichiometric Air-fuel Ratio The

ideal mixture or ratio at which all
of the fuel combines with all of
the oxygen in the air and burns
completely is called the
stoichiometric ratio, a chemically
perfect combination. In theory,
this ratio for gasoline is an air fuel
mixture of 14.7 to 1.
Emission control is most efficient
with an air-fuel ratio between
14.65 to 1 and 14.75 to 1.
 Gasoline Combustion Process
Normal combustion occurs smoothly and progresses across the
combustion chamber from the point of ignition.
Normal flame-front combustion travels between 45 and 90 mph
(72 and 145 km/h).
The speed of the flame front depends on the air-fuel ratio,
combustion chamber design (determining amount of
turbulence), and temperature.

Normal combustion is a smooth, controlled burning of the air-fuel mixture.

 Gasoline Combustion Process
During periods of spark knock (detonation), the combustion
speed increases by up to 10 times to near the speed of sound.
The increased combustion speed also causes increased
temperatures and pressures, which can damage pistons, gaskets,
and cylinder heads.

Detonation is a secondary ignition of the air-fuel mixture. It is also called

spark knock or pinging.
 Gasoline Combustion Process
The octane number is one of the
measure to indicate the characteristics
of gasoline and represent the fuel’s
anti knock characteristics.
The higher the octane number, the
more compression the fuel can
withstand before detonating (engine
knocking). Higher the octane rating
cause slow burning.
Fuels with a higher octane rating are
used in high-compression engines that
generally have higher performance
 Gasoline Combustion Process
To increase the octane
number, some gasoline
contain lead, while others
are unleaded.

Because some engines are

designed to use leaded
gasoline, while others are
designed to use unleaded,
the proper type of gasoline
must be used.

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Fuel Supply System in Vehicle
Vehicle with EFI system
 Fuel Lines and Filter

Fuel and vapor lines made of

steel, nylon tubing, Fuel lines
supply fuel to the throttle body
or fuel rail. They also return
excess fuel and vapors to the
tank The fuel delivery system
supplies up to 60 PSI (414 kPa)
for multiport fuel-injection
systems Fuel Filter
 Fuel Lines and Filter
The pressure regulator and fuel
pump work together to maintain
the required pressure drop at the
injector tips. The fuel-pressure
regulator typically consists of a
spring-loaded, diaphragm-operated
valve in a metal housing. Fuel
pressure regulators on fuel-return-
type fuel-injection systems are
installed on the return
(downstream) side of the injectors
at the end of the fuel rail, or are
built into or mounted upon the
throttle body housing.
Fuel Rail

Injectors
 Injector

Fuel Rail
 Air Cleaner / Filter
Gasoline must be mixed with air to form a
combustible mixture. Air contains dirt and
other materials that cannot be allowed to
reach the engine. Just as fuel filters are used
to clean impurities from gasoline, an air
cleaner and filter are used to remove
contaminants from the air. The three main
jobs of the air cleaner and filter include.

1. Clean the air before it is mixed with fuel

2. Silence intake noise
3. Act as a flame arrester in case of a backfire
 Air Cleaner / Filter

Intake Manifold Throttle Body Duct Air Cleaner

 Electronic Fuel Injection System

The Electronic fuel system consist of

various engine sensors, Electronic Control
Unit (ECU), Fuel Injectors assembly, and
related wiring.

Sensors ECU Injectors

 Electronic Fuel Injection System

The ECU determines precisely how

much fuel needs to be delivered by
the injectors by monitoring the
engine sensors.

The ECU turns the injectors on for a

precise amount of time, referred to
as injection pulse width or injection
duration, to deliver the proper
air/fuel ratio to the engine.
 Electronic Fuel Injection System
The ECU determines the basic
injection quantity based upon
measured intake air volume and
engine rpm. Depending on engine
operating conditions, injection
quantity will vary. The ECU monitors
variables such as coolant
temperature, engine speed, throttle
angle. and exhaust oxygen content
and makes injection corrections
which determine final injection
quantity.
 Electronic Fuel Injection System
Air drawn in by the engine
Throttle Body Injection (TBI)
For many auto manufacturers, TBI
Throttle Body
served as a stepping stone from Fuel Supply

carburetors to more advanced

Throttle Valve
fuel injection systems.
Inlet Manifold
The throttle body unit is mounted
directly to the intake manifold.
The injector(s) spray fuel down
into a throttle body chamber
leading to the intake manifold.
The intake manifold feeds the air-
The Engine
fuel mixture to all cylinders.
Electronic Fuel Injection System
 Electronic Fuel Injection System
Air drawn in by the engine

Port Fuel Injection (PFI)

Inlet Manifold Throttle Valve
PFI systems use at least one
injector at each cylinder. They
are mounted in the intake
manifold near the cylinder Fuel
head where they can inject a Supply

fine, atomized fuel mist as Injectors

close as possible to the intake
valve

Engine
Electronic Fuel Injection System
 Electronic Fuel Injection System

A direct injection system

sprays high pressure fuel,
up to 2,900 PSI, into the
combustion chamber as
the piston approaches the
top of the compression
stroke
Electronic Fuel Injection System
 Electronic Fuel Injection System
Modern automotive control systems
consist of a network of electronic
sensors, actuators, and computer
modules designed.
The onboard automotive computer
has many names. It may be called an
electronic control unit (ECU),
electronic control module (ECM),
power control module (PCM), or a
controller, depending on the
manufacturer and the computer
application.
Electronic Fuel Injection System
 Sensors
Intake air temperature (IAT) sensor is to
provide the engine computer (PCM) the
temperature of the air entering the
engine. The IAT sensor information is
used for fuel control (adding or
subtracting fuel) and spark timing,
depending on the temperature of
incoming air.

Mass airflow (MAF) sensor. This sensor

measures the mass (weight and density)
of the air flowing through the sensor and
entering the engine.
 Sensors

MAP sensor. (Manifold Absolute

Pressure) This sensor detects
engine load by using a signal from a
sensor that measures the vacuum
in the intake manifold.

Throttle position (TP) sensor to

signal to the computer the position
of the throttle. The TP sensor
consists of a potentiometer, a type
of variable resistor.
 Sensors
Engine coolant temperature (ECT)
sensor. This sensor measures the
temperature of the engine coolant.
This is a sensor used for engine
controls and for automatic air-
conditioning control operation.

Oxygen sensor (O2S). This sensor

measures the oxygen in the
exhaust stream. There are as many
as four oxygen sensors in some
vehicles.
 Sensors

Knock sensors (KS) are used to

detect abnormal combustion, often
called ping, spark knock, or
detonation. Whenever abnormal
combustion occurs, a rapid pressure
increase occurs in the cylinder,
creating a vibration in the engine
block. It is this vibration that is
detected by the knock sensor
 Sensors

The camshaft position (CMP)

sensor monitors the position of
the camshaft . The CMP’s
output is used with the Crank
Position Sensor CKP to
determine when cylinder
number 1 is on its compression
stroke.
 IAC Idle Air Control

Port fuel-injection systems

generally use an auxiliary air
bypass to control idle speed. This
air bypass or regulator provides
needed additional airflow, and
thus more fuel.
 Injector Operation
EFI systems use a 12 volt solenoid-
operated injectors. This
electromagnetic device contains an
armature and a spring-loaded needle
valve or ball valve assembly. When
the computer energizes the solenoid,
voltage is applied to the solenoid coil
until the current reaches a specified
level. This permits a quick pull-in of
the armature during turn-on. The
injector opens the same amount each
time it is energized, so the amount of
fuel injected depends on the length of
time the injector remains open.
 Diesel Fuel System
The diesel engine uses heat created by
compression to ignite the fuel, so it
requires no spark ignition system. The
diesel engine requires compression
ratios of 16:1 and higher. Incoming air
is compressed until its temperature
reaches about 1,000°F (540°C). This is
called heat of compression. As the
piston reaches the top of its
compression stroke, fuel is injected
into the cylinder, where it is ignited by
the hot air.
 Diesel Fuel System
Cetane Number
The Cetane number for diesel fuel is
the opposite of the octane number for
gasoline. The cetane number is a
measure of the ease with which the
fuel can be ignited. The cetane rating
of the fuel determines, to a great
extent, its ability to start the engine at
low temperatures and to provide
smooth warm-up and even
combustion. The cetane rating of
diesel fuel should be between 45 and
50. The higher the cetane rating, the
more easily the fuel is ignited.
 Diesel Fuel System

Air-fuel Ratios
Diesel engines adjust their
air-to-fuel ratio depending
on how hard they are
working.
The air-fuel mixture of a
diesel can vary from as lean
as 85:1 at idle to as rich as
20:1 at full load.
Diesel Fuel System
 Diesel Fuel System

The diesel fuel is usually drawn from the fuel tank by a

separate pump, called a lift pump and delivers the fuel to
the injection pump. Between the fuel tank and the lift
pump is a water-fuel separator. Water is heavier than
diesel fuel and sinks to the bottom of the separator. Part
of normal routine maintenance on a vehicle equipped
with a diesel engine is to drain the water from the water-
fuel separator
Diesel Fuel System
 Diesel Fuel Tank

Diesel Fuel Tank

There are no evaporative
emission control devices or a
charcoal (carbon) canister.
Diesel fuel is not as volatile as
gasoline and, therefore, diesel
vehicles do not have evaporative
emission control devices.
 Diesel Fuel System

Pre-Filter/ Sedimentor
The fuel sedimentor separates
the water and large dirt particles
from the diesel fuel.

It uses the specific gravity

difference between the diesel
fuel and water to remove water.

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 Diesel Fuel System
Agglomerator
This should be mounted close to
the sedimentor.
They will retain more than 95% of
water contained in fuel, and hold
up to in the bowl.
It finely retains water droplets left
by sedimentor.
It offers efficient fuel filtration via a
paper filter element. Water is
collected in a clear glass base and
drained via a screw in plug, without
having to dismantle the unit.
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 Diesel Fuel System
Diesel engine injection pump is
used to increase the pressure
of the diesel fuel from very low
values from the lift pump to
the extremely high pressures
needed for injection. The fuel is
forced out of the injection port
to the correct injector nozzle
through the high-pressure line
 Diesel Fuel System

Diesel fuel injection pump

• Two types of fuel injection pump for diesel engines:

1. In line fuel injection pump.

2. Rotary fuel injection pump.

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 Diesel Fuel System
1. In-Line Injection Pump
• An Injection pump with a
separate cylinder and
plunger for each engine
cylinder.
• These elements are arrange
in a row. They are activated
by a camshaft on the in-line
pump which is driven by the
combustion engine via
control wheels or chains.

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 Unit 1.4a & 1.5a

Diesel Fuel System

Rotary fuel injection pump
The distributor-type pump uses a
vane-type transfer pump to fill
the single pumping element. This
then raises fuel pressure to
injection pressure. A distribution
system then distributes fuel to
each cylinder, in the firing order
of the engine.

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1 Fuel tank, 2 Fuel filter, 3 Distributor fuel-injection pump, 4
Nozzle holder with nozzle, 5 Fuel return line, 6 glow plug 7
Battery, 8 Glow-plug and starter switch, 9 Glow control unit.
 Diesel Fuel System
The subassemblies and their functions
1 Vane-type fuel-supply pump with pressure regulating valve:
Draws in fuel and generates pressure inside the pump.
2 High-pressure pump with distributor: Generates injection
pressure, delivers and distributes fuel.

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 Diesel Fuel System
The subassemblies and their functions
3 Mechanical (flyweight) governor: Controls the pump speed
and varies the delivery quantity within the control range.
4 Electromagnetic fuel shutoff valve: Interrupts the fuel supply.

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 Diesel Fuel System
The subassemblies and their functions
5 Timing device: Adjusts the start of delivery (port
closing) as a function of the pump speed and in part as a
function of the load.

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 Diesel Fuel System

Diesel engines can be very hard to

start when they are cold Most diesel
engines use small electric heaters
called glow plugs inside the cylinder
to heat the intake air and help ignite
fuel

starting. A glow plug is a heating

element that uses 12 volts from the
battery and aids in the starting of a
cold engine by providing heat to
help the fuel to ignite.
 Diesel Fuel System

Injectors
The injection pump delivers fuel
to the injector. As fuel pressure
rises, it acts on the needle valve,
eventually lifting it from its seat.

Highly-pressurized fuel enters

the engine in an atomized spray
at a high velocity.
Diesel Fuel Injector
 Diesel Fuel System
In an indirect injection
(abbreviated IDI) diesel
engine, fuel is injected into
a small prechamber, which
is connected to the cylinder
by a narrow opening.
The initial combustion takes
place in this prechamber.
This has the effect of
slowing the rate of
combustion, which tends to
reduce noise.
 Diesel Fuel System

Direct Injection
A direct injection diesel
engine injects the fuel
directly into the combustion
chamber. Many designs do
not use a glow plug.