Automobile Engineering

Unit – 02
Fuel supply systems

Fuel supply system

The fuel system of an internal combustion engine is needed to produce a
combustible mixture composed of the fuel stored in the fuel tank and atmospheric
air, and then delivery both to the cylinders. Petrol engine uses light grade gasoline
fuel (petrol), while the diesel engine uses heavy diesel fuel, so therefore there fuel
supply systems differ greatly in both Petrol and diesel engine.

S.I. Engine (Petrol):

The main parts of fuel supply system of petrol (S.I) engine are
1. Fuel Tank
2. Fuel pump
3. Carburettor
4. Fuel filter

Fuel Pump is used to supply petrol from the petrol Tank to the Carburettor. The fuel
pump may be of mechanical or electrical type. If mechanical fuel pump is employed,
it has to be placed on the engine since it is driven by the engine camshaft through
an eccentric. However, the electrically operated fuel pump may be placed anywhere
on the vehicle. When the engine is cranked (started), vacuum is produced inside the
cylinder. The atmospheric air rushes in to the vacuum through the air cleaner,
carburettor is the main device in this system. It vaporizes the petrol and mixes it
with air in desired proportions depending upon the requirements of operating

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conditions. The charge (Air + fuel mixture) now flows into the inlet valve opens. Lt is
ignited by spark that occurs due to an ignition system.

Fuel Tank :
The Fuel Tank used in a 4 Wheeler is different from that of a 2 Wheeler in location,
construction and control of fuel flow. A 4 Wheeler is not provided with a fuel tap
whereas it is invariably used in 2 Wheeler. Details of Fuel Tank in common use, is
given below.
The Fuel Tank is fabricated from sheet metal of steel or aluminium alloy. Use of
aluminium alloy tank is advantageous due to its lightweight and good resistance to
corrosion.
The Fuel is filled in through a filler tube, which can be closed by a filler cap. Provision
of Lock is generally made on this cap. Provision of lock is generally made on this cap.
A number of baffles (plate) are fitted inside to help in preventing the violent fuel
surging during acceleration, cornering and braking. The bottom surface of the tank is
made sloppy so that even the last drop of fuel may collect here for pumping. For
periodic removal of the sediment, a screwed drain plug is provided at bottom f the
tank. A vent hole is provided in the filler tube or the filler cap through which the air
enters into the tank and Occupies the space left vacant by the pumped fuel.

Fuel Filters:
The function of fuel filter is to clean the fuel by eliminating dirt and abrasive
particles from fuel. The Fuel is filtered at different stages in a fuel supply system.
Therefore, many fuel filters are used in the fuel circuit. The fuel filters serve the
purpose of filtration in the delivery system by preventing foreign particles from
entering into the fuel pump and the carburettor. The modern filtration practice
employs a combination of coarse and fine filters. These Filters are generally located
at the following positions.
Coarse filter (or gauge filter) incorporated within the fuel tank. Medium coarse
filter outside the fuel tank and on the inlet side of the pump. Fine filter of built in
surface type at inlet of fuel pump’s pumping chamber. Fine filter in pipeline
between fuel pump and the carburettor.

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The fuel filter consists of perforated tube & a filter. During engine operation
the fuel enters the bowl from the fuel tank. Then it passes through filter element
and perforated tube and finally leaves to fuel feed pump. Most of the dirt particles
are removed at filter and perforated tube and collected at the bottom of the bowl,
which is removed and cleaned periodically.

Fuel Pump:
A Fuel Pump is used to deliver fuel from the Fuel Tank to the float chamber of
Carburettor. It is generally mounted on the side of engine block near the eccentric
end of the camshaft. In V-type engines, it may be mounted between the two rows of
the cylinders.
Types of Fuel Pumps
01. A.C Mechanical fuel pump
02. S.E Electrical fuel pump
A.C Mechanical fuel pump
This is a diaphragm type of pump. The diaphragm used is made out of a high-grade
cotton impregnated with synthetic rubber. The valves are made up of Bakelite which
is being lighter and keeps the inertia stress minimum.

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Components of A.C. Mechanical Fuel Pump:

The components of A.C. Mechanical Fuel Pump are:
i. Eccentric or Cam
ii. Diaphragm
iii. Pull rod
iv. Strainer
v. Inlet Valve
vi. Pressure Valve
vii. Outlet valve to Carburettor
Working of Mechanical Fuel Pump:
The drive for the pump is taken from the camshaft by means of an eccentric or cam.
The eccentric operates the rocker arm which is in conjunction with the diaphragm
return spring, which pushes the diaphragm up and down.

The downward movement of the diaphragm causes vacuum in in the chamber which
causes the inlet valve to open and the fuel then goes through the strainer into the
chamber. The next upward movement of the diaphragm causes the inlet valve to
close while the outlet valve opens and the fuel goes out to the carburettor float
chamber.

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In this way, the pressure in the petrol pipeline between the fuel pump and the
carburettor is kept under a pressure of 20 Kpa and 35 Kpa. But the exact pressure
range is determined by the stiffness of the diaphragm return spring.
If the pressure is low, the petrol will not be supplied according to the demand under
high speed or high load conditions. On the other hand, if the pressure is excessive,
the needle valve of the carburettor float chamber may be forced open causing the
flooding of the carburettor.
There is no need to pump more fuel when the float chamber of the carburettor is
completely filled up. But if the engine continues to run at light load, the camshaft
will be running all the time and if no other means are provided the pump will build
excessive pressure which may damage the pump itself.
This is taken care of by the diaphragm return spring, which remains partially or fully
compressed depending upon the line pressure even though the rocker arm
continues to be moved up and down by the eccentric.
Thus the movement of the diaphragm gets restricted or even zero which decreases
or even stops the supply of petrol until engine consumption uses some of the petrol
in the carburettor float chamber.

S.U. Electrical Fuel Pump:

In this type also, the diaphragm is used. Alternate vacuum and pressure are
produced due to the movement of the diaphragm which is caused electrically in this
case.
Components of S.U. Electrical Fuel Pump:
S.U. Fuel pump is consists of following components
i. Diaphragm
ii. Breaker Point
iii. Power from the Ignition switch
iv. Solenoid
v. Armature
Working of S.U. Electrical Fuel Pump:
Closing the ignition switch energizes the solenoid winding and the magnetic
flux is created, which pulls the armature to which the diaphragm is attached. Thus
the diaphragm moves to cause suction in the pump chamber and the fuel is drawn
into the chamber.

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But as soon as the armature moves, it interrupts the electric supply by disconnecting
the breaker points, the solenoid is de-energized and the armature falls back causing
the diaphragm to move so as to create the pressure in the pump chamber which
opens the outlet valve and the fuel goes out to the carburettor float chamber.
This movement of the armature, however, completes the circuit again and the
solenoid again gets energized. The whole cycle is again repeated and the fuel
continues to be pumped.
Electrical pumps need not be situated necessarily close to the engine, but they are
mostly located near the fuel tank. Thus these are not subjected to engine heat
Further, an electrical pump does not need to wait for the engine to start. It starts
operating immediately as the ignition is switched on.

CARBURETTOR :
The carburettor is a device which is used to prepare a charge (air- fuel mixture)
in S.I engines by means of vaporising the fuel (petrol) from the fuel pump and mixing
it with the air from the air cleaner. A carburettor vaporises the petrol and mixes it
with the air in such proportion which is in accordance with the engine requirements.
The quality of petrol to be supplied into the engine is controlled by operating
throttle valve. This control can be done by automatic means or manually. If done
manually, it can be in accomplished by hand control (2&3 wheelers) or foot control
(4 wheelers).

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Functions of a Carburettor:
01. It maintains a small reserve of petrol in the float chamber at constant head
(height) to ensure uninterrupted supply for vaporization.
02. It atomizes the fuel and mixes with air.
03. It has to supply air-fuel mixture at correct ratio according to engine
requirements.

Simple carburettor
The main components of a simple carburettor are float chamber, float, nozzle,
venturi, throttle valve, inlet valve and metering jet. In the float chamber, a constant
level of petrol is maintained by the float and a needle valve. The float chamber is
ventilated to atmosphere. It is used to maintain the atmospheric pressure inside the
chamber, The float which is normally a metallic hollow cylinder rises and closes the
inlet valve as the fuel level in the float chamber increases to a certain level.

The mixing chamber contains venturi, nozzle and throttle valve. The venturi tube is
fitted with the inlet manifold. This tube has a narrow opening called venturi. A
nozzle is provided just below the centre of this venturi. The fuel jet with nozzle is
placed in the throat at slightly higher level than the level of petrol in the float
chamber to prevent the over flow of fuel from the nozzle. This is called NOZZLE LIP.

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The mixing chamber has two butterfly valves. One is to allow air into the mixing
chamber known as choke valve. The other one b to allow air-fuel mixture to the
engine known as throttle valve.
During suction stroke, vacuum is created inside the cylinder. It causes the pressure
difference between cylinder and outside the carburettor. Due to this, the
atmospheric air enters the carburettor. The air flows through venturi. The venturi
increases the velocity of air and reduces the pressure. It produces the partial
vacuum at the tip of the nozzle. Because of this vacuum, the fuel comes out from
the nozzle in the form of fine spray. These fine fuel particles mix with the incoming
air to form air-fuel mixture. Thus, it gives a homogeneous mixture of air-fuel to the
engine.
For more understanding, refer the link : https://youtu.be/G9eZs7ELh9o

Limitations
I. It does not supply a constant Air-fuel ratio and mixture strength gets richer &
richer as the engine speed increases.
II. It fails to supply rich mixture during idling and to start the engine from cold.
III. It has no provision to deliver extra fuel during acceleration and over load.

Zenith carburettor
Following are the list of components in a Zenith Carburettor :-
1) Float Chamber
2) Main Line
3) Main Jet
4) Compensating Jet or Auxiliary Jet
5) Starting Jet
6) Reservoir or Auxiliary Chamber
7) Choke
8) Throttle Valve

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Construction :-
In this carburettor, Float Chamber is connected to the Venturi via a Main
Line. Main function of fuel chamber is to take fuel from the fuel tank. This
fuel chamber has two balls, two floats and a spindle. There is choke which
when closed restricts the air flow to the carburettor. A throttle Valve is a
valve between the carburettor and the engine which opens when fuel is
needed by the engine . Fuel from main line enters to form air fuel mixture
through Main Jet. Apart from main jet, there is a compensating jet also
which compensate when more fuel is needed by engine at high speed.
This compensating jet gets fuel from reservoir or auxiliary valve . Apart
from compensating jet, it also has starting jet which aids engine at time of
starting. It also gets fuel from reservoir or auxiliary valve.
Working :-
At first fuel from fuel tank enters into Float Chamber through a passage. The fuel
level in the fuel chamber is maintained constant by the spindle connected to the
two balls which rests over the floats. When the Fuel level drops, the floats descends
and balls will also come down with them. down to block and unblock the fuel supply

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to fuel chamber. As the balls and the spindle are connected like a Seesaw, so when
the balls come down the spindle comes up and fuel passage to fuel chamber is
unblocked and the fuel enters the fuel tank and maintain a constant level.

Working at high Speed :-

At high speed of vehicle the speed of engine increases, hence producing higher
suction. Due to higher suction at venturi more fuel is supplied by main jet and fuel is
also supplied by compensating jet or auxiliary jet. This auxiliary jet get fuel from the
auxiliary valve. But the compensating jet can supply fuel for only sometime because
the fuel stored in auxiliary valve or reservoir is less and empty at high speed. This
reservoir takes time to store the fuel because there is an orifice between the
reservoir and fuel chamber. Very less fuel is allowed to pass from fuel chamber to
reservoir due to orifice. So at high speed fuel is sprayed from main jet as well as
compensating jet for sometime.

Working at Slow Speed & time of starting :-

At time of starting or Slow running, throttle valve is almost at closed position. There
is very little gap for the fuel to pass in throttle valve at time of starting. For starting a
rich mixture is needed by the engine.
The air from air filter passes through the gap in side of throttle valve and as the air
passes through the gap, velocity of air increases and pressure of air decreases on the
upper side of throttle valve and thereby producing suction effect at Starting jet
which is placed at top of throttle valve. This starting jet also gets fuel from the same
reservoir from where the compensating jet gets fuel. This rich mixture reaches the
engine and helps the engine to start. The throttle valve will opens for high speed
and the suction near the throttle valve is ceased and flow of fuel from starting jet
stops.

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Fuel (petrol) injection systems

Fuel injection is a system for admitting fuel into an internal combustion engine.
It has become the primary fuel delivery system used in automotive engines.
The Functions of Fuel Injection System
i. To enhance the engine performance & Fuel economy
ii. Initiating and controlling the combustion Process
iii. Preparation of the combustible charge (Just Like carburettor)
There are number of drawback and limitation of carburettor in petrol engine.
It can be eliminated by petrol injection system so in near future carburettor fully
replace by modern petrol injection system.
Drawback and Limitation
• It has many moving parts so its affects the performance
• In multi cylinder engine A/F ratio may vary in each cylinder
• A/F ratio not available in different condition
• Back firing take place in suction and exhaust manifold
Types of petrol injection systems

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1. According to the location of Injector

a. Direct Injection
b. Port Injection
c. Throttle body Inspection
2. According to Duration and Timing of Fuel Injection
a. Continuous Type
b. Intermittent Type
c. Sequential Type
3. According to number of Injectors
a. Single Point Injection
b. Multi-Point Injection
4. According to the control Method
a. Mechanical Petrol Injection Method
b. Electronic Petrol Injection Method

Mechanical Petrol Injection:

This type of injection is operated Mechanically with the help of a Pump, distributor,
etc. The Mechanical Petrol Injection pump is obsolete now and it is been replaced by
Electronic Petrol Injection Pump so that a higher accuracy is maintained with respect
to the fuel during the firing order.
Components of Mechanical Petrol Injection System:
A Petrol Injection System consists of the following parts:
Fuel Tank, Fuel Filter, Pressure Pump, Relief Valve, Return Pipe for Excess fuel,
Distributor, Injector, Air Filter and Throttle Valve.
Working Principle of Mechanical Petrol Injection:
The fuel is to be stored in the fuel tank to supply it into the combustion chamber
along with the air. The Fuel filter is used to remove the impurities present in the fuel
to avoid the disturbance during the flow.
The Pressure pump is used to check the pressure of the fuel coming from the fuel
tank. It pumps the fuel at a specified pressure (about 700 kPa) into a metering
distributor.

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Relief valve sends the necessary amount of fuel to the distributor and the
remaining(excess fuel) will be sent back to the fuel tank with the help of return pipe
at constant pressure.
The metering distributor supplies fuel to each injector in turn. The quantity of fuel
delivered is also controlled in the distributor by engine manifold pressure.
The injector is ordinarily held closed by spring until the fuel pressure opens it to
deliver an atomized spray of fuel. Manual control on the dashboard controls the
metering distributor and thereby the quantity of fuel delivered by it.
The Throttle valve opens for the air intake into the cylinder along with fuel into the
engine cylinder for proper air fuel mixture.
In this way, by the use of Mechanical Petrol Injection, the fuel is supplied to the
engine cylinder via injector.

Electronic Petrol Injection:

In the mechanical injection system, there are some limitations, but in the case of the
Electronic Petrol Injection system, we can overcome that. By the use of Sensors, and
Electronic Unit we can easily control functions like engine speed, temperature,
engine load, torque and much more.
Components of Electronic Petrol Injection:
An Electronic Petrol Injection system is consist of the following parts:
Fuel Tank, Fuel Filter, Electric Pump, Fuel Pressure Regulator, Injector, Electronic
Control Unit(E.C.U), Air Filter and Throttle Valve.

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Working Principle of Electronic Petrol Injection:

The fuel is to be stored in the fuel tank to supply it into the combustion chamber.
The Fuel filter is used to remove the impurities present in the fuel to avoid the
disturbance during the flow.

An electrically driven Fuel Pump (S.U Electrical Fuel Pump) draws the fuel from the
tank through a filter and supplies the same to the injectors at a pressure which is
held constant using a Fuel-Pressure regulator.
The pump draws more fuel than the required and the excess fuel is returned to the
tank by the fuel pressure regulator. In this way, a vapour lock is prevented in the
fuel lines.
The injectors are held closed using spring and are opened using solenoids energized
by the control signal from the electronic control unit (ECU), which consists of a small
pre-programmed analog computer that translates sensor signals into command
signals.
The strength of the ECU control signal, which determines the open time of the
injector to control the amount of fuel injected, depends upon the engine
requirements which are determined by the ECU from the sensor signals from critical
locations.
In this way, the ECU works properly to supply an accurate amount of fuel to the
injector with respect to air which is drawn into the combustion chamber.

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Multi-Point Fuel Injection system :(MPFI)

The MPFI means Multi Point Fuel Injection, This technology is used in petrol
engine. Similar technology is used in Diesel engine know as CRDI (Common Rail
Direct Injection System).
Conventional Petrol engine uses Carburettor to mix air and fuel. It is very less
responsive to acceleration & deceleration. The main problem in Carburettor is
MORE EMISSION. Due to increasing strict environmental regulations in automobile
industry, it is required to meet very strict emission norms. Hence Electronic Fuel
injection is used to reduce those problems.
The MPFI System uses a Microchip called Electronic Control unit (ECU) to control the
Car’s engine. In this system, there is one fuel injector installed near each cylinder,
that is why it is called as Multi-point (more than one point) Fuel injection.

The MPFI System consists of Fuel tank, fuel pump, fuel filter, fuel rail with
pressure control valve, fuel injectors and the E.C.U.
The fuel from the fuel tank is drawn by the Fuel pump and is delivered to the
fuel rail. The pressure in the Fuel rail is maintained constant by the PCV. Any
excessive pressure build up will be removed by the PCV by dumping the excessive
fuel into the fuel tank. The fuel rail is connected to the fuel injectors. The fuel from
the fuel rail passes through the injectors and is injected.
The amount of fuel to be injected through the injector in the cylinder is
controlled by the ECU. The ECU control the fuel injectors by receiving the feedback

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from the sensors which measures the each and every parameters. Some of the
important parameters are Manifold pressure, Inlet air temp., Throttle opening
(Amount of acceleration given), Engine RPM etc.
Based on all these inputs from the sensors, the ECU (microchip/computer) decides
what amount of fuel to inject. Thus it makes it fuel efficient as it knows what
amount of petrol should go in.
For more understanding, refer the link: https://youtu.be/sbhQ1JEZ11E

Types of MPFI system

D-MPFI
The D stands for Druck (Pressure in
German). It is a Manifold Injection
system
As air enters into intake manifold the
manifold pressure sensor detects the
intake manifold vacuum and sends
the information to the ECU
Vacuum in the intake manifold and
the speed of the engine are sensed
by this system
L-MPFI
The L stands for Luft ( Air in German). It
is Port injection system.
As air enters into intake manifold the
manifold pressure sensor detects the
intake manifold vacuum and sends the
information to the ECU
The mass of air entering the system and
the speed of the engine are sensed by
the system.

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Advantages of Multi-Point Fuel Injection System (MPFI):

1. The power generated by the engine is more than the carburetion system.
2. Due to the accurate mixture of air-fuel supplied to each cylinder, the difference
between power generated at each cylinder is negligible.
3. Engine vibrations from MPFI equipped engines are very less, hence the life of
MPFI system equipped engines is high.
4. This system is very responsive in case of sudden acceleration or deceleration.
5. Lower fuel consumption leads to better mileage
Disadvantages
01.Incresed cost due to high pressure pump & E.C.U.

C.I. Engine (Diesel) :

Requirements of fuel injection system are:
1) Accurate metering of the fuel injected per cycle: The quantity of the fuel
metered should vary to met changing speed and load requirements of the
engine
2) Timing the injection of the fuel correctly in the cycle: to obtain maximum
power ensuring fuel economy and clean burning.
3) Proper control of rate of injection: The desired heat – release pattern is
achieved during combustion.
4) Proper atomization of fuel into very fine droplets.
5) Proper spray pattern to ensure rapid mixing of fuel and air.
6) Uniform distribution of fuel droplets throughout the combustion chamber.
7) To supply equal quantities of metered fuel to all cylinders case of multi
cylinder engines
8) No lag during beginning and end of injection i.e., to eliminate dribbling of fuel
droplets into the cylinder.

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Types of diesel injection systems

Common Rail Direct injection system (CRDI)

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The CRDI means Common Rail Direct Injection system. This is a technology which is
used in Diesel engines. Today, manufacturers use CRDI technology to overcome
some of the deficiencies of conventional diesel engines which were sluggish, noisy
and poor in performance when implemented, especially in passenger vehicles.
The CRDI System uses a Microchip called Electronic Control unit (ECU) to control the
Car’s engine. The CRDI System consists of Fuel tank, fuel pump, fuel filter, fuel rail
with pressure control valve, fuel injectors and the E.C.U.
The fuel from the fuel tank is drawn by the Fuel pump and is delivered to the
fuel rail. The pressure in the Fuel rail is maintained constant by the PCV. Any
excessive pressure build up will be removed by the PCV by dumping the excessive
fuel into the fuel tank. The fuel rail is connected to the fuel injectors. The fuel from
the fuel rail passes through the injectors and is injected.
The amount of fuel to be injected through the injector in the cylinder is
controlled by the ECU. The ECU control the fuel injectors by receiving the feedback
from the sensors which measures the each and every parameters. Some of the
important parameters are Manifold pressure, Inlet air temp., Throttle opening
(Amount of acceleration given), Engine RPM etc.
Based on all these inputs from the sensors, the ECU (microchip/computer) decides
what amount of fuel to inject. Thus it makes it fuel efficient as it knows what
amount of petrol should go in.
Advantages & Disadvantages : same as MPFI system.
For more understanding, refer the link. https://youtu.be/5AQ07-LF5JA

Types of fuel pumps

Common rail fuel injection pump. An electronically controlled diesel fuel supply
system, this pump was developed to meet the strict 21st century exhaust gas
regulations. It consists of a supply pump, common rail, electronically controlled
injectors, a variety of sensors to detect the engine’s running condition, and a
computer that controls all of these devices. The engine drives the supply pump,
which produces high-pressure fuel. The common rail distributes the fuel to the
injectors, which are mounted on each cylinder of the engine.
Distributor (rotary) fuel injection pump. This diesel fuel pump is also controlled
electronically by various sensors, an electronic control unit, and an actuator. Similar

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to the common rail pump, the sensors detect the engine’s running condition and
send signals to the control unit. The actuator controls how much fuel is injected and
its timing according to the signals it receives from the control unit. The control unit
determines what signals it sends by calculating the optimum levels for the engine’s
running condition.
In-line fuel injection pump. One of two mechanically controlled diesel fuel systems,
the in-line fuel injection pump matches the engine cylinders in their number of fuel
pressure mechanisms. This pump is primarily used for medium to large trucks and
construction machinery. A camshaft drives the fuel pressure and injection quantity
control mechanisms within the pump body. The elements in that body follow an
injection order to feed fuel to each engine cylinder.
Distributor injection pump. Also a mechanically controlled diesel fuel pump, the
distributor injection pump has just one fuel pressure mechanism, despite the
number of engine cylinders the vehicle may have. The distributor is designed to
follow the injection order to distribute pressurized fuel to each cylinder. The pump
housing holds all of its components, including the governor, timer, and feed pump.
As it is so compact, this pump is light and can operate at high speeds, making it
perfect for small engines.

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