FUEL SYSTEM FOR CARBURATTED ENGINES

In carburetted engines, the fuel system delivers and mixes gasoline with air before sending it to
the engine's combustion chamber for ignition.

Factors influencing Carburetion:

 Time available for the mixture preparation i.e. atomisation, mixing and the vaporisation.
 Temperature of the incoming air.
 Quality of the fuel supply.
 Design of combustion chamber and induction system.

Here are the key components of a carburetted engine's fuel system:

Fuel tank: Stores the gasoline.
Fuel lines: Transport the fuel from the tank to the rest of the system.
Fuel pump: Pushes the fuel from the tank to the carburettor. Mechanical pumps are often driven
by the engine's camshaft, while electric pumps use an electric motor.
Fuel filter: Removes impurities and contaminants from the fuel to prevent clogging and protect
engine components.

Simple Carburettor
It consists of a fuel jet of small diameter placed in a constricted tube called Venturi or choke
tube, float chamber as shown in the figure. The fuel pump delivers fuel from the fuel tank to the
float chamber. When sufficient fuel enters the float chamber, the float is lifted due to buoyancy
and the conical needle valve engages and thus shuts off the fuel supply. If the fuel level tends to
fall the float drops and thereby opens needle valve thus admitting more fuel. The float chamber
vented to atmosphere a small hole, so that the pressure on the surface of the fuel remains constant
and equal to that of atmosphere.
At the throat of the Venturi tube area of the cross section is minimum, where the fuel discharge
jet is situated. Air thus inducted increases its velocity from inlet and becomes maximum at the
throat whereas pressure at the throat is below atmospheric. Due to the pressure difference of fuel,
the fuel is forced out of the jet where it mixes with high velocity air and atomized and finally
passed through the engine via throttle valve.

Simple Carburettor
Drawbacks of Simple Carburettor
1. At low loads throttle valve is partially open, so the mixture is lean whereas engine requires rich
mixture at low loads.
2. At high load throttle valve is fully open that leads to maximum air flow. However engine
requires the rich mixture at high load.
3. The simple carburettor cannot enrich the mixture during engine start and warm-up.
4. The simple carburettor cannot adjust to change in altitude.

Modern Carburettor
The heart of the system, mixing fuel and air to create a combustible mixture, according to the
Engineering Choice. Key parts of a modern carburettor include:
 Float chamber: A reservoir that maintains a constant fuel level for consistent supply.
 Float: A hollow component (often made of plastic or brass) that floats on the fuel in the float
chamber and controls the fuel inlet valve.
 Needle valve (or float valve): Works with the float to regulate the flow of fuel into the float
chamber, closing when the fuel reaches the desired level and opening as it's consumed.
 Venturi: A narrowing in the carburettor’s air passage that speeds up airflow and creates a
vacuum, drawing fuel into the airstream.
 Main jet and idle jet: Small orifices that regulate the flow of fuel into the venturi, controlling
the fuel-air mixture at different engine speeds and loads.
 Throttle valve: Controls the amount of air and fuel mixture entering the engine cylinders,
affecting engine speed.
 Choke valve: Restricts airflow into the carburettor during cold starts, creating a richer fuel
mixture to aid combustion.
 Accelerator pump: Delivers a brief burst of extra fuel when the throttle is opened quickly to
compensate for the lag in fuel delivery.
 Inlet manifold: Distributes the air-fuel mixture evenly to each cylinder.
 Hot spot: A heated area (often on the intake manifold) that aids in vaporizing the fuel for
more efficient combustion.
 Air cleaner: Filters incoming air, removing dust and other contaminants before the air enters
the carburettor.

Fuel supply methods

 Gravity feed: The fuel tank is placed higher than the carburettor, allowing gravity to deliver
the fuel.
 Pressure feed/Pump system: A fuel pump is used to lift fuel from the tank to the carburettor.
This is the more common method in modern vehicles, offering flexibility in tank placement.
Drawbacks of Morden Carburettor
1. Improper mixture proportion in multi-cylinder engine.
2. Surging when carburettor is tilted or during acrobatics in aircraft.
3. Loss of volumetric efficiency due to obstruction of flow of mixture from choke tubes, jets,
throttle valve etc.
4. Freezing at low temperature.
5. Wear of carburettor parts.
6. Backfiring in fuel pipe line.

FUEL INJECTION SYSTEM

The purpose of the fuel injection system is to deliver fuel into the engine cylinders, while
precisely controlling the injection timing, fuel atomization, and other parameters.

Fuel Injection System in SI Engine

To avoid above problem of modern carburettor, fuel is injected in SI Engine just like Diesel
Engine. The System is getting more popular on Morden vehicles with multi cylinder engine.
Petrol injected during the suction stroke in the intake manifold at low pressure.
There are two types of fuel injection system used in SI engine:
1. Mechanical Fuel Injection System
2. Electronic Fuel Injection System
Due to complexity in design, mechanical fuel injection systems have been suppressed by
electronic fuel injection systems (EFI) in modern days.
The EFI Systems are of two types mentioned below.

I. SINGLE POINT THROTTLE BODY INJECTION

Electronically controlled Injector meters the fuel and injects into the air flow. The Injector meters
the fuel based on intake manifold pressure, air temperature and engine speed. Disadvantage of
this system is unequal distribution of fuel in each cylinder, deposit of fuel particles on the wall of
intake manifold and less power.

II. MULTI POINT FUEL INJECTION SYSTEM (MPFI)

In this system an electrically driven fuel pump draws fuel from fuel tank and supplies it to a
common header or tube. A pressure regulator fitted at the end maintains a constant pressure of
fuel approx. 3 bars in the header.
The header is connected to different branches of inlet manifold through fuel injectors. For each
cylinder of engine there is separate fuel injector which injects fuel in the corresponding air
passage of that cylinder. Due to this the system is called multi-point fuel injection (MPFI)
system.
The fuel injectors are precision built solenoid valves having single or multiple orifices. Due to
constant pressure of fuel maintained in the common header, the quantity of fuel injected depends
only on the time period for which the solenoid valve type fuel injectors are kept in open
position.
An on-board ECU (Electronic control unit) i.e. microprocessor controls the quantity of fuel
injected to each cylinder individually and also the ignition timing of each cylinder.
The data input to the ECU comes from a number of sensors located all over the engine. These
sensors collect the following data continuously.

1. Ambient temperature
2. Inlet manifold vacuum or Air Velocity
3. Exhaust gases temperature
4. Exhaust O2 content
5. Throttle position
6. Engine r.p.m.
7. Crankshaft & position
8. Engine coolant temperature

Based on programmed interpretation or processing of this data, ECU calculates the amount of
fuel needed to maintain stoichiometry i.e. air/fuel ratio of 14.7:1 and converts it into required
pulse width i.e. time period for which it keeps the solenoid injector energized.
ECU also gives command to spark ignition system. In this way ECU ensures overall
satisfactory performance of the engine from start to shut down including emission control by
sending right quantity and quality of fuel air mixture to each cylinder of engine at right time
based on requirement of engine and also ignites it at right time.

MPFI (Electronic fuel injection system)

Engine Sensors
In order to provide the correct amount of fuel for every operating condition, the engine control
unit (ECU) has to monitor a huge number of input sensors. Here are just a few-
Mass airflow sensor - Tells the ECU the mass of air entering the engine.
Oxygen sensor(s) - Monitors the amount of oxygen in the exhaust so the ECU can determine
how rich or lean the fuel mixture is and make adjustments accordingly
Throttle position sensor - Monitors the throttle valve position (which determines how much
air goes into the engine) so the ECU can respond quickly to changes, increasing or decreasing the
fuel rate as necessary.
Coolant temperature sensor - Allows the ECU to determine when the engine has reached its
proper operating temperature Voltage sensor - Monitors the system voltage in the car so the ECU
can raise the idle speed if voltage is dropping (which would indicate a high electrical load).
Engine speed sensor - Monitors engine speed, which is one of the factors used to calculate the
pulse width

Advantage of Electronic Fuel injection over carburettor:-

Better atomization of fuel
Lower emission of pollutant
Better flow due to elimination of venture
Rapid response time with respect to the changes
Improved fuel efficiency
I guess this explains MPFI system in sufficient detail.

Advantages of multi point fuel injection system

The multi-point fuel injection technology improves fuel efficiency of the vehicles. MPFI uses
individual fuel injector for each cylinder, thus there is no gas wastage over time. It reduces the
fuel consumption and makes the vehicle more efficient and economical.
The vehicles with MPFI automobile technology have lower carbon emissions than a few
decades old vehicles. It reduces the emission of the hazardous chemicals or smoke, released when
fuel is burned. The more precise fuel delivery cleans the exhaust and produces less toxic by-
products. Therefore, the engine and the air remain cleaner.
MPFI system improves the engine performance. It atomizes the air in small tube instead
additional air intake, and enhances the cylinder-to-cylinder fuel distribution that aid to the engine
performance.
It encourages distribution of more uniform air-fuel mixture to each cylinder that reduces the
power difference developed in individual cylinder.
The MPFI automobile technology improves the engine response during sudden acceleration
and deceleration.
The MPFI engines vibrate less and don‘t require to be cranked twice or thrice in cold
weather.
It improves functionality and durability of the engine components.
The MPFI system encourages effective fuel utilization and distribution. .

Other benefits of MPFI

Smooth operations and drivability
Reliability
Competent to accommodate alternative fuels
Easy engine tuning
Diagnostic capability
Initial and maintenance cost

Fuel injection system in CI Engine

In Diesel engine fuel injection system is implemented to inject a definite quantity of fuel at the
desired time and a definite rate into the combustion chamber.

Requirements of diesel injection system:

 Fuel must introduce precisely defined period of cycle.

 Good atomisation of fuel.
 Good spray pattern for rapid mixing of fuel and air.
 Distribution of fuel in multi-cylinder should uniform.
 No dribbling and after injection of fuel i.e. Sharp injection.
 Rate of injection meet desired heat release pattern.
 Quantities of fuel meet changing speed and load condition.
 Injection timing suits the speed and load requirements.

Types of diesel injection System

I. Air Injection System

 Injecting Air along with liquid fuel.
 Fuel supplied through camshaft driven fuel pump.
 Fuel valve is also connected with high pressure airline to inject into cylinder.
 Multi-stage compressor which supply air at a pressure of about 60 to 70 bar.
 Blast air sweeps the fuel along with it.
 Good atomisation results in good mixture formation and hence high mean effective pressure.
 Heavy and viscous fuels are used.
 Fuel pump require small pressure.
 Complicated due to compressor arrangement and expensive.
 Bulky engine and low bhp.
 Overheating and burning of valve seat.

II. Solid Injection System

 Fuel directly injected to combustion chamber without primary atomisation termed as solid
injection.
 Also known as airless mechanical injection.
 2 units-pressurise and atomising unit.

COMMON RAIL FUEL INJECTION SYSTEM FOR CI ENGINES

In this system of diesel injection, a common rail diesel injection (CRDI) technology is used. It
is more or less same as Common Rail System of Mechanical Injection but the difference comes in
the control over metering & timing of injectors which is done by an on-board computer system or
electronic control unit. Thus it resembles with the operation of MPFI system of S.I engine.
The basic system is same; there is a high pressure fuel pump which maintains high pressure in
a common rail (steel tube) through high pressure regulator. But here the pressure maintained is
very high of the order of 2000 bar as compared to 3-5 bars in MPFI system. The fuel injectors are
very special either solenoid type or piezzo-electric type which control the fuel injection from
common rail to each cylinder very precisely.
The opening time, pulse width etc. of fuel injectors can be electrically controlled by the E.C.U.
Here is the main advantage of system that the fuel can be injected in more than one pulse in a
very controlled manner unlike only one pulse or one injection per cycle in the mechanical
system.
Here a pilot injection is done before the main injection for fast burning and less ignition delay
of the fuel. It reduces the noise level very much and also ensures complete burning of fuel, high
efficiency, low emission and good cold start.
This new technology has considerably removed the demerits of diesel engines like high noise
level, high pollution, difficulty in starting etc. and improved fuel efficiency a lot. A schematic
diagram of CRDI system is given here in fig.
The CRDI technology works in tandem with the engine ECU which gets inputs from various
sensors. It then calculates the precise quantity of fuel and timing of injection. The fuel system
features components which are more intelligent in nature and controls them electrically /
electronically. Additionally, the conventional injectors are replaced with more advanced,
electrically operated, solenoid injectors. They are opened by an ECU signal, depending upon the
variables such as engine speed, load and engine temperature etc.
A Common Rail system uses a common-for-all-cylinders ‘fuel-rail or in simple words a 'fuel
distribution pipe'. It maintains optimum residual fuel pressure and also acts as a shared fuel
reservoir for all the injectors. In the CRDI system, the fuel-rail constantly stores and supplies the
fuel to the solenoid valve injectors at the required pressure. This is quite opposite to the fuel
injection pump supplying diesel through independent fuel lines to injectors in case of earlier
generation (DI) design.

Components of Common Rail Direct Injection System

1. High Pressure Fuel Pump
2. Common Fuel Rail
3. Injectors
4. Engine Control Unit

The working principle of Common Rail Direct Injection

A high-pressure pump supplies pressurized fuel. The pump compresses the fuel at the
pressures of about 1,000 bar or about 15,000 psi. It, then, supplies the pressurized fuel via a high-
pressure pipe to the inlet of the fuel rail. From there, the fuel-rail distributes the fuel to individual
injectors which then inject it into the combustion chamber.
Most modern CRDI engines use the Unit-Injector system with Turbocharger which increases
power output and meets stringent emission norms. Additionally, it improves engine power,
throttle response, fuel efficiency, and controls emissions. Barring some design changes, the basic
principle & working of the CRDi technology remains primarily the same across the board.
However, its performance depends mainly on the combustion chamber design, fuel pressures and
the type of injectors used.

Advantages 
1. Lower Emissions – One of the reasons that common rail diesel engines were invented by
vehicle manufacturers was because the government created stricter regulations on carbon
emissions. This is better for the environment and is one step closer to fighting global warming.
2. More Power – Studies have shown that vehicles with a common rail diesel engine will
produce 25% more power than a traditional diesel engine. This means the overall performance of
the diesel engine will be improved.
3. Less Noise – Direct fuel injection systems were known for being noisy while driving. The
common rail will reduce a lot of the noise that you might remember hearing. This makes it a more
pleasant driving experience for you and those around you on the road.
4. Fewer Vibrations – There used to be a lot of vibrations felt in traditional direct fuel diesel
engines. Now those vibrations have been reduced with the common rail direct injection system.
5. Better Mileage – Since the common rail diesel engine provides more power, that means you
will get better mileage on your fuel. As a result, your fuel economy will be better as well. This
means less money spent on fuel when you‘re on the road.

Disadvantages
1. Expensive Vehicle – Vehicles with a common rail diesel engine are going to be more
expensive than those with the traditional diesel engine.
2. Expensive Parts – Since the common rail vehicles are more expensive, you can expect that
replacement parts are going to be expensive as well.
3. More Maintenance – Common rail diesel engines will need more maintenance than a
traditional diesel engine. Even if you do the maintenance yourself, it still takes more time, effort,
and possibly expense.

The common rail diesel engine is certainly an advancement in diesel technology that will
eventually replace the traditional direct injection system altogether. Perhaps when this new
technology becomes more common in every diesel-powered vehicle, then it will become less
expensive. Until then, you will be making an investment into an engine that gives you better
performance, better mileage, better driving experience, and promotes an environmentally
friendlier agenda.

Fuel Injector
Mainly there having 3 types of fuel injectors, namely:
A. Blast injector:
These are superseded by mechanically operated injectors used in air injection system.

B. Mechanically operated injector:

Consist of a set of camshaft, cams and rocker gear and other cams for controlling the timing of
the fuel injection

C. Automatic injector:
Consists of spring loaded needle valve and operated hydraulically by the pressure of fuel
Quantity of fuel is metered by the fuel pump