Automotive

Fundamentals Overview
 Module-1 Content Date Executed
Sl No Topic Date of planned
1 Automotive Fundamentals
Overview: Four Stroke Cycle,
Engine Control
2 Ignition System, Spark Plug
3 Spark Pulse generation, Ignition
Timing
4 Drive Train, Transmission
5 Brakes, Steering System
6 Batteries
7 Starting System
8 Air Fuel Systems; Fuel Handling

9 Air Intake System

10 Air Fuel Management
Automobile Physical Configuration
These systems include the following:

1. Engine
2. Drivetrain (transmission, differential, axle)
3. Suspension
4. Steering
5. Brakes
6. Instrumentation
7. Electrical/electronic
8. Motion control
9. Comfort/convenience
10. Entertainment/communication/navigation
 Components of IC Engine
The major components of the engine include the following:
• 1. Engine block
• 2. Cylinder
• 3. Crankshaft
• 4. Pistons
• 5. Connecting rods
• 6. Camshaft
• 7. Cylinder head
• 8. Valves
• 9. Fuel control system
• 10. Ignition system
• 11. Exhaust system
• 12. Cooling system
Parts of IC engine
 Engine Block
• Mechanical power is produced by combustion
of Gasoline inside the cylinder in the engine
block.
• Consist of Piston and crankshaft
 Engine Block
• The cylinders are cast in the engine block and
machined to a smooth finish.
• The pistons fit tightly into the cylinder and have
rings that provide a tight sliding seal against the
cylinder wall.
• The pistons are connected to the crankshaft by
connecting rods, as shown in Figure .
• The crankshaft converts the up and down motion
of the pistons to the rotary motion needed to drive
the wheels.
 Cylinder Head
• The cylinder head contains an intake and exhaust valve for each
cylinder.
• When both valves are closed, the head seals the top of the cylinder
while the piston rings seal the bottom of the cylinder.
• During combustion – high pressure is developed and give force to
piston and it create torque on crankshaft.
• The camshaft rotates at exactly half the crankshaft speed because a
complete cycle of any cylinder involves two complete crankshaft
rotations and only one sequence of opening and closing of the
associated intake and exhaust valves.
• The valves are normally held closed by powerful springs. When the
time comes for a valve to open, the lobe on the cam forces the
pushrod upward against one end of the rocker arm.
• The other end of the rocker arm moves downward and forces the
valve open.
Valve Operating Mechanism
 Valve actuation

A complete mechanism is involved in actuating the inlet and

exhaust valves (opening & closing) through the motion of
different components come in valve train. A cam is used as a
drive to actuate the valve and this cam rotates at half of the
speed of crankshaft in a four stroke engine. Following are the
various components of valve train.
i) Camshaft
ii) Tappet
iii) Push rod
iv) Rocker arm
v) Valves
 Four Stroke Cycle

1.Intake
2. Compression
3. Power
4. Exhaust
 Intake Stroke
• The intake event is when the air-fuel mixture is introduced
to fill the combustion chamber. The intake event occurs
when the piston moves from TDC to BDC and the intake
valve is open.
• The movement of the piston toward BDC creates a low
pressure in the cylinder. Ambient atmospheric pressure
forces the air-fuel mixture through the open intake valve
into the cylinder to fill the low pressure area created by the
piston movement.
• The cylinder continues to fill slightly past BDC as the air-
fuel mixture continues to flow by its own inertia while the
piston begins to change direction.
• The intake valve remains open a few degrees of crankshaft
rotation after BDC. Depending on engine design. The intake
valve then closes and the air-fuel mixture is sealed inside
the cylinder.
 Compression Stroke
• The compression stroke is when the trapped air-fuel
mixture is compressed inside the cylinder. The
combustion chamber is sealed to form the charge.
• The charge is the volume of compressed air-fuel
mixture trapped inside the combustion chamber ready
for ignition. Compressing the air-fuel mixture allows
more energy to be released when the charge is ignited.
• Intake and exhaust valves must be closed to ensure that
the cylinder is sealed to provide
compression. Compression is the process of reducing or
squeezing a charge from a large volume to a smaller
volume in the combustion chamber.
• The flywheel helps to maintain the momentum
necessary to compress the charge.
 Power Stroke
• The power stroke is an engine operation Stroke in
which hot expanding gases force the piston head
away from the cylinder head.
• Piston force and subsequent motion are
transferred through the connecting rod to apply
torque to the crankshaft.
• The torque applied initiates crankshaft rotation.
The amount of torque produced is determined by
the pressure on the piston, the size of the piston,
and the throw of the engine.
• During the power Stroke, both valves are closed.
 Exhaust Stroke
• The exhaust stroke occurs when spent gases
are expelled from the combustion chamber and
released to the atmosphere.
• The exhaust stroke is the final stroke and
occurs when the exhaust valve is open and the
intake valve is closed. Piston movement
evacuates exhaust gases to the atmosphere.
 Engine Control

Control of the engine in any car means regulating the power that it
produces at any time in accordance with driving needs.

The driver controls engine power via the accelerator pedal, which,
in turn, determines the setting of the throttle plate via a mechanical
linkage system.
The throttle plate is situated in the air intake system (Figure). The
intake system is an assembly of pipes or passageways through
which the air flows from outside into each cylinder.
The air flowing into the engine flows past the throttle plate, which,
in fact, controls the amount of air being drawn into the engine
during each intake stroke.
Intake Manifold and Fuel Metering
• The power produced by the engine depends on
fuel being present in the correct proportions.
• Air combines with fuel in the fuel metering
device.
• This device automatically delivers fuel in the
correct amount as determined by the air flow.
• The classic fuel metering device was the
carburettor,
 Ignition System in Gasoline Engine

1. Spark plug

2. High voltage circuit and distribution

3. Spark pulse generation

 Ignition System
• To produce power, the gasoline engine must not
only have a correct mixture of fuel and air, but
also some means of initiating combustion of the
mixture.
• Essentially the only practical means is with an
electric spark produced across the gap between a
pair of electrodes of a spark plug.
• The electric arc or spark provides sufficient
energy to cause combustion.
• This phenomenon is called ignition
• The spark must persist for a period of about a
millisecond
• The ignition system itself consists of several
components:
1. the spark plug,
2. one or more pulse transformers (typically called
coils),
3. timing control circuitry,
4. distribution apparatus that supplies the high-
voltage pulse to the correct cylinder.
1. Spark plug
• The spark is produced by applying a high-
voltage pulse of from 20 kV to 40 kV between
the centre electrode and ground.
• The actual voltage required to start the arc
varies with the size of the gap, the
compression ratio, and the air–fuel ratio.
• The spark plug consists of a pair of electrodes,
called the centre and ground electrodes,
separated by a gap.
2. High voltage circuit and distribution
• The high-voltage pulse is generated by inductive
discharge of a special high-voltage transformer
commonly called an ignition coil.
• The distribution of high-voltage pulses was
accomplished with a rotary switch called the
distributor
• The centre electrode is mechanically driven by the
camshaft (via gears) and rotates synchronously at
camshaft speed (i.e., one-half of crankshaft speed).
3. Spark Pulse Generation
• The actual generation of the high-voltage pulse is
accomplished by switching the current through
the primary circuit (see Figure).
• The mechanism in the distributor of a traditional
ignition system for switching the primary circuit
of the coil consists of opening and closing the
breaker points (of a switch) by a rotary cam in the
distributor (explained later).
• During the intervals between ignition pulses (i.e.,
when the rotor is between contacts), the breaker
points are closed (known as dwell).
• Current flows through the primary of the coil, and
a magnetic field is created that links the primary
and secondary of the coil.
• At the instant the spark pulse is required, the breaker
points are opened.
• This interrupts the flow of current in the primary of the
coil and the magnetic field collapses rapidly.
• The rapid collapse of the magnetic field induces the
high voltage pulse in the secondary of the coil.
• This pulse is routed through the distributor rotor, the
terminal in the distributor cap, and the spark plug wire
to the appropriate spark plug.
• The capacitor absorbs the primary current, which
continues to flow during the short interval in which the
points are opening, and limits arcing at the breaker
points.
 4. Ignition Timing
• Ignition occurs some time before top dead
centre (BTDC) during the compression
stroke of the piston.
• This time is measured in degrees of
crankshaft rotation BTDC.
• For a modern SI engine, this timing is
typically 8 to 10 degrees for the basic
mechanical setting with the engine running
at low speed (low rpm).
• This change in ignition timing is called spark
advance.
• That is, spark advance should increase with
increasing engine rpm.
• In a conventional ignition system, the
mechanism for this is called a centrifugal
spark advance.
 DRIVETRAIN

• The engine drivetrain system of the

automobile consists of the;
Engine, transmission, drive shaft,
differential and driven wheels.
 Transmission

• The transmission is a gear system that adjusts the ratio of

engine speed to wheel speed.
• It provides a gear ratio between the engine speed and
vehicle speed such that the engine provides adequate
power to drive the vehicle at any speed.
• To accomplish this with a manual transmission, the driver
selects the correct gear ratio from a set of possible gear
ratios (usually three to five for passenger cars).
• An automatic transmission selects this gear ratio by
means of an automatic control system.
• Most automatic transmissions have three forward gear
ratios, although a few have two and some have four.
• The proper gear ratio is actually computed in
the electronic transmission control system.
• Automatic transmissions have three forward
gear ratios, although a few have two and some
have four.
To summarise, torque converter are used
in automatic transmission for automatic
decoupling between engine & transmission
and also because of its torque
multiplication advantage.
• A planetary gearbox is a gearbox with the input shaft and the
output shaft aligned. A planetary gearbox is used to transfer the
largest torque in the most compact form (known as torque
density).
• For a three-speed hub, a one-stage planetary gear system is used,
for a five-speed hub a 2-stage. Each planet gear system has a
reduction state, a direct coupling and an acceleration mode.
• In mathematical terms, the smallest reduction ratio is 3: 1, the
largest is 10: 1. At a ratio of less than 3, the sun gear becomes too
big against the planet gears. At a ratio greater than 10 the sun
wheel becomes too small and the torque will drop. The ratios are
usually absolute i.e. an integer number.
Torque Convertor
• Config: Fluid coupling mechanism- Torque Convertor.
• Semi toroidal Shape-donut
• 2 toroid's.
• Two vanes in axial plane
• Other vanes fixed in frame connected to reactor
• Structure filled with hydraulic fluid(Transmission fluid).
Gear
• Inner gear- sun gear
• Three gear-cage gear
• Third- Ring gear
 Drive Shaft

• It is used on front-engine, rear wheel drive

vehicles to couple the transmission output shaft
to the differential input shaft.
• Flexible couplings, called universal joints, allow
the rear axle housing and wheels to move up and
down while the transmission remains stationary.
• In front wheel drive automobiles, a pair of drive
shafts couples the transmission to the drive
wheels through flexible joints known as constant
velocity (CV) joints.
Differential
• It has three purposes;
• The most obvious is the right angle transfer of the
rotary motion of the drive shaft to the wheels.
• The second purpose is to allow each driven wheel
to turn at a different speed. This is necessary
because the “outside” wheel must turn faster
than the “inside’’ wheel when the vehicle is
turning a corner.
• The third purpose is the torque increase
provided by the gear ratio.
• In front wheel drive cars, the transmission
differential and drive shafts are known
collectively as the transaxle assembly.
 SUSPENSION

• Is the mechanical assembly that connects each wheel

to the car body.
• the wheel assembly is connected through a movable
assembly to the body.
• The weight of the car is supported by springs. In
addition, there is a so-called shock absorber which is in
effect a viscous damping device.
• The mass of the car body is called the sprung mass,
that is, the mass that is supported by springs.
• The mass of the wheel assemblies at the other end of
the springs is called unsprung mass.
• The proportionality constant is known as the
spring rate.
 BRAKES

• Brakes are as basic to the automobile as the

engine drive train system and are responsible
for slowing and stopping the vehicle.
• Most of the kinetic energy of the car is
dissipated by the brakes during deceleration
and stopping
• Two major types of conventional automotive
brakes: drum and disc brakes.
• Drum brakes are an extension of the type of
brakes used on early cars and horse drawn
wagons.
• Increasingly, automobile manufacturers are
using disk brakes.
• Disk brakes are illustrated in Figure. A flat disk
is attached to each wheel and rotates with it
as the car moves.
• A wheel cylinder assembly (often called a
calliper) is connected to the axle assembly.
• A pair of pistons having brake pad material are
mounted in the calliper assembly and are
close to the disk.
Braking System:
• Required for slowing down or stopping a moving vehicle
• May be operated mechanically or hydraulically
• Components:- Brake pedal, master cylinder, wheel cylinders,
brake drum, brake pipe, brake shoes and linkages
STEERING SYSTEM
• A gear mechanism, which is known as steering gear, is used in
this system to increase the steering effort provided by the
driver.
• It is one of the major automotive subsystems
required for operation of the car.
• It provides the driver control of the path of
the car over the ground.
• Steering functions by rotating the plane of
the front wheels in the desired direction of
the turn.
• The angle between the front wheel plane and
the longitudinal axis of the car is known as the
steering angle.
• Angle is proportional to the rotation angle of
the steering wheel.
 Starter Batteries
• The starter battery is an electrochemical storage
facility for the excess electrical energy that is
generated by the alternator while the engine is
running.
• This stored energy is needed during vehicle operation
in the phases when the energy required by the active
consumers is greater than the energy that is generated
by the alternator
Function and requirements:
• The starter battery is the electrical energy storage
facility in the vehicle electrical system.
• It has the following tasks:
▶ Provide electrical energy for the starter
▶ Compensate for the deficit between generation and
consumption if the vehicle electrical system is not
being supplied with an adequate amount of energy
by the alternator (e.g. at idle speed or if the
engine is stopped)
▶ Damping of voltage peaks from the vehicle system
voltage to protect sensitive electronic and electrical
components
Classification
Starter batteries can be subdivided into two types:
▶ Closed batteries:
• These are batteries with freely moving electrolytes in
which any gas that builds up can escape through holes
in the cover. The vast majority of all starter batteries
are closed batteries.
▶ Sealed batteries:
• These batteries only allow gas to escape if the pressure
in the battery exceeds a certain value. The battery
cannot be topped up with sulfuric acid. The electrolyte
is fixed, i.e. it is not freemoving.
• With regard to maintenance, starter batteries
are categorized into;

▶ Conventional and low-maintenance

batteries

▶ Maintenance-free batteries
 Starting System
• Internal-combustion engines must be cranked by a
starter at a minimum speed before they can supply
sufficient energy in sustained operation from the
combustion cycles to cover the momentary
requirements for the compression and gas exchange
cycles.
• When an engine is first started, the bearing surfaces
are not adequately lubricated so that high levels of
friction have to be overcome when cranking the
engine.
• The electrical direct current series motor is
particularly suitable as a starter motor, as it develops
the high initial torque required to overcome the
engine’s initial resistance to rotation and to accelerate
the masses in the engine.
• The energy required for starting is generally drawn
from the battery, which also supplies other electrical
components in the vehicle electrical system.
• The torque from the starter is more often than not
transferred by way of a pinion and a ring gear on the
engine, but in some cases a V-belt, toothed belt or
chain is used, or it is applied directly to the
crankshaft.
 Classification of Automobile Engines
• Based on Number of cylinders
Single Cylinder: Vertical or Horizontal
Multi Cylinder: Vertical or Inclined

• Based on Cylinder Arrangement

Inline Cylinder Engine: All the cylinders arranged in one straight
line, each cylinder has an independent crank
V Cylinder engine: Two cylinders inclined at 90o to each other.
Connecting rods are connected to a common crank pin. There is
common crank for both cylinders
• Based on Valve arrangement in Cylinder Head assembly
T-Head Engine: The suction valve and the exhaust valve are on the
cylinder block in opposite direction
F-Head Engine: One valve is in the cylinder block and the other
valve in the cylinder head
L-Head Engine: Suction and Exhaust valves are arranged side by side in
the cylinder block

I Head Engine:

Overhead Engine: Cylinder head has a hemispherical shape, suction

and exhaust valves are arranged in the cylinder head.
• Cooling Methods:
Air cooled engines: Have fins to radiate heat into the
surrounding air.
Water cooled engines: Fitted with radiators. Radiator offers
resistance to the flow of air through the passages in between
the small diameter tubes carrying hot water. An induced
draught fan provided at the back of the radiator. Water pump
is provided which draws water from the radiator and forces it
into the water jacket of the engine
• Based on Fuel used:
Gasoline Engine
Diesel Engine

• Based on Mechanical cycle:

Two stroke cycle engine
Four stroke cycle engine
Conventional Two Stroke Engine
• Based on Ignition System:
-Spark Ignition Engine: Electrical energy required to produce
spark in the spark plug is obtained either from a battery.
-Compression Ignition Engine

• Based on Lubrication Systems:

Petrol Lubrication systems - 2 stroke gasoline engine
Wet pump lubrication system
Dry pump lubrication system
Merits of Vertical Engine

• Lubrication

• Weight of the piston does not wear the cylinder liner during
motion.

Demerits of Vertical Engine

• Vertical vibrations to the vehicle chassis frame, which can be

felt by the passengers sitting in the vehicle.

• The foundation bolts may get fatigue failure.

Merits of Horizontal Engine

• Driving impulse is obtained from the engine.

• Engine having horizontal stroke tends to push forward the

moped or the scooter by its impulsive forces.

Demerits of Horizontal Engine

• crankcase cannot be used for storing lubricating oil for splash

lubrication..

• Causes excessive wear at lower side of piston & cylinder liner.

• More consumption of lubricating oil

Merits of Two-Stroke Cycle Engines
• Two-stroke cycle engines are compact and occupy less space
for the same output.
• A lighter flywheel is required in a two-stroke cycle engine.
• Its weight to power ratio is less.

Demerits of Two-Stroke Cycle Engines

• Its specific fuel consumption is more, i.e. it consumes more
fuel per horsepower
• A two-stroke cycle engine runs at higher temperature because
of poor cooling.
Merits of Four-Stroke Cycle Engines
• The specific fuel consumption of a four-stroke cycle engine is less, i.e. it
gives better economy in fuel consumption.
• It can be supercharged.
• It runs cooler because it gets sufficient time (three strokes, i.e. 5400 crank
rotation) for cooling thus preventing detonation.

Demerits of Four-Stroke Cycle Engines

• The weight to power ratio of a four-stroke cycle engine is greater than a
two-stroke cycle engine.
• It needs a heavier flywheel to minimise fluctuations in cyclic speed.
• It occupies more space because it has a larger cylinder diameter for the
same output (power).
Fuel System for
Petrol Engine
 Introduction
• In a petrol engine (gasoline engine), the combustible
mixture of air and petrol is prepared outside the
cylinder.
• A petrol engine needs a richer mixture while starting
and a leaner (weaker) mixture while normal running.
• Such requirements of a petrol engine must be fulfilled
before the charge (air-fuel mixture) enters the cylinder.
FUEL SYSTEM FOR PETROL ENGINE
• Fuel Tank: Petrol is stored in a tank
• Fuel gauge: To indicate quantity of petrol available in the
fuel tank. [ battery-operated, Placed away from the fuel
tank]
• Fuel Pump & filter: Either operated mechanically or
electrically. It maintains constant petrol pressure in the
float chamber attached to a carburettor.
• Fresh air from the atmosphere enters the carburettor
where air mixes with fuel and forms a combustible mixture.
• The air filter traps or arrests dust particles which are
suspended in atmospheric air.
• when the fuel tank is full with petrol, pressure on the
float is greater than the pressure when the tank is
not full.
• float valve is pushed down with greater force and
more fuel (petrol) enters the float chamber.

When the fuel tank is full

with petrol, the carburettor
supplies richer mixture
and, it supplies leaner
mixture when reserved
petrol is left in the fuel
tank.
Simple carburetor
• Car is going up a Gradient. Due to the load on the
engine its speed is decreased. This means that the
rate of flow of air through the venturi is decreased
and the carburettor supplies a weaker mixture,
whereas the engine needs a richer mixture to develop
more power to go up the hill.

• Car is descending the hill. Since there is no load or the

load is decreased, the engine runs faster and this
increases the rate of flow of air through the venturi.
This action in the venturi increases depression and
pulls more fuel. Air density decreases, which makes
mixture richer, developing more power. But engine
needs weaker mixture because there is no load on the
engine
 Throttle Valve

• The throttle valve controls the quantity of charge

passing to the engine cylinder, means the engine
speed is controlled by operating the throttle valve.
• Operation of the throttle valve only controls the
flow area and not the air-fuel ratio. It is the venturi
depression (Vh) which controls the air-fuel ratio
and also affects air density which is responsible for
the preparation of a leaner mixture or a rich
mixture in the carburettor.
• It can be concluded that a simple carburettor working
satisfactorily for throttle opening 'x‘ fails to supply the
required mixture when:
✓ Vehicle is going up hill.
✓ Vehicle is going down hill.
✓ Vehicle is not moving but the engine is running
(idling of the engine).

• It is difficult to start a petrol engine with a simple

carburettor.
• Hence a mechanical control device or a suction control
device is used to overcome this limitation.
 Fuel injection
equipment for diesel
engine
 Introduction
• Fuel is supplied through hot compressed air in the
combustion chamber
• The liquid fuel has to absorb heat for evaporation and
find air for combustion in short duration of time.
• To meet these requirements, the fuel has to be
atomized into fine particles so that the heat-absorbing
area is increased for immediate evaporation.
 Requirements
• To spray the correct quantity of fuel as required,
depending on the load.
• To inject the fuel at the correct time in the cycle.
• To inject the quantity of fuel at such rate that
constant pressure combustion is obtained.
• The sprayed fuel must be atomized such that the fuel
gets depression and penetration.
• Starting and ending of injection must be sharp
without dribbling.
• The fuel injection pump has a small plunger and a
small stroke. The movement of the plunger cannot
create sufficient vacuum to suck fuel from the fuel
tank. Therefore an auxiliary fuel pump is used to lift
the fuel above the level of the injection pump

• The fuel injector has either a single hole nozzle or a

multi-hole nozzle. A jet of fuel passes through this
hole at high velocity and atomizes.
 Fuel injector
• The purpose of an injector is to atomize or to divide
the fuel into fine droplets and to direct the spray such
that every fuel particle finds sufficient air to burn
completely.
 Injector

• Main element in an injector is a

nozzle
• There is a valve which is spring-
loaded.
• Due to the spring force, gases of
the cylinder cannot enter the
injection system.
• Pressure chamber or gallery which receives fuel under
pressure from the fuel injection pump.
• When the force applied by the fuel pressure is greater than
the spring force, the valve opens and fuel under pressure
flows at a very high velocity into the combustion chamber
through the opening of the orifice.
• During the flow of the fuel, fuel undergoes atomization.
• The degree of atomization depends on the pressure
difference between the fuel pressure and the combustion
chamber pressure.
 Spray formation
• When a jet of fuel comes out from the nozzle of the
injector at very high velocity, then the stream of fuel is
torn away by the resistance offered by air in the
combustion chamber, and the fuel is drawn into drops
by surface tension.
• The fuel droplets also provide viscous drag to the air
molecules leaving a partial vacuum behind them.
• The result is that the core of the spray moves ahead
and the process of atomization continues until all the
fuel is atomized.
Spray formation is affected by the following factors:
• Injection Pressure: Increasing the injection pressure increases
the degree of atomization, i.e. fine atomization.
• Orifice Diameter Increase in the orifice diameter reduces the
degree of atomization.
• Fuel Viscosity: Increased viscosity of the fuel
increases the internal resistance and a greater
injection pressure is required to get the same
amount of atomization.
• Design of Nozzle Valve: The nozzle valve
which is extended into the orifice, produces a
hollow cone spray which has less penetration
due to fine atomization.
Electronic Fuel Control Configuration
Closed-Loop Fuel Control System
Air/Fuel Management
Air flow through the engine is either measured by a sensor inserted in the air intake duct or calculated
by the PCM through precise measurement of intake manifold pressure, throttle position and engine
speed. All the air entering the engine needs to be accounted for by this system in order for the PCM to
calculate the correct amount of fuel to be added to the air/fuel mixture; resulting in complete
combustion and proper catalytic converter operation. If unmeasured air enters the engine not enough
fuel will be added resulting in incomplete combustion and misfires. Under these conditions the engine
is less fuel efficient and runs the risk of adding excessive pollution back into the air we breathe.
Fuel Tank
The fuel tank stores fuel until it is needed by the injectors for combustion in the engine. It is usually
constructed from metal or composite plastic materials. The fuel tank has an inlet pipe and an outlet
pipe.
Fuel Pump
Fuel injection systems operate at high fuel pressures, typically in the 40-60 psi range, or higher for
direct injection. To achieve proper pressure and volume flow fuel pumps are generally electric motors
located in the fuel tank, utilizing the fuel in the tank to cool the pump and to ensure a steady supply of
fuel.
Fuel Rail
Fuel rails are used on engines with multi-point fuel injection systems. A fuel rail is basically a
pipe or two connected pipes (sometimes called a fuel manifold) used to deliver fuel to the
individual fuel injectors on the engine.
Fuel Injectors
A fuel injector is an electronically controlled solenoid valve that opens and closes many times
per second. When the injector is energized, an electromagnet moves a plunger that opens the
valve allowing the pressurized fuel to squirt out through a tiny nozzle. The nozzle is designed
to atomize the fuel for better combustion.
Fuel Pressure Regulator
The function of the fuel pressure regulator is to maintain the desired fuel pressure delivered to
the fuel injector under all engine operating conditions.
Mass Air Flow Sensor
The mass air flow sensor (MAF) is used to measure the flow rate of air entering a fuel injected
engine.
Manifold Absolute Pressure Sensor
On some fuel injection systems a manifold absolute pressure sensor (MAP) is used to
calculate air volume entering the engine.
Oxygen Sensor
The sensor tells the engine management computer (PCM) if the fuel mixture is burning rich
(less oxygen) or lean (more oxygen).
Throttle Position Sensor
The throttle position sensor (TPS) is usually connected to the throttle plate shaft in the
throttle body. The TPS reads the angle of the throttle valve and transmits an electrical signal
to the PCM.
Powertrain Control Module (PCM)
The PCM's job is to manage the powertrain. This includes the engine's ignition system, fuel
injection system and emission controls. The PCM receives inputs from a wide variety of
sensors and switches. In turn the PCM controls -directly or indirectly- relays, solenoid and
other components to achieve proper ignition timing, fuel delivery and proper treatment of
pollutants.