Topic 2 - Fuel Delivery

Components
 FUEL SYSTEM
The fuel system mixes the fuel (gasoline) from the fuel tank
with air, and delivers the mixture, in the form of droplets of fuel
suspended in air to the engine.
Component:
1. Fuel tank
2. Fuel line
3. Charcoal canister
4. Fuel filter
5. Fuel pump

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 FUEL TANK
Fuel tank, where fuel is stored and where most fuel pumps are located
Is constructed of thin sheet steel.
Located in the rear of the vehicle to prevent the leakage of gasoline in
case of collision.
Inside of tank is plated to avoid rusting.
Is equipped with separators to avoid changes in the fuel level when the
vehicle is moving.
The mouth of inlet tube is located 2 to 3cm above the bottom of the tank
to prevent sediment and water in the gasoline from being sucked into the
tube.

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A vehicle fuel tank is made of corrosion-resistant steel or polyethylene plastic. Some models, such as sport
utility vehicles (SUVs) and light trucks, may have an auxiliary fuel tank.
Tank design and capacity are a compromise between available space, filler location, fuel expansion room,
and fuel movement. Some later-model tanks deliberately limit tank capacity by extending the filler tube
neck into the tank low enough to prevent complete filling or by providing for expansion room.
Regardless of size and shape, all fuel tanks incorporate most if not all of the following features:
➢ Inlet or filler tube through which fuel enters the tank
➢ Filler cap with pressure holding and relief features
➢ An outlet to the fuel line leading to the fuel pump or fuel injector
➢ Fuel pump mounted within the tank
➢ Tank vent system
➢ Fuel pickup tube and fuel level sending unit
 A three-piece filler tube assembly. The
main three parts include the upper neck,
hose and lower neck.

A typical fuel tank installation

Vehicles equipped with onboard refuelling vapor

recovery usually have a reduced-size fill tube.
FUEL TANK

Fuel tank and related components used on Jeep CJ/Scrambler

1982-86 models (https://www.autozone.com/repairguides/Jeep-CJ-
Scrambler-1971-1986-Repair-Guide/EMISSION-CONTROLS/Fuel-
Tank-Vapor-Emission-Control-System/)
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TANK VENTING REQUIREMENTS
Fuel tanks must be vented to prevent a vacuum lock as fuel is drawn from the tank. As fuel is used and its
level drops in the tank, the space above the fuel increases. As the air in the tank expands to fill this greater
space, its pressure drops. Without a vent, the air pressure inside the tank would drop below atmospheric
pressure, developing a vacuum which prevents the flow of fuel. Under extreme pressure variance, the tank
could collapse. Venting the tank allows outside air to enter as the fuel level drops, preventing a vacuum from
developing.
An Evaporative Emission Control (EVAP) system vents gasoline vapors from the fuel tank directly to a
charcoal-filled vapor storage canister and uses an unvented filler cap. Many filler caps contain valves that
open to relieve pressure or vacuum above specified safety levels. Systems that use completely sealed caps
have separate pressure and vacuum relief valves for venting.
Because fuel tanks are not vented directly to the atmosphere, the tank must allow for fuel expansion,
contraction, and overflow that can result from changes in temperature or overfilling. One way is to use a
dome in the top of the tank. Many General Motors vehicles use a design that includes a vertical slosh baffle
that reserves up to 12% of the total tank capacity for fuel expansion.
EVAPORATIVE EMISSION CONTROL (EVAP) SYSTEM
The purpose of the evaporative emission control system is to trap and hold gasoline vapors, also called volatile
organic compounds (VOCs). The evaporative control (EVAP) system includes the charcoal canister, hoses, and
valves. These vapors are routed into a charcoal canister, then into the intake airflow, where they are burned in
the engine instead of being released into the atmosphere.

The purge valve precisely controls the amount of fuel vapor that is
purged from the charcoal canister. In modern cars, the purge
valve is an electrically-operated solenoid, that is controlled by the
engine computer. When the engine is off, the purge valve is
The EVAP system includes all of the lines, closed.
hoses, and valves, plus the charcoal canister.
 FUEL LINE
Fuel lines, which transfer the fuel for the fuel tank to the engine
There are 3 fuel lines:
1. Main fuel line
• Which carries fuel from the fuel tank to fuel pump.
2. Return fuel line
• Which carries the fuel back to the fuel tank from the engine.
3. Fuel emission line
• Carries HC gas from the inside of the fuel tank to the charcoal canister.
They usually run under the floor pan or frame.
To avoid damage to the lines by stones flying up from the surface of the road, a protector is also provided.
Due the engine vibration, rubber hoses are used where the fuel line connects with the carburetor and the fuel
pump.
Fuel and vapor lines made of steel, nylon tubing, or fuel- resistant rubber hoses connect the parts of the fuel
system.

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Fuel lines must remain as cool as possible. If any part of the line is
located near too much heat, the gasoline passing through it vaporizes,
and vapor lock occurs. When this happens, the fuel pump supplies only
vapor that passes into the injectors. Without liquid gasoline, the engine
stalls, and a hot restart problem develops.
The fuel delivery system supplies 10 to 15 PSI (69 to 103 kPa) or up to
35 PSI (241 kPa) to many throttle-body injection units and up to 60 PSI
(414 kPa) for multiport fuel-injection systems. Fuel injection systems
retain residual or rest pressure in the lines for a half hour or longer
when the engine is turned off to prevent hot engine restart problems.
Higher-pressure systems such as these require special fuel lines.
 FUEL LINE

2008 Honda Accord EX

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 FUEL FILTER
It is located between the fuel tank and fuel pump to remove any dirt or water that there
are maybe in the gasoline.
The element inside the filter (paper/cotton) reduces the flow speed of the fuel, causing
the water and dirt particles that are heavier than gasoline to settle to the bottom.
The particles of dirt that are lighter than gasoline are filtered out by the element.
• Despite the care generally taken in refining, storing, and delivering gasoline, some impurities get into
the automotive fuel system. Fuel filters remove dirt, rust, water, and other contamination from the
gasoline before it can reach the fuel injectors. Most fuel filters are designed to filter particles that are
10 to 20 microns or larger in size.
• The useful life of many filters is limited, but vehicles that use a returnless-type fuel-injection system
often use filters that are part of the fuel pump assembly and do have any specified replacement
interval. This means that they should last the life of the vehicle. If fuel filters are not replaced
according to the manufacturer’s recommendations, they can become clogged and restrict fuel flow.

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 FUEL FILTER

Inline fuel filters are usually attached to the fuel line with
screw clamps or threaded connections. The fuel filter must
be installed in the proper direction or a restricted fuel flow
can result.

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 FUEL PUMP
There are 2 types of fuel pump:
1. The type without a return pipe
2. The type with a return pipe

The basic construction and operation of these 2 types are the

same.
In most previous engines the fuel was returned to the fuel tank
from the carburetor but now it is usually returned from the fuel
pump through the fuel return line.
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FUEL PUMP

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 FUEL PUMP
• Impeller type pump with an integral Check valve
DC motor.
Relief valve
• A relief valve is incorporated
into the delivery side of the fuel Brush
pump.
Armature
• Delivery pressure can exceed
450 kPa. Magnet

•The check valve maintains Impeller

fuel line pressure Filter

•Prevents vapour locks for

rapid restarting of the engine.

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 ELECTRIC FUEL PUMPS
The electric fuel pump is a pusher unit. When the pump is mounted in
the tank, the entire fuel supply line to the engine can be pressurized.
Because the fuel, when pressurized, has a higher boiling point, it is
unlikely that vapor will form to interfere with fuel flow.
Most vehicles use the impeller or turbine pumps. All electrical pumps
are driven by a small electric motor, but the turbine pump turns at
higher speeds and is quieter than the others.

How Can an Electric Pump Work Inside a Gas Tank and Not Cause a Fire?
Even though fuel fills the entire pump, no burnable mixture exists inside the pump because
there is no air and no danger of commutator brush arcing, igniting the fuel.
 An exploded
view of a
gerotor electric
fuel pump.

An internal gear pump, called a gerotor, is another type of positive

displacement pump that is often used in engine oil pumps. It uses the
meshing of internal and external gear teeth to pressurize the fuel. The
gerotor-type fuel pump uses an impeller as the first stage and is used
to move the fuel gerotor section where it is pressurized.
A roller cell-type electric fuel pump
 Charcoal canister
Temporarily absorbs fuel vapors (HC) from the carburetor float chamber
and fuel vapors exhausted from emission tube when the pressure in the
fuel tank rises due to increases in the temperature into its internal
canister to prevent them from being exhausted.
The fuel vapors which are absorbed by the charcoal canister are directed
from the intake manifold to the combustion chamber for burning when
the engine is running.
Decreases in the ambient temperature also result in lowering of the
pressure inside the fuel tank, causing the fuel vapors in the canister to be
drawn back into the fuel tank to prevent them from being exhausted.

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Charcoal canister

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 FUEL SYSTEM

Fuel tank

Fuel pump
Fuel filter

Filter
Injector

Pressure regulator
Delivery pipe

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 FUEL PASSAGE
FUEL FILTER
FUEL
PRESSURE
REGULATOR

Fuel filter
Fuel
FUEL tank
RETURN INJECTOR

Fuel
Pressure
Engine regulator FUEL PUMP

• The fuel, pumped from the thak by the fuel pump, passes through the fuel main pipe and
is filtered by the external fuel filter before being distributed to the injectors through the
deliverypipe.
• The fuel delivered to the injectors is maintained at a pressure 3.35 kg/cm² (328.5 KPa)

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FUEL PRESSURE REGULATOR

• Regulates the fuel pressure

applied to the injector.

• To prevents changes in the

internal pressure of the
manifold from effectig the fuel
injection amount- 330kpa –
360 kpa

Fuel-pressure regulator - mechanically operated spring loaded

rubber diaphragm to maintain proper fuel pressure.

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FUEL PRESSURE REGULATOR

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PRINCIPLE OF GOOD COMBUSTION

STRONG
SPARK

GOOD
COMBUSTION
SUITABLE
A/F RATIO
ENOUGH MIXTURE
COMPRESSION

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