UNIT II

LESSON 1 – FUEL SYSTEM

Introduction to the Purpose and Components of a Vehicle’s Fuel System

Purpose of the Fuel System: The fuel system's primary role in a vehicle is to store, transport, and deliver
fuel to the engine in the precise air-fuel mixture needed for combustion. This mixture is essential for the
engine to produce power efficiently. In short, it:

• Stores fuel safely.

• Delivers fuel at the right pressure and quantity.

• Regulates the air-fuel mixture to match the engine's demands.

An engine needs a balanced combination of fuel and air to operate smoothly. The fuel system must
adjust the ratio of fuel to air based on various factors like load, speed, and temperature.

Key Components of the Fuel System

• Fuel Tank:

o The fuel tank is where gasoline or diesel is stored. It’s typically located at the rear of the
vehicle and designed to prevent fuel leakage while ensuring proper ventilation.

• Fuel Pump:

o The fuel pump moves fuel from the tank to the engine. In modern cars, an electric pump
located inside the tank (submerged pump) is common, providing consistent fuel
pressure.

• Fuel Lines:

o Fuel lines carry fuel from the tank to the engine. These lines are often made of metal or
reinforced rubber to withstand pressure and prevent leaks.

• Fuel Filters:

o Fuel filters remove contaminants from the fuel before it reaches the engine, preventing
dirt or debris from clogging the system and damaging components.

• Carburetor/Fuel Injectors:

o These components mix air and fuel for combustion:

▪ Carburetors (used in older vehicles) rely on mechanical components to mix fuel

with air before it enters the engine. They operate on vacuum pressure and are
simpler but less efficient than modern systems.
 ▪ Fuel Injectors (common in modern vehicles) spray fuel directly into the intake
manifold or combustion chamber. Electronic control units (ECUs) precisely
manage fuel injection to optimize efficiency and performance.

Function of Fuel Systems in Providing the Correct Air-Fuel Mixture

For optimal engine performance, the air-fuel mixture must be properly balanced:

• Rich mixture: More fuel than air; provides more power but can lead to inefficient combustion,
increasing fuel consumption and emissions.

• Lean mixture: More air than fuel; improves fuel economy but can cause overheating or engine
knocking.

The fuel system dynamically adjusts the mixture to match operating conditions such as engine load and
temperature.

Overview of Fuel Delivery: Carbureted vs. Fuel-Injected Systems

• Carbureted Systems:

o These systems are mechanically simple and rely on air pressure to mix fuel and air. The
carburetor meters the amount of fuel and air based on throttle position and engine
vacuum.

o Advantages: Simple design, easy to repair.

o Disadvantages: Less precise fuel delivery, leading to inefficiencies, particularly at varying

speeds and loads.

• Fuel-Injected Systems:

o Fuel injection systems deliver fuel directly into the engine's combustion chamber or
intake manifold. The Electronic Fuel Injection (EFI) system uses sensors and an ECU to
precisely control the fuel amount, ensuring an optimal air-fuel mixture for every engine
condition.

o Advantages: Better fuel economy, improved power, lower emissions, and more
responsive throttle.

o Disadvantages: More complex, higher repair costs.

 Topic # 1: Carburetor: Basic Principles and Operation

The carburetor is a mechanical device found in older vehicles (before the widespread adoption of fuel
injection systems). It’s responsible for mixing the correct amount of fuel with air before delivering it to
the engine for combustion. While fuel injection has largely replaced carburetors, they are still found in
many classic cars, motorcycles, and small engines.

1. Basic Principles of a Carburetor

The carburetor operates based on a venturi effect, where airflow speeds up as it passes through a
narrow section of the carburetor, creating a pressure drop that draws fuel into the airstream. The
carburetor uses various components to regulate this air-fuel mixture depending on the engine's demand.

At its core, the carburetor:

• Mixes fuel with air in the correct ratio.

• Adjusts the air-fuel mixture according to engine load, speed, and throttle position.

• Operates without electronic control, relying entirely on mechanical and pneumatic principles.

2. Key Components of a Carburetor

• Venturi:

o The venturi is a narrow tube that air passes through, increasing airspeed and lowering
air pressure. This creates a suction effect that draws fuel from the float chamber into the
airstream.

• Throttle Valve:

o The throttle valve controls the amount of air entering the carburetor. When you press
the accelerator pedal, the throttle valve opens, allowing more air into the engine, which
in turn draws more fuel.

• Fuel Jet (Main Jet):

o The fuel jet meters the fuel as it's drawn into the air passing through the venturi. The
size of the jet determines how much fuel is mixed with the air.

• Float Chamber:

o The float chamber stores a small amount of fuel, keeping it ready to be mixed with the
air. A float within the chamber maintains a consistent fuel level by controlling a needle
valve that opens and closes the fuel supply from the tank.
 • Choke:

o The choke reduces the air intake, allowing more fuel to mix with less air. This rich
mixture helps the engine start when cold.

3. Operation of the Carburetor

The operation of a carburetor can be broken down into several stages, depending on the engine's needs:

• Idle Operation:

o When the engine is idling, only a small amount of air is entering the carburetor. At this
point, the idle jet provides a rich air-fuel mixture to keep the engine running at low
speed. The throttle valve is mostly closed, allowing only a small amount of air to mix
with fuel.

• Low-Speed/Partial Throttle Operation:

o As you press the accelerator slightly, the main fuel jet starts to take over from the idle
jet. The throttle valve opens slightly, allowing more air to flow through the carburetor,
drawing more fuel with it. The carburetor maintains a balanced air-fuel mixture
appropriate for lower speeds and light loads.

• High-Speed Operation:

o At higher speeds or under heavier loads, the throttle valve opens wider, allowing a larger
volume of air into the engine. The venturi effect increases, pulling more fuel from the
main jet into the airstream. The air-fuel mixture is now finely balanced to meet the
engine's power demands.

• Acceleration:

o When you suddenly press the accelerator, the carburetor enriches the air-fuel mixture
temporarily for better acceleration. This is done through an accelerator pump, which
squirts extra fuel into the venturi, helping the engine handle the sudden increase in
load.

• Cold Start:

o During a cold start, the engine needs a richer air-fuel mixture because fuel vaporizes less
effectively at low temperatures. The choke is used to restrict the amount of air entering
the carburetor, thereby enriching the mixture, making it easier for the engine to start
and run until it warms up.
4. Air-Fuel Mixture Control in Carburetors

The carburetor must maintain a precise balance between air and fuel to ensure efficient combustion:

• Lean Mixture: More air than fuel; good for fuel economy but can cause overheating or engine
knocking.

• Rich Mixture: More fuel than air; provides more power but can lead to incomplete combustion,
increasing emissions and fuel consumption.

In a carburetor, these mixtures are controlled mechanically based on the air flowing through the venturi
and the size of the jets that allow fuel to mix with the air. There are no electronic sensors or computers,
making the carburetor a fully mechanical system that requires manual tuning to operate optimally.

5. Limitations of Carburetors

While carburetors were the standard for many years, they have certain drawbacks:

• Lack of Precision: Unlike fuel injection systems, carburetors can’t precisely adjust the air-fuel
mixture in real-time based on engine conditions. This results in inefficiencies, especially under
variable load and speed conditions.

• Difficulty in Cold Starts: Carburetors often require manual adjustments (using the choke) to start
engines in cold weather.

• Emissions: Carburetors tend to produce more emissions due to less precise fuel control.
 Topic #2: Fuel Injection Systems: Port Injection and Direct Injection

Fuel injection systems have largely replaced carburetors due to their precision, efficiency, and ability to
meet modern emission standards. These systems deliver fuel directly into the engine, controlling the air-
fuel mixture more accurately than carburetors. There are two main types of fuel injection systems
commonly used in modern vehicles: Port Fuel Injection (PFI) and Direct Fuel Injection (DI).

1. Overview of Fuel Injection Systems

Both Port Fuel Injection and Direct Injection systems aim to:

• Deliver fuel precisely to the engine for combustion.

• Optimize the air-fuel mixture for different driving conditions (load, speed, temperature).

• Improve efficiency, performance, and emissions by electronically controlling the fuel delivery.

These systems rely on a network of sensors, a fuel pump, and an Electronic Control Unit (ECU) to
manage the fuel flow, ensuring that the engine receives the exact amount of fuel needed for efficient
combustion.

2. Port Fuel Injection (PFI)

Port Fuel Injection is a system where fuel is injected into the intake port of the engine, just before the
intake valve. When the intake valve opens, the fuel-air mixture is drawn into the combustion chamber.

How PFI Works:

• Fuel injectors are located in the intake manifold, spraying fuel into the intake port.

• The fuel mixes with the incoming air just before entering the combustion chamber.

• The Electronic Control Unit (ECU) regulates the amount of fuel injected based on data from
sensors that monitor engine conditions such as throttle position, air temperature, and engine
load.

Advantages of PFI:

• Better mixing: Since the fuel has more time to mix with air before entering the combustion
chamber, the mixture is more uniform, which helps with smoother combustion.

• Cost-effective: PFI is generally simpler and less expensive to manufacture and maintain than
direct injection systems.

• Less prone to carbon buildup: Since the fuel is sprayed over the intake valves, it helps to keep
the valves cleaner, reducing carbon buildup.
Disadvantages of PFI:

• Less efficient: Compared to direct injection, PFI is less efficient because the fuel-air mixture is
less precisely controlled.

• Lower power output: Since fuel is injected before the intake valve, the engine can't optimize the
timing of fuel delivery as precisely as direct injection systems.

3. Direct Fuel Injection (DI)

Direct Injection is a more advanced system where fuel is injected directly into the combustion chamber,
rather than the intake port. This allows for more precise control of the air-fuel mixture and the timing of
injection, leading to higher performance and better fuel efficiency.

How DI Works:

• Fuel injectors are located inside the combustion chamber, injecting fuel directly into it at high
pressure.

• The timing of the injection is controlled by the ECU, allowing for fuel to be injected during the
compression stroke, after the intake valve has closed.

• This enables stratified combustion, where a rich fuel mixture is concentrated around the spark
plug while the rest of the chamber remains lean, improving efficiency.

Advantages of DI:

• Improved fuel efficiency: Direct injection allows for better control of the air-fuel mixture,
particularly at high loads, improving fuel economy.

• Higher power output: DI enables higher compression ratios, which leads to more power and
torque.

• Reduced emissions: By allowing stratified combustion, DI reduces the amount of fuel burned at
low loads, leading to lower emissions.

Disadvantages of DI:

• Carbon buildup: Since fuel is injected directly into the combustion chamber, the intake valves
don't get cleaned by the fuel spray, leading to carbon buildup over time.

• Complexity and cost: DI systems are more complex, requiring higher-pressure fuel pumps and
more precise injectors, making them more expensive to manufacture and maintain.
4. Comparison of Port Fuel Injection (PFI) and Direct Injection (DI)

Feature Port Fuel Injection (PFI) Direct Fuel Injection (DI)

Fuel Injection Injects fuel into the intake port, Injects fuel directly into the combustion
Location before the intake valve. chamber.

Mixed in the intake port; longer Mixed directly in the combustion chamber,
Fuel-Air Mixture
time to mix with air. leading to better control.

Lower efficiency compared to direct

Efficiency Higher efficiency due to precise fuel delivery.
injection.

Higher power and torque due to more precise

Power Output Lower power potential.
fuel control.

Less prone to carbon buildup on

Carbon Buildup More prone to carbon buildup on intake valves.
intake valves.

Cost and More expensive, requires high-pressure fuel

Less expensive, simpler design.
Complexity pumps and complex injectors.

Use in Modern Used in older or more budget- Common in modern, high-performance, and
Vehicles friendly vehicles. fuel-efficient vehicles.

5. Combined Systems: Dual Injection

Many modern engines use dual injection systems, combining both port and direct fuel injection. This
allows manufacturers to take advantage of the benefits of both systems. Typically, the engine will use
port injection at low speeds and light loads to reduce carbon buildup and improve fuel atomization,
while direct injection is used at higher loads to improve performance and efficiency.

6. Key Components of Fuel Injection Systems

Whether PFI or DI, the components are similar, though their configuration and operation differ slightly:

• Fuel Injectors:

o These are the nozzles that spray fuel into the intake port (PFI) or directly into the
combustion chamber (DI). They are controlled by the ECU to release the right amount of
fuel at the right time.
• Fuel Pump:

o Direct injection systems require high-pressure fuel pumps because the fuel must be
injected directly into the combustion chamber under high pressure (sometimes over
2000 psi), whereas PFI systems use lower-pressure pumps.

• Fuel Pressure Regulator:

o This component maintains consistent fuel pressure, ensuring that the injectors receive
the correct amount of fuel regardless of engine load.

• Electronic Control Unit (ECU):

o The ECU uses data from various sensors (e.g., oxygen sensors, throttle position sensors,
mass air flow sensors) to determine the optimal air-fuel ratio and control the injectors
accordingly.
 Topic # 3: Fuel Pumps and Filters: Overview and Functions

The fuel pump and fuel filter are essential components of a vehicle's fuel system. Together, they ensure
that clean fuel is delivered from the fuel tank to the engine at the correct pressure for optimal
combustion. Understanding how these components work and their role in maintaining fuel system
health is crucial for vehicle performance and longevity.

1. Fuel Pump: Function and Types

The fuel pump is responsible for delivering fuel from the fuel tank to the engine. The pump must supply
the correct amount of fuel at the right pressure, ensuring the engine receives an adequate and
consistent fuel supply under all operating conditions, whether at idle or full throttle.

Types of Fuel Pumps

There are two main types of fuel pumps used in modern vehicles: mechanical fuel pumps (commonly
found in older, carbureted vehicles) and electric fuel pumps (found in most modern vehicles with fuel
injection systems).

Mechanical Fuel Pumps

• Location: Typically located on the engine block.

• Operation: Driven by the engine’s camshaft or crankshaft. As the engine rotates, it powers a
diaphragm inside the pump that creates suction, drawing fuel from the tank and pushing it to
the carburetor.

• Pressure: Delivers low fuel pressure (about 4-10 psi), suitable for carburetors, which do not
require high pressure.

Electric Fuel Pumps

• Location: Usually located inside the fuel tank (submerged pumps) or outside the tank near the
fuel lines.

• Operation: Controlled electronically by the vehicle’s Electronic Control Unit (ECU), these pumps
supply a constant flow of fuel at a higher pressure (30-100 psi), which is necessary for fuel
injection systems.

• Submerged Pumps: Electric pumps often sit inside the fuel tank, using fuel as a coolant and
lubricant, which helps with efficiency and longevity.

Fuel Pump Functions

• Maintain Fuel Pressure: The pump must deliver fuel at a specific pressure to ensure the fuel
injectors work correctly. If the pressure is too low, the injectors can’t atomize the fuel properly; if
too high, the system can become overwhelmed.

• Supply Adequate Fuel Volume: The pump ensures a steady fuel supply even during high-
demand situations like heavy acceleration or high-speed driving.
2. Fuel Filters: Function and Types

The fuel filter plays a vital role in protecting the engine by removing contaminants, debris, rust, and dirt
from the fuel before it reaches the engine. Clean fuel is essential for proper combustion and to prevent
clogging or damage to sensitive components like fuel injectors.

How Fuel Filters Work

• As fuel passes through the filter, it traps dirt, rust particles, and other impurities that may have
entered the fuel tank.

• The filter media inside the fuel filter is usually made of paper, synthetic fibers, or mesh that
captures contaminants as fuel flows through.

Types of Fuel Filters

Inline Fuel Filters

• Location: Positioned along the fuel lines between the fuel tank and the engine.

• Design: These filters are typically found in older vehicles or some modern designs, where the
fuel filter is an independent component that can be easily replaced. They are cylindrical and
made of metal or plastic with connectors for the fuel lines at each end.

In-Tank Fuel Filters

• Location: These are integrated into the fuel pump assembly inside the fuel tank. Many modern
vehicles use this design.

• Design: While harder to access, these filters are often more efficient and last longer. However,
they are typically replaced less frequently since accessing the filter requires removing the fuel
pump assembly from the tank.

3. Common Issues with Fuel Pumps and Filters

Fuel Pump Issues

• Fuel Pump Failure: A failing fuel pump can cause inconsistent fuel delivery, leading to
performance issues like hesitation, stalling, or a complete inability to start the engine.

o Symptoms of a Bad Fuel Pump:

▪ Engine sputtering or stalling at high speeds.

▪ Difficulty starting the vehicle.

▪ A whining noise coming from the fuel tank.

▪ Decreased fuel efficiency or performance.

 • Low Fuel Pressure: If the pump cannot generate enough pressure, the engine may run lean (too
much air, not enough fuel), leading to poor performance, rough idling, and possible engine
damage over time.

Fuel Filter Issues

• Clogged Fuel Filter: Over time, the fuel filter can become clogged with dirt and debris, restricting
fuel flow. This can lead to poor engine performance, difficulty starting, or stalling.

o Symptoms of a Clogged Fuel Filter:

▪ Hesitation or loss of power during acceleration.

▪ Difficulty starting the engine, especially in cold weather.

▪ Engine misfires or rough idling.

▪ Noticeable drop in fuel efficiency.

4. Importance of Maintenance

Regular maintenance of the fuel pump and filter is essential to keep the fuel system working efficiently
and to prevent more serious problems:

Fuel Pump Maintenance

• Replace when necessary: Fuel pumps do not require regular maintenance, but they can fail over
time, especially in high-mileage vehicles. If you experience symptoms of pump failure, testing
fuel pressure with a gauge can help confirm if the pump is the issue.

• Keep the tank at least 1/4 full: Running a vehicle on very low fuel levels can strain the fuel
pump, especially for in-tank pumps that rely on fuel to cool and lubricate them.

Fuel Filter Maintenance

• Replace regularly: Depending on the vehicle, fuel filters are generally replaced every 20,000 to
30,000 miles, though some in-tank filters may last longer. Check your vehicle's manufacturer
recommendations.

• Watch for symptoms: If you notice any signs of poor fuel delivery, like stalling or power loss,
replacing the fuel filter is a good first step to avoid more costly repairs later.

5. Fuel Pump and Filter Interaction

The fuel pump and fuel filter work in tandem to ensure that fuel is delivered efficiently and cleanly to the
engine:

• The fuel pump provides the pressure needed to move fuel through the lines.
 • The fuel filter ensures that contaminants do not enter the fuel system, protecting the injectors
and engine from damage.

A failing fuel pump or clogged filter can create similar symptoms (poor acceleration, stalling, hard
starting), so both components are often checked together when diagnosing fuel system issues.