Fuel Delivery Systems

Objectives (1 of 3)
• Explain the purpose of the fuel delivery
system.
• List the commonly used components of the
fuel delivery system.
• Explain how expansion, contraction, and
overflow are controlled in the fuel tank.
 Objectives (2 of 3)
• Explain the purpose of the check valves
used in the fuel delivery system.
• Describe the function of the rollover valve.
• Detail the emission controls associated
with the fuel delivery system.
• Describe the operation of the electric fuel
pump.
 Objectives (3 of 3)
• Explain how the pressure regulator operates.
• Explain the differences between return type and
returnless fuel systems.
• Describe the types of materials and fittings used
in common fuel lines.
• Detail the function of the intake manifold.
• Explain typical fuel pump circuit operation.
 Introduction
• The fuel delivery system is responsible for:
– Storing and delivering fuel to the engine
– Controlling emissions from evaporating fuel
– Filtering fuel
 Fuel Tank
• Can be made of steel, aluminum, or plastic
• Contains baffles to prevent fuel slosh
• Must contend with expansion, contraction,
and overflow
• Must control fuel evaporation
 Rollover Valve
• Prevents leakage from the gasoline supply
or vent line in case of a roll-over accident
• Mandated in 1976
On-board Refueling Vapor Recovery
• Large amounts of hydrocarbon emissions
occur when a vehicle is refueled.
• Beginning in 1998, there was a phase-in of
regulations to control the release of
hydrocarbons (raw fuel vapors).
– See the text for descriptions of systems in
use.
 Fuel Pumps
• Most modern vehicles utilize an electric
fuel pump.
– Supplies a constant fuel pressure
– Less prone to vapor lock than a
mechanical pump
– Delivers fuel pressure high enough for fuel
injection
 Reservoir Chamber
• The chamber prevents the fuel pump from
losing its prime, especially when the level
is low and the vehicle is maneuvering.
 Pressure Relief Valve
• The relief valve prevents excessive fuel
pressure from damaging components in
case the fuel line is restricted.
• Pressure relief occurs at about 120
pounds.
 One-way Check Valve
• This valve prevents fuel from running back
to the tank when the pump is off.
• This fuel trapped in the line helps promote
faster starts.
 Return Line Check Valve
• This valve prevents fuel from running from
the tank into the return line in a roll-over
accident.
 Fuel Filters
• A typical fuel injection system has two
filters and a screen.
– Strainer filter inside the fuel tank for large
debris
– Main fuel filter
– Fine screen located at each injector port
 Fuel Lines
• All systems have a pressurized fuel
delivery system, some have a non-
pressurized return system.
• They can be made from metal tubing,
flexible nylon, or synthetic rubber.
 Fuel Line Connections
• Fuel lines are connected by utilizing:
– Banjo fittings
– Quick-connects
– Compression fittings
– Double-flare fittings
 Fuel Rail
• The fuel rail connects directly to the
injectors.
• It is either mounted on intake, or as a part
of the intake.
 Fuel Pressure Regulation
• The fuel pump is capable of delivering
more pressure than needed.
• A fuel pressure regulator keeps fuel pump
pressure constant.
 Return-type Systems
• The pressure regulator is mounted on the
fuel rail.
• Fuel not needed is returned to the tank via
the return line.
• Intake manifold vacuum is applied to the
regulator to sense engine load.
 Returnless-type Systems
• Returnless fuel systems are becoming
more common.
• The major advantages are:
– Lower fuel temperature
• Fuel is not returned from hot engine to tank.
• Fuel only goes through the filter once.
 Intake Manifolds
• Intake manifold design has changed over
the years.
• Carburetor and throttle body manifolds
carried the air/fuel mixture to the cylinders.
• Port fuel injected intakes carry only air,
and are not heated by crossover exhaust.
 Electric Fuel Pump Circuits
• Most electric fuel pumps use a PCM-
controlled relay.
• Most are turned on at key on for a short
time for a “prime pulse.”
• The pump will shut down after prime if the
PCM does not see engine rpm.