Chapter 4

Gasoline Fuel Systems

Topics
1.0.0 Gasoline Fuel Systems
2.0.0 Gasoline Fuel Injection Systems
3.0.0 Exhaust and Emission Control Systems
To hear audio, click on the box.

Overview
As a Construction Mechanic, you will be working with different types of fuel systems for
the internal combustion engine. It is important to know how these components function
to provide fuel to the engine and how to service those systems. You will need to be able
to identify the properties of gasoline and the components of a fuel system. The
information provided in this chapter will help you identify the different systems and
understand how they operate.

Objectives
When you have completed this chapter, you will be able to do the following:
1. Understand the different types of gasoline fuel systems, including how the
components function to provide fuel to the engine in proper quantities and how to
service the gasoline fuel systems.
2. Identify the properties of gasoline.
3. Identify the components of a fuel system.
4. Identify and understand the different gasoline fuel injection systems.
5. Identify components of the exhaust and emission control systems.
6. Understand the operation of the exhaust and emission control systems.

Prerequisites
None

NAVEDTRA 14264A 4-1

This course map shows all of the chapters in Construction Mechanic Basic. The
suggested training order begins at the bottom and proceeds up. Skill levels increase as
you advance on the course map.

Automotive Chassis and Body C

Brakes M
Construction Equipment Power Trains
Drive Lines, Differentials, Drive Axles,
and Power Train Accessories
Automotive Clutches, Transmissions,
and Transaxles
Hydraulic and Pneumatic Systems

Automotive Electrical Circuits and B

Wiring A
Basic Automotive Electricity S
Cooling and Lubrication Systems I
Diesel Fuel Systems C
Gasoline Fuel Systems
Construction of an Internal Combustion
Engine
Principles of an Internal Combustion
Engine
Technical Administration

Features of this Manual

This manual has several features which make it easy to use online.
• Figure and table numbers in the text are italicized. The figure or table is either
next to or below the text that refers to it.
• The first time a glossary term appears in the text, it is bold and italicized. When
your cursor crosses over that word or phrase, a popup box displays with the
appropriate definition.
• Audio and video clips are included in the text, with italicized instructions telling
you where to click to activate it.
• Review questions that apply to a section are listed under the Test Your
Knowledge banner at the end of the section. Select the answer you choose. If the
answer is correct, you will be taken to the next section heading. If the answer is
incorrect, you will be taken to the area in the chapter where the information is for

NAVEDTRA 14264A 4-2

 review. When you have completed your review, select anywhere in that area to
return to the review question. Try to answer the question again.
• Review questions are included at the end of this chapter. Select the answer you
choose. If the answer is correct, you will be taken to the next question. If the
answer is incorrect, you will be taken to the area in the chapter where the
information is for review. When you have completed your review, select
anywhere in that area to return to the review question. Try to answer the question
again.

NAVEDTRA 14264A 4-3

1.0.0 GASOLINE FUEL SYSTEMS
The function of the fuel system is to supply a combustible mixture of air and fuel to the
engine. Major elements of the gasoline fuel supply system include the following: fuel
tank and cap, fuel system emissions controls, fuel lines, fuel pump, fuel filter,
carburetor or fuel injection system, air cleaner, and exhaust system. Before learning
about these components of a gasoline fuel system, you should understand the
composition and properties of gasoline.

1.1.0 Gasoline
Gasoline is a highly volatile, flammable liquid hydrocarbon mixture used as a fuel for
internal combustion engines. A comparatively economical fuel, gasoline is the primary
fuel for automobiles worldwide. Chemicals called additives such as lead, detergents,
and anti-oxidants, are mixed into gasoline to improve its operating characteristics.
Antiknock additives are used to slow down the ignition and burning of gasoline. This
action helps to prevent engine ping or knock. Leaded gasoline has lead antiknock
additives. The lead allows a higher engine compression ratio to be used without the fuel
igniting prematurely. Leaded gasoline is designed to be used in older vehicles that have
little or no emission controls.
The fuel used today is unleaded gasoline. Unleaded gasoline, also called no-lead or
lead-free, does NOT contain lead antiknock additives. Congress has passed laws
requiring that all vehicles meet strict emission levels. As a result, manufacturers began
using catalytic converters and unleaded fuel.

1.2.0 Properties of Gasoline

For a gasoline fuel system to function properly, the fuel must have the right qualities to
burn evenly no matter what the demands of the engine are. To help you recognize the
qualities required of gasoline used for fuel, let’s examine the three properties of gasoline
and their effects on the operation of the engine.

1.2.1 Volatility
The ease with which gasoline vaporizes is called volatility. A high volatility gasoline
vaporizes very quickly. A low volatility gasoline vaporizes slowly. A good gasoline
should have the right volatility for the climate in which the gasoline is used.
If the gasoline is too volatile, it will vaporize in the fuel system. The result will be a
condition called vapor lock. Vapor lock is the formation of vapor in the fuel lines in a
quantity sufficient to prevent the flow of gasoline through the system. Vapor lock causes
the vehicle to stall from lack of fuel. In the summer and in hot climates, fuels with low
volatility lessen the tendency toward vapor lock.

1.2.2 Antiknock Quality

In modern high compression gasoline engines, the air-fuel mixture tends to ignite
spontaneously or to explode instead of burning rather slowly and uniformly. The result is
a knock, a ping, or a detonation. For this reason, gasoline refiners have various ways to
make gasoline that does not detonate easily.

1.2.3 Octane Rating

A gasoline that detonates easily is called low octane gasoline. A gasoline that resists
detonation is called high octane gasoline.
NAVEDTRA 14264A 4-4
The octane rating of a gasoline is a measurement of the ability of the fuel to resist knock
or ping. A high octane rating indicates the fuel will NOT knock or ping easily. It should
be used in a high compression or turbocharged engine. A low octane gasoline is
suitable for a low compression engine.
Octane numbers give the antiknock value of gasoline. A higher octane number (91) will
resist ping better than a gasoline with a low octane number (83). Each manufacturer
recommends an octane number for its engine.

1.3.0 Air-Fuel Ratio

For proper combustion and engine performance, the right amounts of air and fuel must
be mixed together. If too much fuel or too little fuel is used, engine power, fuel economy,
and efficiency are reduced.
For a gasoline engine, the perfect air-fuel ratio is 14.7:1 (14.7 parts air to 1 part fuel by
weight). Under constant engine conditions, this ratio can help assure that all fuel is
burned during combustion. The fuel system must change the air-fuel ratio with the
changes in engine-operating conditions.

1.3.1 Lean Air-Fuel Mixture

A lean air-fuel mixture contains a large amount of air. For example, 20:1 would be a
very lean mixture. A slightly lean mixture is desirable for high gas mileage and low
exhaust emissions. Extra air in the cylinder ensures that all the fuel will be burned;
however, too lean of a mixture can cause poor engine performance (lack of power,
missing) and even engine damage.

1.3.2 Rich Air-Fuel Mixture

A rich air-fuel mixture contains a little more fuel mixed with the air. For gasoline, 8:1(8
parts air to 1 part fuel) is a very rich mixture. A slightly rich mixture tends to increase
power; however, it also increases fuel consumption and exhaust emissions. An overly
rich mixture will reduce engine power, foul spark plugs, and cause incomplete burning
(black smoke at engine exhaust).

1.4.0 Gasoline Combustion

For gasoline or any other fuel to burn properly, it must be mixed with the right amount of
air. The mixture must then be compressed and ignited. The resulting combustion
produces heat, expansion of the gases, and pressure.

1.4.1 Normal Combustion

Normal gasoline combustion occurs when the spark plug ignites the fuel and burning
progresses smoothly through the fuel mixture. Maximum cylinder pressure should be
produced after a few degrees of crank rotation after the piston passes TDC on the
power stroke.
Normal combustion takes only about 3/1,000 of a second. This is much slower than an
explosion. Dynamite explodes in about 1/50,000 of a second. Under some undesirable
conditions, however, gasoline can be made to bum quickly, making part of the
combustion like an explosion.

NAVEDTRA 14264A 4-5

1.4.2 Abnormal Combustion
Abnormal combustion occurs when the flame does NOT spread evenly and smoothly
through the combustion chamber. The lean air-fuel mixture, high operating
temperatures, low octane, and unleaded fuels used today make abnormal combustion a
major problem that creates unfavorable conditions, such as the following:
• Detonation results when part of the unburned fuel mixture explodes violently.
This is the most severe engine-damaging type of abnormal combustion. Engine
knock is a symptom of detonation because pressure rises so quickly that parts of
the engine vibrate. Detonation sounds like a hammer hitting the side of the
engine. It can crack cylinder heads, blow head gaskets, burn pistons, and shatter
spark plugs.
• Pre-ignition results when an overheated surface in the combustion chamber
ignites the fuel mixture. Termed surface ignition, a hot spot (overheated bit of
carbon, sharp edge, and hot exhaust valve) causes the mixture to burn
prematurely. A ping or mild knock is a light tapping noise that can be heard
during pre-ignition. Pre-ignition is similar to detonation, but the action is reversed.
Detonation begins after the start of normal combustion, and pre-ignition occurs
before the start of normal combustion. Pre-ignition is common to modern
vehicles. Some manufacturers say that some pre-ignition is normal when
accelerating under a load.
• Dieseling, also called after-running or run on, is a problem when the engine
keeps running after the key is turned off. A knocking, coughing, or fluttering noise
may be heard as the fuel ignites and the crankshaft spins. When dieseling, the
engine ignites the fuel from heat and pressure, somewhat like a diesel engine.
With the key off, the engine runs without voltage to the spark plugs. The most
common causes of dieseling are high idle speed, carbon deposits in the
combustion chambers, low octane fuel, overheated engine, or spark plugs with
too high of a heat range.
• Spark knock is another combustion problem caused by the spark plug firing too
soon in relation to the position of the piston. The spark timing is advanced too far,
causing combustion to slam into the upward moving piston. This causes
maximum cylinder pressures to form before TDC, not after TDC as it should.
Spark knock and pre-ignition both produce about the same symptoms—pinging
under load. To find its cause, first check ignition timing. If ignition timing is
correct, check other possible causes.

1.5.0 Gasoline Fuel System Components

A gasoline fuel system draws fuel from the tank and forces it into the fuel-metering
device (carburetor, gasoline injectors), using either a mechanical (engine-driven) or
electric fuel pump. The basic parts of a fuel supply system include the following:
• Fuel tank (stores gasoline)
• Fuel pump (draws fuel from the tank and forces it to the fuel-metering device)
• Fuel filters (remove contaminants in the fuel)
• Fuel lines (carry fuel between the tank, the pump, and other parts)

NAVEDTRA 14264A 4-6

1.5.1 Fuel Tank
An automotive fuel tank must safely hold an adequate supply of fuel for prolonged
engine operation. The location of the fuel tank should be in an area that is protected
from flying debris, shielded from collision damage, and not subjected to bottoming
(Figure 4-1). A fuel tank can be located just about anywhere in the vehicle that meets
these requirements.

Figure 4-1— Common fuel tank locations.

Figure 4-2 shows the general construction of a fuel tank used on automotive equipment.
Fuel tanks are usually made of thin sheet metal or plastic. The main body of a metal
tank is made by soldering or welding two
formed pieces of sheet metal together. Other
parts (filer neck, fuel tank cap, and baffles)
are added to the form to complete the fuel
tank assembly. A lead-tin alloy is normally
plated to the sheet metal to prevent the tank
from rusting.
The fuel tank filler neck is an extension on
the tank for filling the tank with fuel. The filler
cap fits on the end of the filler neck. The
neck extends from the tank through the body
of the vehicle. A flexible hose is normally
used as part of the filler neck to allow for
tank vibration without breakage.
In vehicles requiring unleaded fuel, a fuel
neck restrictor is used inside the filler neck.
This prevents the accidental use of leaded
Figure 4-2— Fuel tank
gasoline in an engine designed for unleaded.
construction.
The restrictor is too small to accept the larger
leaded fuel type pump nozzle.

WARNING
If the restrictor is removed and leaded fuel is used in a vehicle designed for unleaded
fuel, the catalytic converter will be damaged. This action is a violation of federal law;
therefore, NEVER remove the filler neck restrictor.

NAVEDTRA 14264A 4-7

Modern fuel tank caps are sealed to prevent escape of fuel and fuel vapors (emissions)
from the tank. The cap has pressure and vacuum valves that open only under abnormal
conditions of high pressure or vacuum.
Fuel tank baffles are placed inside the tank to prevent the fuel from sloshing or
splashing around in the tank. The baffles are metal plates that restrict fuel movement
when the vehicle accelerates, decelerates, or turns corners.
Fuel tanks give little or no trouble, and generally require no servicing other than an
occasional draining and cleaning.

WARNING
If a fuel tank is punctured or develops leaks, it should NOT be welded or repaired with
or near an open flame until all traces of fuel and fuel vapors have been completely
removed from the tank. Before attempting to make any repairs to a fuel tank, consult
with the shop supervisor for specific instructions on all safety precautions to be
observed.

1.5.2 Fuel Gauges

The fuel gauge indicates the fuel level in the fuel tank. It is a magnetic indicating system
that can be found on either an analog or digital instrument panel.
The fuel sending unit is combined with the fuel pump assembly and consists of a
variable resistor controlled by the level of an attached float mechanism in the tank.
When the fuel is low, resistance in the sender is low; therefore movement of lift of the
gauge is low. When the resistance is high, such as with a full tank, the indicator is high,
showing the gauge higher up the scale on the instrument panel.

1.5.3 Fuel Filters

The fuel injection system is highly sensitive to foreign particles. Fuel filters prevent
water, dirt, and rust particles from entering the system. Contaminated fuel can cause
incomplete combustion, smoky exhaust,
engine knocking, and difficulties starting the
engine. Most heavy equipment has a fuel
pressure gauge that indicates when the
filters are dirty.
The fuel filter operates by passing fuel
through a porous element that removes
particles large enough to cause problems in
the system (Figure 4-3). Particles are often
measured in microns. A micron is one
millionth of a meter.
Some filters serve as sediment bowls.
These types of filters separate water and
larger particles from the fuel. After
separation, the water and particles settle to
the bottom of the bowl, where they can be
removed through a drain plug.
Figure 4-3— Fuel filter operation.

NAVEDTRA 14264A 4-8

Filter elements can be made of ceramic,
treated paper, sintered bronze or metal
screen (Figure 4-4). Some filter elements
are made of laminated disks that are
spaced 0.0003 inches apart. Foreign matter
is blocked out as the fuel passes between
the disks.

1.5.4 Fuel Pump

A fuel pump is the device that draws the
fuel from the tank to the engine’s injection
system. All late model vehicles use an
electric fuel pump.
The fuel pump can be located either inside
the tank or in the fuel system after the tank.
There are four types of fuel pumps: the
diaphragm, plunger, bellows, and impeller Figure 4-4— Fuel filter elements.
or rotary pump. The in-tank electric pump is
usually a rotary pump. The others are
usually of the demand style, meaning that
when the ignition is turned on, the fuel pump starts and when the pressure in the system
is correct, it shuts off. When more fuel is required, the pump starts again.
Most vehicles have an in-tank fuel pump. Some other vehicles also have a secondary
pump along the fuel line. Fuel pumps are mounted in the tank to help keep the pump
cool.
Nearly all electric fuel pump circuits have some sort of rollover protection. Typically this
protection includes the installation of an inertia switch that shuts off the fuel pump if the
vehicle rolls over or is in an accident.

1.5.5 Fuel Lines and Hoses

Fuel lines and hoses carry fuel from the tank to the filter and fuel injection assembly.
They can be made from either metal tubing or flexible nylon or synthetic rubber hoses.
The latter must be able to resist gasoline. The hoses must be nonpermeable so gas and
gas vapors cannot evaporate through the hose.
Fuel supply lines from the tank to the injectors usually follow the frame of the vehicle
along the underchassis. Generally, rigid lines are used from the tank to the fuel pump or
filter. To absorb vibration, these lines can be joined with short lengths of flexible hose.
Many tanks also have vent hoses to allow air in the tank to escape when the tank is
being filled. Vent hoses are usually routed alongside the filler neck.
Faulty fuel lines and hoses are a common source of fuel leaks. Fuel hoses can become
hard and brittle after being exposed to the engine heat and the elements. Engine oil can
soften and swell them. Always inspect hoses closely and replace any in poor condition.
Metal fuel lines rarely cause problems; however, they should be replaced if they
become smashed, kinked, rusted, or leaky. Remember these rules when working with
fuel lines and hoses:
• Place a rag around the fuel line fitting during removal to keep fuel from spraying
on you or on a hot engine. Use a flare nut or tubing wrench on fuel line fittings.

NAVEDTRA 14264A 4-9

 • Use only approved double wall steel tubing for fuel lines. NEVER use copper or
plastic tubing.
• Make smooth bends when forming a new fuel line. Use a bending spring or
bending tool.
• Form double lap flares on the ends of fuel lines. A single lap flare is NOT
approved for fuel lines.
• Reinstall fuel line hold-down clamps and brackets. If not properly supported, the
fuel line can vibrate and fail.
• Route all fuel lines and hoses away from hot or moving parts. Double-check the
clearance after installation.
• Use only approved synthetic rubber hoses in a fuel system. Vacuum hose is NOT
to be used as fuel hose.
• Make sure fuel hoses completely cover their fittings or lines before installing
clamps. Pressure in the fuel system could force a hose off if not installed
properly.
• Double-check all fittings for leaks. Start the engine and inspect the connections
closely.

CAUTION
Most fuel injection systems have very high fuel pressure. Follow recommended
procedures for bleeding or releasing pressure before disconnecting a fuel line or fitting.
This action will prevent fuel spray from possibly causing injury or a fire.

1.5.6 Fuel Pressure Regulator

The fuel pressure regulator controls the amount of pressure entering the injector valves.
When sufficient pressure is attained, the regulator returns excess fuel to the tank. This
maintains a preset amount of fuel pressure for injector valve operation.

1.5.7 Fuel Injectors

Fuel injection systems can have one or
more fuel supply devices called fuel
injectors (Figure 4-5). Fuel injectors are
controlled by an ECM. The computer
system sends an electrical current to
activate the solenoid inside the injector.
When the solenoid is activated, the injector
nozzle opens and squirts atomized fuel in a
cone-shaped pattern. The computer
system controls the fuel-air ratio by varying
the length of time that the injector nozzle
remains open.
In gasoline engines injectors squirt fuel into
the intake manifold. In diesel engines, fuel
is delivered directly into the combustion
chamber. Spring pressure closes the Figure 4-5— Fuel injector.
injector nozzle when the solenoid is
deactivated.
NAVEDTRA 14264A 4-10
1.6.0 Air Cleaner
Air cleaners are used to prevent foreign matter, such as sand, dust, and lint, from
entering the intake system (Figure 4-6). Contaminated air in the intake system can
cause engine wear, poor combustion, and engine breakdown. In addition to supplying
clean air, air cleaners reduce vibration sounds and other noises caused by air entering
the intake system.

Figure 4-6 — Air cleaners.

Test your Knowledge (Select the Correct Response)

1. Which of the following is NOT a property of gasoline?

A. Volatility
B. Antiknock quality
C. Cetane number
D. Octane rating

2. Which of the following air-fuel ratios is considered to be perfect for a gasoline

engine?

A. 20:1
B. 14.7:1
C. 17.4:1
D. 18.8:1

3. The fuel pressure regulator controls the amount of pressure entering the ______.

A. intake
B. valves
C. injectors
D. pump

NAVEDTRA 14264A 4-11

2.0.0 GASOLINE FUEL INJECTION SYSTEMS
A modern gasoline injection system uses pressure from an electric fuel pump to spray
fuel into the engine intake manifold. Like a carburetor, it must provide the engine with
the correct air-fuel mixture for specific operating conditions. Unlike a carburetor,
however, PRESSURE, not engine vacuum, is used to feed fuel into the engine. This
makes the gasoline injection system very efficient. A gasoline injection system has
several possible advantages over a carburetor type of fuel system. Some advantages
are as follows:
• Improved atomization. Fuel is forced into the intake manifold under pressure
that helps break fuel droplets into a fine mist.
• Better fuel distribution. Each cylinder receives an equal flow of fuel vapors.
• Smoother idle. Lean fuel mixture can be used without rough idle because of
better fuel distribution and low-speed atomization.
• Lower emissions. Lean, efficient air-fuel mixture reduces exhaust pollution.
• Better cold weather drivability. Injection provides better control of mixture
enrichment than a carburetor.
• Increased engine power. Precise metering of fuel to each cylinder and
increased air flow can result in more horsepower output.
• Fewer parts. Simpler, late model, electronic fuel injection systems have fewer
parts than modern computer-controlled carburetors.
There are many types of gasoline injection systems. Before studying the most common
ones, you should have a basic knowledge of the different classifications. Systems are
classified as either single- or multi-point injection and as either indirect or direct
injection.
The point or location of fuel injection is one way to classify a gasoline injection system.
A single-point injection system, also call throttle body injection (TBI), has the injector
nozzles in a throttle body assembly on top of the engine. Fuel is sprayed into the top
center of the intake manifold.
A multi-point injection system, also called port injection, has an injector in the port (air-
fuel passage) going to each cylinder. Gasoline is sprayed into each intake port and
toward each intake valve. Thereby, the term multi-point (more than one location) fuel
injection is used.
An indirect injection system sprays fuel into the engine intake manifold. Most gasoline
injection systems are of this type. Direct injection forces fuel into the engine combustion
chambers.
There are several basic configurations of gasoline fuel injection we will discuss the
timed, and throttle body.

2.1.0 Timed Fuel Injection System

Timed fuel injection systems for gasoline engines inject a measured amount of fuel in
timed bursts that are synchronized to the intake strokes of the engine. Timed injection
is the most precise form of fuel injection but is also the most complex. There are two
basic forms of timed fuel injection: mechanical and electronic.

NAVEDTRA 14264A 4-12

The basic operation of a
mechanical-timed injection
system (Figure 4-7) is as follows:
A high-pressure electric pump
draws fuel from the fuel tank and
delivers it to the metering unit. A
pressure relief valve is installed
between the fuel pump and the
metering unit to regulate fuel line
pressure by bleeding off excess
fuel back to the tank.
The metering unit is a pump that
is driven by the engine camshaft.
It is always in the same rotational
relationship with the camshaft so
it can be timed to feed the fuel to
the injectors just at the right
moment.
Each injector contains a spring-
loaded valve that is opened by
fuel pressure, injecting fuel into Figure 4-7 — Mechanical-timed injection
the intake at a point just before system.
the intake valve opens.
The throttle valve regulates engine speed and power output by regulating manifold
vacuum, which, in turn, regulates the amount of fuel supplied to the injectors by the
metering pump.
The more common type of timed fuel injection is the electronic-timed fuel injection, also
known as electronic fuel injection, or EFI (Figure 4-8). An electronic fuel injection
system can be divided into four
subsystems:
• Fuel delivery system
• Air induction system
• Sensor system
• Computer control
system
The fuel delivery system of an
EFI system includes an electric
fuel pump, a fuel filter, a
pressure regulator, the injector
valves, and the connecting
lines and hoses.
The electric fuel pump draws
fuel out of the tank and forces it
into the pressure regulator.
The fuel pressure regulator
controls the amount of
NAVEDTRA 14264A Figure 4-8 — Electronic fuel injection. 4-13
pressure entering the injector valves. When sufficient pressure is attained, the regulator
returns excess fuel to the tank. This maintains a preset amount of fuel pressure for
injector valve operation.
The fuel injector for an EFI system is a coil or solenoid-operated fuel valve. When not
energized, spring pressure keeps the injector closed, keeping fuel from entering the
engine. When current flows through the injector coil or solenoid, the magnetic field
attracts the injector armature. The injector opens, squirting fuel into the intake manifold
under pressure.
The air induction system for the EFI typically consists of a throttle valve, sensors, an air
filter, and connecting ducts.
The throttle valve regulates how much air flows into the engine. In turn, it controls
engine power output. Like the carburetor throttle valve, it is connected to the gas pedal.
When the pedal is depressed, the throttle valve swings open to allow more air to rush
into the engine.
The EFI sensor system monitors engine operating conditions and reports this
information to the computer. A sensor is an electrical device that changes circuit
resistance or voltage with a change in a condition (temperature, pressure, position of
parts, etc.). For example, the resistance of a temperature sensor may decrease as
temperature increases. The computer can use the increased current flow through the
sensor to calculate any needed change in the injector valve opening. Typical sensors
for an EFI system include the following:
• Exhaust gas or oxygen sensor
• Manifold pressure sensor
• Throttle position sensor
• Engine temperature sensor
• Air flow sensor
• Inlet air temperature sensor
• Crankshaft position sensor
Since some of these sensors were discussed in the section on computerized carburetor
systems, we will concentrate only on the sensors that are particular to the EFI system.
These sensors are as follows:
The throttle position sensor is a variable resistor connected to the throttle plate shaft.
When the throttle swings open for more power or closes for less power, the sensor
changes resistance and signals the computer. The computer can then enrich or lean the
mixture as needed.
The air flow sensor is used in many EFI systems to measure the amount of outside air
entering the engine. It is usually an air flap or door that operates a variable resistor.
Increased air flow opens the air flap more to change the position of the resistor.
Information is sent to the computer indicating air inlet volume.
The inlet air temperature sensor measures the temperature of the air entering the
engine. Cold air is denser, requiring a little more fuel. Warm air is not as dense as cold,
requiring a little less fuel. The sensor helps the computer compensate for changes in
outside air temperature and maintain an almost perfect air-fuel mixture ratio.

NAVEDTRA 14264A 4-14

The crankshaft position sensor is used to detect engine speed. It allows the computer to
change injector openings with changes in engine rpm.
The signal from the engine sensors can be either a digital or an analog type output.
Digital signals are on/off signals. An example is the crankshaft position sensor that
shows engine rpm. Voltage output or resistance goes from maximum to minimum, like a
switch. An analog signal changes in strength to let the computer know about a change
in condition. Sensor internal resistance may smoothly increase or decrease with
temperature, pressure, or part position. The sensor acts as a variable resistor.
Basic operation of an electronic-timed injection system is as follows:
Fuel is fed by a high-pressure electric fuel pump to the injectors that are connected in
parallel to a common fuel line.
The fuel pressure regulator is installed in line with the injectors to keep fuel pressure
constant by diverting excess fuel back to the tank.
Each injector contains a solenoid valve and is normally in a closed position. With a
pressurized supply of fuel behind it, each injector will operate individually whenever
electric current is applied to the solenoid valve.
The electronic computer sends the electric impulses and provides the proper amount of
fuel. The computer receives a signal for the ignition distributor to establish the timing
sequence.
By sending electric current impulses to the injectors in a sequence timed to coincide
with the needs of the engine, the system will supply fuel to the engine as it should.

2.2.0 Throttle Body Injection System

The throttle body injection (TBI) system
uses one or two injector valves mounted in
a throttle body assembly (Figure 4-9). The
injectors spray fuel into the top of the
throttle body air horn The TBI fuel spray
mixes with the air flowing through the air
horn. The mixture is then pulled into the
engine by intake manifold vacuum. The
throttle body injection assembly typically
consists of the following: throttle body
housing, fuel injectors, fuel pressure
regulator, Idle air control sensor, throttle
position sensor, and throttle plates.
The throttle body housing, like a carburetor
body, bolts to the pad on the intake
manifold.
It houses the metal castings that hold the
Figure 4-9 — Throttle body
injectors, the fuel pressure regulator, and
injection.
the throttle plates. The throttle plates are
located in the lower section of the body. A linkage or cable connects the throttle plates
with the accelerator pedal. An inlet fuel line and an outlet return line connect to the
fittings on the body.
The throttle body injector consists of an electric solenoid coil, armature or plunger, ball
or needle valve and seat, and injector spring. Wires from the computer connect to
NAVEDTRA 14264A 4-15
terminals on the injectors. When the computer energizes the injectors, a magnetic field
is produced in the injector coil. The magnetic field pulls the plunger and valve up to
open the injector. Fuel can then squirt through the injector nozzle and into the engine.
The throttle body pressure regulator consists of a fuel valve, a diaphragm, and a spring.
When fuel pressure is low, the spring holds the fuel valve closed, causing pressure to
build as fuel flows into the regulator from the fuel pump. When a preset pressure is
reached, pressure acts on the diaphragm. The diaphragm compresses the spring and
opens the fuel valve. Fuel can then flow back to the fuel tank, limiting the maximum fuel
pressure at the injectors.
Although throttle body injection does not provide the precise fuel distribution of the
direct port injection, it is much cheaper to produce and provides a much higher degree
of precision fuel metering than a carburetor.

2.3.0 Multi-Port Injection

Multi-port injection systems use a computer, engine sensors, and one solenoid injector
for each cylinder. This is the most common fuel injection system in late model vehicles.
The multi-port injection system operates similar to that of a throttle body injection
system, except that the fuel is injected at each intake port instead of at the top of the
intake manifold.
A fuel rail feeds fuel to the injectors. It connects the main fuel line to the inlet of each
injector. The injector is pressure fit into a port in the intake manifold. Each injector is
aimed to spray fuel toward the engine’s intake valve. Each injector is connected to the
computer and is electronically fired just before the intake valve is to open.

2.4.0 Direct Injection

Direct injection has been around for many
years on a diesel engine. With gasoline
direct injection (GDI), the gasoline is
injected directly into the combustion
chamber (Figure 4-10). To make this
possible, specially designed injectors
deliver fuel into the high pressures and
temperatures in the cylinders. To prevent
heat from igniting the fuel in the injector,
the injectors are designed to completely
seal after the fuel is sprayed. The injectors
must also be able to spray the fuel at a
higher pressure than what is in the
cylinder.
GDI allows for very lean operation during
cruising. When the engine is operating
under heavy loads, the system provides
near perfect air-fuel mixture. The ability to Figure 4-10 — Gasoline direct
run at such lean mixtures allows for injection.
increased fuel economy, nearly 30%.
Spraying the fuel directly into the cylinder also increases volumetric efficiency. GDI
decreases an engine’s tendency to knock, allowing for a higher compression ratio
without the need for a higher octane gasoline.

NAVEDTRA 14264A 4-16

With GDI, fuel can be injected at any time, not just during intake. The injectors can
pulse twice during the transition from the compression stroke to combustion. The two
pulses promote complete combustion when the PCM senses operating conditions may
prevent a complete burning of fuel.
The fuel is injected into the cylinder under enormous pressure, typically between 400
and 1,500 psi. The injector delivers a relatively small, precisely shaped burst of fuel
around the spark plug just before ignition. This means only the area around the spark
plug has air and fuel to begin combustion; the rest of the chamber is filled with air.
The fuel pump that delivers this high pressure is driven by the engine. The pump is fed
by an in-tank electric fuel pump. A PCM controls the timing of injection and ignition for
each cylinder.

Test your Knowledge (Select the Correct Response)

4. A gasoline injection system has all these advantages over a carburetor, except
which one?

A. Improved atomization
B. Better fuel distribution
C. Lower horse power
D. Lower emissions

5. What gasoline fuel injection system is the most precise and also the most
complex?

A. Hydraulic-timed
B. Throttle body fuel
C. Timed fuel
D. Continuous fuel

3.0.0 EXHAUST and EMISSION CONTROL SYSTEMS

Over the past several years, exhaust and emission control has greatly increased
because of stringent anti-pollution laws and EPA guidelines. This has made the exhaust
and emission control systems of vehicles invaluable and a vital part of today’s vehicles.
The waste products of combustion are carried away from the engine to the rear of the
vehicle by the exhaust system where they are expelled to the atmosphere. The exhaust
system also serves to dampen engine noise. The parts of a typical exhaust system
include the following: exhaust manifold, header pipe, catalytic converter, intermediate
pipe, muffler, tailpipe, hangers, heat shields, and muffler clamps.
The control of exhaust emissions is a difficult job. The ideal situation would be to have
the fuel combine completely with the oxygen from the intake air. The carbon would then
combine with the oxygen to form carbon dioxide (CO2), the hydrogen would combine to
form water (H2O), and the nitrogen present in the intake would stand alone. The only
other product present in the exhaust would be the oxygen from the intake air that was
not used in the burning of the fuel. In a real life situation, however, this is not what
happens. The fuel never combines completely with the oxygen, and undesirable
exhaust emissions are created as a result.

NAVEDTRA 14264A 4-17

The most dangerous of the emissions is carbon monoxide (CO), which is a poisonous
gas that is colorless and odorless. CO is formed as a result of insufficient oxygen in the
combustion mixture and combustion chamber temperatures that are too low. Other
exhaust emissions that are considered major pollutants are as follows:
Hydrocarbons (HC) are unburned fuel. They are particulate (solid) in form, and, like
carbon monoxide, are manufactured by insufficient oxygen in the combustion mixture
and combustion chamber temperatures that are too low. Hydrocarbons are harmful to
all living things. In any urban area where vehicular traffic is heavy, hydrocarbons in
heavy concentrations react with the sunlight to produce a brown fog known as
photochemical smog.
Oxides of nitrogen (NOx) are formed when nitrogen and oxygen in the intake air
combine when subjected to high temperatures of combustion. Oxides of nitrogen are
harmful to all living things.
The temperatures of the combustion chamber would have to be raised to a point that
would melt pistons and valves to eliminate carbon monoxide and carbon dioxide
emissions. Furthermore, oxides of nitrogen emissions go up with any increase in the
combustion chamber temperature. Knowing these facts, you can see why emission
control devices are necessary.

3.1.0 Exhaust Manifold

The exhaust manifold connects all the engine cylinders to the exhaust system. It is
usually made of cast iron. If the exhaust manifold is properly formed, it can create a
scavenging action that will cause all of the cylinders to help each other get rid of
exhaust gases. Back pressure (the force that the pistons must exert to push out the
exhaust gases) can be reduced by making the manifold with smooth walls and without
any sharp bends. All these factors are taken into consideration when the exhaust
manifold is designed, and the best possible manifold is manufactured to fit into the
confines of the engine compartment.

3.2.0 Catalytic Converters

It is impossible to keep carbon monoxide and hydrocarbon emissions at acceptable
levels by controlling them in the cylinder without shortening engine life considerably.
The most practical method of controlling these emissions is outside the engine using a
catalytic converter. The catalytic converter is similar in appearance to the muffler and is
positioned in the exhaust system between the engine and muffler. As the engine
exhaust passes through the converter, carbon monoxide and hydrocarbons are oxided
(combined with oxygen), changing them into carbon dioxide and water.
The catalytic converter contains a material (usually platinum or palladium) that acts as a
catalyst. The catalyst is something that causes a reaction between two substances
without actually getting involved. In the case of the catalytic converter, oxygen is joined
chemically with carbon monoxide and hydrocarbons in the presence of its catalyst.
Because platinum and palladium are both very precious metals and the catalyst must
have a tremendous amount of surface area in order to work properly, it has been found
that the following internal structures work best for catalytic converters:
Pellet type is filled with aluminum oxide pellets that have a very thin coating of catalytic
material (Figure 4-11, View A). Aluminum oxide has a rough outer surface, giving each
pellet a tremendous amount of surface area. The converter contains baffles to ensure
maximum exposure of the exhaust to the pellets.

NAVEDTRA 14264A 4-18

Monolithic type uses a one-piece ceramic structure in a honeycomb style form (Figure
4-11, View B). The structure is coated thinly with a catalytic material. The honeycomb
shape has a tremendous surface area to ensure maximum exposure of exhaust gases
to the catalyst.

Figure 4-11— Catalytic converter.

An adequate amount of oxygen must be present in the exhaust system for the catalytic
converter to operate; therefore, a supporting system, such as an air injection system,
usually is placed on catalytic converter-equipped engines to dilute the exhaust stream
with fresh air.

3.3.0 Muffler
The muffler reduces the acoustic pressure of exhaust gases and discharges them to the
atmosphere with a minimum of noise (Figure 4-12). The muffler usually is located at
about midpoint in the vehicle with the exhaust pipe between it and the exhaust manifold,
and the tailpipe leading from the muffler to
the rear of the vehicle.
The inlet and outlet of the muffler usually
are slightly larger than their connecting
pipes so that they may hook up by slipping
over them. The muffler is then secured to
the exhaust pipe and tailpipe by clamps.
A typical muffler has several concentric
chambers with openings between them.
The gas enters the inner chamber and
expands as it works its way through a
series of holes in the other chambers and
finally to the atmosphere. They must be
designed also to quiet exhaust noise while
creating minimum back pressure. High
back pressure could cause loss of engine
power and economy as well as
Figure 4-12 — Muffler.
overheating.
Exhaust system components usually are
made of steel. They are coated with
aluminum or zinc to retard corrosion. Stainless steel also is used in exhaust systems in
NAVEDTRA 14264A 4-19
limited quantities due to its high cost. A stainless steel exhaust system will last
indefinitely.

3.4.0 Air Injection System

An air injection system forces fresh air into the exhaust ports of the engine to reduce HC
and CO emissions (Figure 4-13). The exhaust gases leaving an engine can contain
unburned and partially burned fuel. Oxygen from the air injection system causes this
fuel to continue to burn. The major parts of the system are the air pump, the diverter
valve, the air distribution manifold, and the air check valve.

Figure 4-13 — Air injection system.

The air pump is belt-driven and forces air at low pressure into the system. A hose is
connected to the output of the diverter valve.
The diverter valve keeps air from entering the exhaust system during deceleration. This
prevents backfiring in the exhaust system. Also, the diverter valve limits maximum
system air pressure when needed, releasing excessive pressure through a silencer or a
muffler.
The air distribution manifold directs a stream of fresh air toward each engine exhaust
valve. Fittings on the air distribution manifold screw into a threaded hole in the exhaust
manifold or cylinder head.
The air check valve is usually located in the line between the diverter valve and the air
distribution manifold. It keeps exhaust gases from entering the air injection system.
NAVEDTRA 14264A 4-20
Basic operation of the air injection system is as follows:
When the engine is running, the spinning vanes of the air pump force air into the
diverter valve. If the engine is not decelerating, the air is forced through the diverter
valve, the check valve, the air injection manifold, and into the engine. The fresh air
blows on the exhaust valves.
During periods of deceleration, the diverter valve blocks air flow into the engine exhaust
manifold. This prevents a possible backfire that could damage the exhaust system of
the vehicle. When needed, the diverter valve will release excess pressure in the system.

3.5.0 Positive Crankcase Ventilation (PCV) System

The positive crankcase ventilation system uses manifold vacuum to purge the
crankcase blow-by fumes. The fumes are then aspirated back into the engine where
they are reburned.
A hose is tapped into the crankcase at a point that is well above the engine oil level.
The other end of the hose is tapped into the intake manifold.
An inlet breather is installed on the crankcase in a location that is well above the level of
the engine oil. The inlet breather also is located strategically to ensure complete purging
of the crankcase fresh air. The areas of the crankcase where the vacuum hose and inlet
breather are tapped have baffles to keep motor oil from leaving the crankcase.
A flow control valve is installed in
the line that connects the
crankcase to the manifold. It is
called a positive crankcase
ventilation (PCV) valve (Figure
4-14) and serves to avoid the
air-fuel mixture by doing the
following:
Any periods of large throttle
opening will be accompanied by
heavy engine loads. Crankcase
blow-by will be at its maximum
during heavy engine loads. The
PCV valve will react to the small
amount of manifold vacuum that
also is present during heavy
engine loading by opening fully
through the force of its control
valve spring. In this way, the
system provides maximum
effectiveness during maximum Figure 4-14 — Positive crankcase ventilation
blow-by periods. system.
Any period of small throttle
opening will be accompanied by small engine loads, high manifold vacuum, and a
minimum amount of crankcase blow-by. During these periods, the high manifold
vacuum will pull the PCV valve to its position of minimum opening. This is important to
prevent an excessively lean air-fuel mixture.
In the event of engine backfire (flame traveling back through the intake manifold), the
reverse pressure will push the rear shoulder of the control valve against the valve body.
NAVEDTRA 14264A 4-21
This will seal the crankcase from the backfire which could otherwise cause an
explosion.
A PCV system keeps the inside of the engine clean and reduces air pollution. Older
engines used an open PCV system. This system is no longer in use. The closed system
uses a sealed oil filler cap, a sealed dip stick, ventilation hoses, and either a PCV valve
or flow restrictor. The gases are drawn into the engine and burned. The system stores
the gases when the engine is not being run.

3.6.0 Exhaust Gas Recirculation (EGR) System

The exhaust gas recirculation system allows burned gases to enter the engine intake
manifold to help reduce oxides of nitrogen (NOx) emissions. When exhaust gases are
added to the air-fuel mixture, they decrease peak combustion temperatures (maximum
temperature produced when the air-fuel mixture burns). For this reason, an exhaust gas
recirculation system lowers the amount of NOx in the engine exhaust. EGR systems can
be controlled by engine vacuum or by the engine control module.
Vacuum controlled EGR systems use engine vacuum to operate the EGR valve (Figure
4-15). This system is found on older vehicles.

Figure 4-15 — Vacuum controlled EGR valve.

The basic vacuum EGR system consists of a vacuum-operated EGR valve and a
vacuum line from the throttle body or carburetor. The EGR valve is bolted to the engine
intake manifold to control the air-fuel ratio and reduce exhaust emissions. Exhaust
gases are routed through the cylinder head and intake manifold to the EGR valve.
The EGR valve consists of a vacuum diaphragm, spring, plunger, exhaust gas valve,
and diaphragm housing. It is designed to control exhaust flow into the intake when the
throttle is opened and the increased vacuum pulls the diaphragm open on the EGR
valve, in turn opening the exhaust outlet to allow exhaust gas into the intake manifold.
An electronic-vacuum EGR valve uses both engine vacuum and electronic control for
better exhaust gas metering. An EGR position sensor is located on top of the EGR
valve. This sensor sends data to the ECM and allows the computer to determine how
far to open the EGR valve.
Electronic EGR systems use vehicle sensors, the ECM, and a solenoid-operated EGR
valve. This is the most common type of EGR system used on late model engines.
The ECM uses data from the EGR position sensor, engine coolant temperature sensor,
mass airflow sensor, throttle position sensor, crankshaft position sensor, and various
NAVEDTRA 14264A 4-22
other sensors to control the air fuel ratio and reduce exhaust emission. The data
collected will determine the duty cycle for the EGR valve to allow certain amounts of
gases to be recirculated for maximum efficiency.

3.7.0 Fuel Evaporation Control System

The fuel evaporization control system prevents vapors from the fuel tank and carburetor
from entering the atmosphere (Figure 4-16). Older, pre-emission vehicles used vented
fuel tank caps. Carburetor bowls were also vented to the atmosphere. This caused a
considerable amount of emissions. Modern vehicles commonly use fuel evaporization
control systems to prevent this source of pollution. The major components of the fuel
evaporization control systems are the sealed fuel tank cap, fuel air dome, liquid-vapor
separator, rollover valve, fuel tank vent line, charcoal canister, carburetor vent line, and
the purge line.

Figure 4-16 — Fuel evaporation system.

The sealed fuel tank cap is used to keep fuel vapors from entering the atmosphere
through the tank filler neck. It may contain pressure and vacuum valves that open in
extreme cases of pressure or vacuum. When the fuel expands (from warming), tank
pressure forces fuel vapors out a vent line or line at the top of the fuel tank, not out of
the cap.
The fuel air dome is a hump designed into the top of the fuel tank to allow for fuel
expansion. The dome normally provides about 10 percent air space to allow for fuel
heating and volume increase.
The liquid-vapor separator is frequently used to keep liquid fuel from entering the
evaporation control system. It is simply a metal tank located above the main fuel tank.
Liquid fuel condenses on the walls of the separator and then flows back into the fuel
tank.
The roll-over valve is sometimes used in the vent line from the fuel tank. It keeps liquid
fuel from entering the vent line after an accident where the vehicle rolled upside down.
The valve contains a metal ball or plunger valve that blocks the vent line when the valve
is turned over.

NAVEDTRA 14264A 4-23

The fuel tank vent line carries fuel vapors up to a charcoal canister in the engine
compartment.
The charcoal canister stores fuel vapors when the engine is not running. The metal or
plastic canister is filled with activated charcoal granules capable of absorbing fuel
vapors.
The purge line is used for removing or cleaning the stored vapors out of the charcoal
canister. It connects the canister and the engine intake manifold.
Basic operation of a fuel evaporization control system is as follows:
When the engine is running, intake manifold vacuum acts on the purge line, causing
fresh air to flow through the filter at the bottom of the canister. The incoming fresh air
picks up the stored fuel vapors and carries them through the purge line. The vapors
enter the intake manifold and are pulled into the combustion chambers for burning.
When the engine is shut off, engine heat produces excess vapors. These vapors flow
through the vent line and into the charcoal canister for storage. The vapors that form in
the tank flow through the liquid vapor separator into the tank vent line to the charcoal
canister. The charcoal canister absorbs these fuel vapors and holds them until the
engine is started again.

3.8.0 Oxygen Sensor

The oxygen sensor monitors the exhaust gases for oxygen content. The amount of
oxygen in the exhaust gases is a good indicator of the engine’s operational state. The
oxygen sensor’s voltage output varies with any changes in the exhaust’s oxygen
content. For example, an increase in oxygen, which would indicate a lean mixture, will
make the sensor output voltage decrease. A decrease in oxygen which occurs during
rich mixture conditions causes the sensor output voltage to increase.
In this way, the oxygen sensor supplies data to the computer. The computer can then
alter the opening and closing of the injectors to maintain a correct air-fuel ratio for
maximum efficiency.

3.8.1 Pre Oxygen Sensor

A pre oxygen (O2) sensor is the O2 sensor located in front of the catalytic converter.
The signal from the pre O2 sensor indicates whether the engine’s air-fuel mixture is too
lean or too rich.

3.8.2 Post Oxygen Sensor

The post oxygen sensor is located further down the exhaust system after the catalytic
converter. It checks the oxygen content of the exhaust gases to determine if the
converter is working properly. If the oxygen content after the converter is the same as
before, it will send a signal to the trouble light on the dash board to let the operator
know there is a problem with the catalytic converter.

3.8.3 Heated Oxygen Sensor

The heated oxygen sensor (HO2) uses an electrical heating element to warm the
sensor to normal operating temperature. This element will stabilize the temperature and
operation of the sensor. The heating element allows the computer system to utilize the
sensor’s input sooner since the sensor operates at a higher temperature.

NAVEDTRA 14264A 4-24

Test your Knowledge (Select the Correct Response)
6. Of the following chemical compounds, which one is the most dangerous
emission?

A. Carbon dioxide
B. Carbon monoxide
C. Hydrocarbons
D. Oxides of nitrogen

7. The exhaust gas recirculation system allows burned gases to enter the engine
intake manifold to help reduce what gas?

A. Carbon dioxide
B. Carbon monoxide
C. Hydrocarbons
D. Oxides of nitrogen

Summary
Your knowledge of the gasoline fuel system will enable you to evaluate certain engine
problems with confidence. The ability to diagnose a gasoline fuel system will help the
environment because your ability to determine that the problem is in the exhaust system
will alleviate some of the pollutants being dispersed into the atmosphere. Technicians
and engineers have developed automobile parts and various systems to help extend
fuel economy, gain horsepower, and lower emissions.

NAVEDTRA 14264A 4-25

Review Questions (Select the Correct Response)
1. What types of additives are used in gasoline to slow down ignition?

A. Antiping
B. Antiknock
C. Anticombustion
D. Antioxidants

2. Which property is NOT a property of gasoline?

A. Volatility
B. Antiknock quality
C. Cetane number
D. Octane rating

3. What term refers to the measurement of the ability of a fuel to resist knock or
ping?

A. Air-fuel ratio
B. Cetane number
C. Volatility
D. Octane rating

4. An air-fuel mixture that is too lean will cause which condition?

A. Increased power
B. Increased fuel consumption
C. Poor engine performance
D. Decreased exhaust emissions

5. Which is NOT a condition of abnormal combustion?

A. Detonation
B. Dieseling
C. Pre-ignition
D. Spark ping

6. Which factor can cause dieseling in a gasoline engine?

A. Low octane fuel

B. Low heat range spark plugs
C. Incorrect timing
D. Hot exhaust valve

NAVEDTRA 14264A 4-26

7. What device is used in the filler neck of a gasoline fuel tank to prevent the
accidental use of leaded fuel?

A. Fuel valve
B. Restrictor
C. Vacuum valve
D. Fuel nozzle

8. What is the function of the baffles in a fuel tank?

A. To reinforce the bottom of the fuel tank

B. To reinforce the sides of the fuel tank
C. To prevent the fuel from sloshing and splashing
D. To prevent the escape of fuel and fuel vapors from the tank

9. Fuel filters are NOT made of which material?

A. Sintered brass
B. Ceramic
C. Treated paper
D. Metal screen

10. What is the function of the fuel pump?

A. To measure the amount of fuel that enters the carburetor or fuel injectors
B. To deliver the fuel from the tank to the engine under pressure
C. To pump fuel from the carburetor to the intake manifold
D. To pump fuel from the carburetor through the fuel filter into the manifold

11. Fuel line tubing is normally made of what material?

A. Single-wall steel
B. Double-wall steel
C. Single-wall copper
D. Double-wall copper

12. Which attribute is NOT an advantage of a gasoline injection system over a

carburetor type system?

A. Improved atomization
B. Better fuel distribution
C. Richer fuel mixture
D. Lower emissions

13. In a gasoline indirect injection system, fuel is sprayed into what part?

A. Precombustion chamber
B. Cylinder
C. Combustion chamber
D. Intake manifold

NAVEDTRA 14264A 4-27

14. Of the gasoline fuel injection systems, what system is the most precise and also
the most complex?

A. Hydraulic-timed injection
B. Throttle body fuel injection
C. Timed fuel injection
D. Continuous fuel injection

15. In a mechanical-timed injection system, the throttle valve regulates engine speed
and power output by regulating the _______.

A. intake pressure
B. manifold vacuum
C. exhaust pressure
D. metering pump vacuum

16. Which is NOT a subsystem of an electronic-timed fuel injection system?

A. Fuel delivery system

B. Air induction system
C. Computer control system
D. Fuel metering system

17. In an electronic fuel injection system, what sensor measures the amount of
outside air entering the engine?

A. Air flow
B. Inlet air temperature
C. Manifold pressure
D. Oxygen

18. In an electronic fuel injection system, where does the fuel pressure regulator
divert the excess fuel?

A. Back to the fuel tank

B. To the inlet side of the fuel filter
C. To the inlet side of the fuel pump
D. Back to the inlet side of the fuel line

19. What component of a throttle body injection system contains the fuel pressure
regulator?

A. Throttle air horn

B. Throttle body housing
C. Throttle positioner
D. Throttle fuel mixture valve

NAVEDTRA 14264A 4-28

20. In a multi port fuel injection system, what component supplies fuel to the
injectors?

A. Fuel tube
B. Fuel rail
C. Siphon pipe
D. Pressure regulator

21. Of the following chemical compounds, which is the most dangerous emission?

A. Carbon dioxide
B. Carbon monoxide
C. Hydrocarbons
D. Oxides of nitrogen

22. Exhaust manifolds are made from what type of material?

A. Aluminum
B. Steel
C. Cast iron
D. Iron alloy

23. What device is used to reduce the acoustic pressure of exhaust gases and
discharge the gases into the atmosphere?

A. Resonator
B. Catalytic converter
C. Muffler
D. Exhaust manifold

24. The catalytic converter changes carbon monoxide and hydrocarbons into carbon
dioxide and _____.

A. hydrogen
B. oxygen
C. methane
D. water

25. What two materials that act as a catalyst can be found inside a catalytic
converter?

A. Silver and bronze

B. Bronze and platinum
C. Silver and palladium
D. Platinum and palladium

NAVEDTRA 14264A 4-29

26. In an air injection system, what device is used to prevent air from entering the
exhaust system during deceleration?

A. Air distribution manifold

B. Air check valve
C. Air pump
D. Diverter valve

27. What device keeps exhaust gases from entering the air injection system?

A. Air check valve

B. Diverter valve
C. Air distribution manifold
D. Air pump

28. (True or False) The open type positive crankcase ventilation system has a
sealed breather that is connected to the air filter by a hose.

A. True
B. False

29. To control the formation of oxides of nitrogen, the exhaust gas recirculation
system recirculates a portion of the exhaust gases back through the _______.

A. intake manifold
B. exhaust manifold
C. muffler
D. catalytic converter

30. At idle, engine vacuum is blocked off so it cannot act on the EGR valve. This is
accomplished by a closed _______.

A. diverter valve
B. vacuum diaphragm
C. throttle plate
D. heat control valve

31. What valve prevents fuel from entering the fuel tank vent line in the event of a
accident in which the vehicle turns over?

A. Purge
B. Fuel tank
C. Roll-over
D. Spillage

32. (True or False) The charcoal canister does NOT store fuel vapors when the
engine is running.

A. True
B. False

NAVEDTRA 14264A 4-30

33. What component connects the charcoal canister to the engine intake manifold
and is used to clean out stored fuel vapors from the charcoal canister?

A. Purge line
B. Carburetor vent line
C. Fuel tank vent line
D. Liquid-vapor separator

NAVEDTRA 14264A 4-31

Trade Terms Introduced in this Chapter
Emissions Any release of toxic substances into the environment.
Spark plugs A device that emits an electrical arc at the tip to ignite
the air-fuel mixture if an engine.
Contaminated The intrusion of a foreign substance that ruins the
quality of the original element.

Synchronized The coordination of events to operate a system in

unison.
Solenoid A loop of wire, often wrapped around a metallic core,
which produces a magnetic field when an electric
current is passed through it. It can create a controlled
magnetic field and can be used as an electromagnet.

NAVEDTRA 14264A 4-32

Additional Resources and References
This chapter is intended to present thorough resources for task training. The following
reference works are suggested for further study. This is optional material for continued
education rather than for task training.
Modern Automotive Technology Seventh Edition, James E. Duffy, The Goodheart-
Willcox Company, Inc., 2009. (ISBN 978-1-59070-956-6)
Automotive Technology, A systems Approach Fourth Edition, Jack Erjavec, The
Thomson-Delmar Learning Company, Inc., 2005. (ISBN 1-4018-4831-1)
Diesel Technology Seventh Edition, Andrew Norman and John “Drew” Corinchock, The
Goodheart-Wilcox Company, Inc., 2007. (ISBN-13: 978-1-59070-770-8)

NAVEDTRA 14264A 4-33

CSFE Nonresident Training Course – User Update
CSFE makes every effort to keep their manuals up-to-date and free of technical errors.
We appreciate your help in this process. If you have an idea for improving this manual,
or if you find an error, a typographical mistake, or an inaccuracy in CSFE manuals,
please write or email us, using this form or a photocopy. Be sure to include the exact
chapter number, topic, detailed description, and correction, if applicable. Your input will
be brought to the attention of the Technical Review Committee. Thank you for your
assistance.
Write: CSFE N7A
3502 Goodspeed St.
Port Hueneme, CA 93130
FAX: 805/982-5508
E-mail: [email protected]

Rate____ Course Name_____________________________________________

Revision Date__________ Chapter Number____ Page Number(s)____________

Description
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________

(Optional) Correction
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________

(Optional) Your Name and Address

_______________________________________________________________
_______________________________________________________________
_______________________________________________________________

NAVEDTRA 14264A 4-34