Introduction

of
Automobile
Engineering

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UNIT-2

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6. Fuel System of SI
Engine

6-1. Components of carbureted Fuel System

6-2. Construction, Working Principle & Type of Carburetor
6-3. Fuel Pump, Fuel Filter, Air Filter
6-4. Petrol Injection System
6-5. MPFI(Multi-Point Fuel Injection) System
6-6. EFI(Electronic Fuel Injection) System

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6-1. Components of Carbureted Fuel
System
1. Inlet
2. Venturi Throat
3. Floating Chamber
4. Pressure Equalizing Passage
1 5. Calibrated Orifice
4 6. Fuel Discharge Tube
7. Throttle Plate

2
6

5 3
7

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6-2. Construction, Working Principle
& Type of Carburetor
■ Carburetor Working Principle
 Fuel Vaporization (Air-Fuel Mixing)

 Air-Fuel Ratio

Idle Partial Load 5:10 Full Load

6-3. Fuel Pump, Fuel Filter & Air Filter
■ Electronic Fuel Delivering System for Gasoline Engine

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6-3. Fuel Pump, Fuel Filter & Air Filter
■ Simplified Fuel Delivering System for Gasoline Engine

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6-3. Fuel Pump, Fuel Filter & Air Filter
■ Fuel Tank and Fuel Pump

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6-4. Petrol Injection System
■ Gasoline Fuel Injector

Port Fuel Injection System

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Direct Injection System
6-4. Petrol Injection System
■ ADVANTAGES OF GASOLINE INJECTION SYSTEM

 Fuel supply as per engine requirement under all load & speed
condition
 Design of manifold is simple since only air is passing through
manifold
 Better volumetric efficiency and increased power due to absence of
venturi
 Fuel injection system is free from icing
 Starting and acceleration is much better than carburetor system
such as rapid engine response
 Provides identical air-fuel ratio mixture to all cylinders
 Overall, fuel injection produces much more lower emission and low
fuel consumption than carburetors

■ DISADVANTAGES OF GASOLINE INJECTION SYSTEM

 Expensive and complicated
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6-4. Petrol Injection System

■ SPI(Single Point Injection) System

 Located at same place as carburetor
 Also called TBI(Throttle Body Injector)
or CPI(Central Point Injection)
 Low Cost
 Step stone from Carburetor to MPI
(Multi-Port Injection)
Cannot solve unequal distribution of
Air-Fuel mixture cylinder by cylinder

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6-5. MPFI(Multi-Point Fuel Injection)
system
■ Inject fuel into intake ports just
upstream of each cylinder’s intake
valve

■ Three type by injection style

 Batch
Injected to the cylinders in groups, with
out precisely bringing together to any
particular cylinder’s intake stroke
 Simultaneous
Injected at the same time to all cylinders
 Sequential
Injection is timed to coincide with each
cylinder’s intake stroke

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6-5. MPFI(Multi-Point Fuel Injection)
system
■ ADVANTAGE OF MPI SYSTEM

 More uniform A/F mixture will be supplied to each cylinder, hence

the difference in power developed in each cylinder is minimum.
Vibration from the engine equipped with this system is less, due to
this the life of engine components is improved
 No need to crank the engine twice or thrice in case of cold
starting as happens in the carburetor system
 Immediate response, in case of sudden acceleration /deceleration
 Since the engine is controlled by ECM* (Engine Control Module),
more accurate amount of A/F mixture will be supplied and as a
result complete combustion will take place. This leads to effective
utilization of fuel supplied and hence low emission level
 The mileage of the vehicle will be improved

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6-5. MPFI(Multi-Point Fuel Injection)
system
Carburetor vs Fuel Injector System

SPI MPI 14:10

GDI
6-5. MPFI(Multi-Point Fuel Injection)
system
GDI(Gasoline Direct Injection) System

 Major Technology of GDI Engine

 Upright straight intake port
 High pressure fuel pump
 High pressure swirl injector
 curved top piston

15:10
6-5. MPFI(Multi-Point Fuel Injection)
System
GDI(Gasoline Direct Injection) System

 GDI vs MPI SYSTEM

GDI MPI
Bore x Stroke, mm 81.0 x 89.0 ←

Displacement, cc 1834 ←

Number of Cylinder L4 ←

Configuration DOHC ←
Valve Train
Number of Valve Intake : 2, Exhaust : 2 ←

Compression Ratio 12.0 10.5

Combustion Chamber Curved top piston Plat top piston

Intake Port Upright Straight Standard

Fuel System In-cylinder Direct Injection Port Injection

Fuel Pressure, MPa 50 3.3

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6-5. MPFI(Multi-Point Fuel Injection)
System
Variable Air Induction System

2 Stage Variable System

Low RPM Medium RPM High RPM

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3 Stage Variable System
6-6. EFI(Electronic Fuel Injection)
System
■ In EFI System, all the process of injection (injected fuel quantity, injection
time etc) is controlled by ECM(Engine Control Module)
■ History of EFI System
 D-Jetronic : Electronically controlled system with pressure sensor
 L-Jetronic : Electronically controlled system with airflow measurement
 K-Jetronic : Combined mechanical and hydraulic system, with airflow measurement
 Modern EFI System INPUT(sensor) & OUTPUT(actuator)

18:10
7. Fuel System of CI Engine

7-1. Components of Diesel Fuel System

7-2. Fuel Feed Pump & Fuel Filter
7-3. Fuel Injection Pump
7-4. Calibration of Fuel Injection Pump
7-5. Fuel Injector
7-6. CRDI(Common Rail Direct Injection) System
7-7. Combustion Chamber of Diesel Engine

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7-1. Components of Diesel Fuel System

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7-2. Fuel feed Pump & Fuel Filter
■ Feed Pump
 Delivers fuel from tank to the injection pump continuously and at a reasonable
pressure
 Prevent possible formation of vapor bubbles and subsequently cavitation in
pump due to suction of rapidly moving plunger of injection pump
 Generally delivery pressures of between about 29 and 98 kPa adequate for
preventing vapor formation on suction side of in-line type injection pump
 Diaphragm Type
 Plunger Type

Plunger Type
Diaphragm Type 21:10
7-2. Fuel feed Pump & Fuel Filter
■ Fuel Filter
Remove water and solid contaminants from diesel fuel

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7-3. Fuel Injection Pump
■ In-line Injection Pump System

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7-3. Fuel Injection Pump
■ In-line Injection Pump
Boosting Maintain Injection Control
Distribution Injection
Pressure Pressure Quantity Timing
In-Line Pump Governor Pump Injector

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7-3. Fuel Injection Pump
■ In-line Injection Pump
Fuel Distribution & Injection Control

Delivery
Inlet
Valve
Port
Barrel
Plunger

Intake Delivery Injection Finish

Barrel

Plunger

Control
Rod

Close Low Quantity High Quantity

25:10
7-3. Fuel Injection Pump
■ Distributor Type Fuel Injection Pump System

Fuel Injection Pump

Fuel Tank

Injector
Fuel Filter

Fuel Feed Pump 26:10

7-3. Fuel Injection Pump
■ Distributor Type Fuel Injection Pump
Boosting Maintain Injection Control
Distribution Injection
Pressure Pressure Quantity Timing
Rotary Pump Distributor Distributor Injector

27:10
7-3. Fuel Injection Pump
■ High Pressure Injection System

28:10
7-3. Fuel Injection Pump
■ High Pressure Common Rail Injection Pump
Boosting Maintain Injection Control
Distribution Injection
Pressure Pressure Quantity Timing
High Pressure Common
ECU Injector
pump Rail

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7-4. Calibration of Fuel Injection Pump
ISO 4008 Diesel Engines - Fuel Injection Pump Testing part3 :
Application and test procedures

SAE J1668-21605 Diesel Engines - Fuel Injection Pump Testing

 Bosch P Pump Calibration

 Denso In-Line Pump Calibration

 Bosch VE Pump Calibration

 Bosch CRDi System Calibration

30:10
7-5. Fuel Injector
■ Mechanical(1st Gen) Injector
Hydraulic power by pressurized fuel lift pressure spring

Pressure
Spring

Needle
Valve

Pintle
Nozzle

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7-5. Fuel Injector
■ Solenoid (2nd Gen) Injector
Solenoid Actuator
Injection Interval : 4/10 mm sec

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7-5. Fuel Injector
■ Piezoelectric (3rd Gen) Injector
Piezo Actuator
Injection Interval : 1/100 mm sec

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7-6. CRDi(Common Rail Direct injection)

34:10
7-7. Combustion Chamber of Diesel
Engines
IDI(Indirect Injection)
Pre-Combustion Type Swirl Combustion Type

Glow Plug
Nozzle
Nozzle Swirl Chamber

Piston
Glow Plug
Pre-Chamber
Piston
Combustion
Chamber

35:10
7-7. Combustion Chamber of Diesel
Engines
DI(Direct Injection)
Nozzle

Piston Combustion
Chamber

36:10
8. Ignition System

8-1. Components and Function of Ignition System

8-2. Types of Ignition System
8-3. Ignition Timing
8-4. Ignition Advance Mechanism
8-5. Magneto Ignition System
8-6. Battery Point Ignition System
8-7. CDI(Capacitor Discharge Ignition) System
8-8. DIS(Distributor-less Ignition System)

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8-1. Components & Function of Ignition
System
■ Function of Ignition System
 To generate an electric spark that has enough heat to ignite air/fuel mixture
in combustion chamber
 To maintain the spark long enough to allow for combustion of all the air and
fuel in cylinder
 To deliver the spark to each cylinder so combustion can begin at the right
time during combustion stroke of each cylinder

■ Components of Ignition System

 Power Source
 Magnetor
 Capacitor
 Battery
 Primary Coil
 Break Point
 Mechanical(Contact Breaker)
 Electrical(Power TR, SCR)
 Secondary Coil
 Distribution System
 Mechanical(Distributor)
 Electrical(Distributorless) 38:10

 Spark Plug
8-1. Components & Function of Ignition
System
■ Spark Plug

39:10
8-2. Types of Ignition System

IGNITION SYSTEM

MAGNETOR POWERED BATTERY POWERED

with without with without

Breaker Point Breaker Point Breaker Point Breaker Point

Capacitor Battery Distributor

Magneto Discharge Point Less
Ignition Ignition Ignition Ignition
System System System System

40:10
8-2. Types of Ignition System
■ Voltage Boosting Mechanism (Battery Point Ignition Type)
Function Component Voltage Boost
Power Source Battery 12V
Self-Induction Primary Coil
DistributorContact Breaker)
Magnetic Field Corruption 200~300V
Power TR
Count Electromotive (Surge) Primary Coil
Mutual Induction Secondary Coil 20,000~30,000V

41:10
8-3. Ignition Timing
 Spark should occur after compression stroke with piston at TDC
 This will change as engine speeds up because fuel can only burn at one
rate of speed.
 Piston could move faster than fuel burns, which means piston could be
gone from TDC before fuel can push down on piston

42:10
Spark must be timed earlier as engine speed increase
8-4. Ignition Advance Mechanism
■ Mechanical Ignition System
Use in Distributor System
 Mechanical(Centrifugal) Timing Advance
Uses centrifugal force to move some weights
and cause shaft to move ahead of rotation and
open points sooner

Centrifugal System
 Vacuum Timing Advance
Uses vacuum to pull on the breaker plate and
cause points to open sooner

■ Computer Controlled Ignition System

ECM having a timing map with spark advance data for
all combinations of engine speed and engine
load, control ignition timing

43:10
Vacuum System
8-5. Magneto Ignition System
 No need of outside primary source of electricity such as battery
 Mostly small gasoline engine such as lawnmower, chainsaw etc.

44:10
8-6. Battery Point Ignition System
 Use battery power as primary source of electricity
 Mostly gasoline engine for vehicles (old)

45:10
8-7. CDI(Capacitor Discharge Ignition)
System
 Thyristor or SCR(Silicon Controlled Rectifier)
 Widely used in outboard motor, lawnmower, turbine –powered aircraft

46:10
8-8. Distributor-less Ignition System
 Use battery power as primary source of electricity
 DIS(Direct Ignition System) or DIS(Distributor-less Ignition System)
 Mostly gasoline engine for vehicles (recent)

47:10
8-8. Distributor-less Ignition System
Typical Firing Order

Number
Of Firing Order
Cylinder
4 1-3-4-2
6 1-4-3-6-5-2
8 1-8-4-3-6-5-7-2

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49:10