Fuel injection

system

1/16/2023 BY: Yonathan M. 1

 Fuel Injection in the CI Engine

▪ For the compression ignition engine, it is very important to

promote a means of injecting fuel into the cylinder at the
proper time in the cycle.

▪ This is so because the injection system starts and controls the

combustion process.
 Function of fuel injection
▪ The function of the fuel injection system is to provide
the right amount of fuel at the right moment and a
suitable condition for the combustion process.

▪ There must therefore be some form of metered supply,

a means of timing the delivery, of atomization and
distribution of fuel.

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 Direct injection method

▪ Most new commercial-

vehicle diesel engines are of
the direct-injection type.
▪ Here, the fuel is injected
directly into the compression
chamber via the piston.
▪ The special shape of intake
port in the cylinder head
generates a swirl effect and
therefore draws in the
incoming air more vigorously.
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 Direct injection method Cont…
▪ The fuel is evenly distributed through the combustion
chamber as a result of the multi-orifice injection
nozzles.
▪ A distinction is made between wall-applied and air-
distributed direct injection, according to the injection
procedure.
▪ Direct-injection engines generate considerable
combustion noise on account of the relatively high
ignition delay.
▪ However, they achieve low specific fuel consumption
and exhibit good cold-starting properties.

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 Fuel injection systems consist of three types.

1. Individual (Inline) pump system: This consists of a separate

metering and compression pump for each cylinder.

2. Distribution system: This consists of a single pump for

compressing the fuel (which may also meter), plus a delivery
device for distributing the fuel to the cylinders (which may
also meter).

3. Common rail system: A single pump for compressing the

fuel, plus a metering element for each cylinder.

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 Distributor-type pumps
▪ Unlike the inline injection pump, the distributor type
pump has only one pump element with one piston for all
cylinders.
▪ The piston operates as many strokes as there are
cylinders for every revolution of the crankshaft.

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Distributor-type pumps Cont…
▪ The simultaneous movement of the piston during
the stroke distributes the fuel to the various inlets and
pumps it to the corresponding injectors.
▪ A mechanical speed governor and a hydraulic
injection timing device are integrated into the
distributor pump housing.
▪Distributor-type pumps are used on high speed
passenger-car and commercial vehicle diesel
engines with an output per cylinder of up to 25 kW.
▪ The injection pressure is approximately 700 bar
Distributor type pumps with electronic control are
capable of injection pressures as high as 1400 bar.
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Fuel-injection system with mechanically-controlled (governed) distributor
injection pump
1 Fuel tank, 2 Fuel filter, 3 Distributor fuel-injection pump, 4 Nozzle holder with
nozzle, 5 Fuel return line, 6 glow plug 7 Battery, 8 Glow-plug and starter switch, 9
Glow control unit .

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 Inline injection pumps

▪ Inlineinjection pumps have a separate camshaft and one

pump element per engine cylinder.
▪ The stroke of the pistons always remains the same. The
pump rate is regulated via metering ramps.

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Inline injection pumps Cont…
▪The fuel is pumped through a separate high-pressure
line to the corresponding injector for each cylinder of
the engine.
▪ The injection pumps camshaft, driven by the engine,
controls the injection processes in the individual
injectors.
▪A mechanical injection timing device adjusts the start
of delivery according to engine speed, as necessary.
▪ It rotates the camshaft in relation to the engine
crankshaft, thus displacing the start of delivery.
▪ The inline injection pump is connected up to the
engine oil circuit for lubrication of the moving pump
components.
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 Common rail system

1 – Fuel tank 2 – Filter 3 – Pressure supply pump 4 – High pressure supply

pump 5 – Pressure limiting valve 6 – Pressure sensor 7 – Distributor rail
8 - Injectors 9 – Sensors 10 – Electronic control unit

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 Fuel delivery control
• The diesel fuel is delivered to the injectors by
individual pump elements (pistons).
• These have rotary mounts and fit in the cylinders with
very high precision.
• Depending on design, there are one or two inlet
orifices in the cylinder.
• The second inlet orifice is also known as the spill port.
These orifices connect the inlet and high pressure
chambers.
• Each pump element delivers the fuel to the injectors.
• The delivery process comprises the admission stroke,
preliminary stroke, delivery stroke and residual stroke
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Fuel delivery control Cont…

1 - Delivery Valve 2- Inlet orifice 3 – Split port 4 – Longitudinal or perpendicular

groove 5 – Line to injector 6 – Delivery chamber 7 – Intake chamber 8 – pump
element 9- Control pump
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Fuel delivery control Cont…
Admission stroke

• The pump element is at the base. The inlet orifices are open;
diesel fuel flows from the intake chamber (via a line from the fuel
supply pump) into the cylinder`s high-pressure chamber.

Preliminary stroke

• During the upward movement, the pump element closes the inlet
orifices. The delivery stroke proper now begins.

Delivery stroke

• As the stroke progresses, the pressure continues to rise until the

delivery valve opens. The pump element then pumps fuel
through the pressure line to the injector.
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Fuel delivery control Cont…

Residual stroke

▪ When the lower end of the control ramp reaches the spill port, the
delivery stroke is completed. The fuel is forced back through the
longitudinal groove into the intake chamber.

▪ When TDC is reached, the inlet orifice is opened again during the
downward movement of the pump element. A partial vacuum is
generated, fuel is drawn in and a new delivery cycle begins.

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 First Generation Common Rail Diesel Injection System

▪ The Common Rail Diesel Injection System delivers a more

controlled quantity of atomized fuel, which leads to better fuel
economy; a reduction in exhaust emissions; and a significant
decrease in engine noise during operation.

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 Second Generation (Electronically Controlled) CRDI

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Common rail diesel injection system
▪ In the Common Rail system, an accumulator, or rail, is
used to create a common reservoir of fuel under a
consistent controlled pressure that is separate from
the fuel injection points.
▪ A high-pressure pump increases the fuel pressure in
the accumulator up to 1,600 bar.
▪ The pressure is set by the engine control unit and is
independent of the engine speed and quantity of fuel
being injected into any of the cylinders.
▪ The fuel is then transferred through rigid pipes to the
fuel injectors, which inject the correct amount of fuel
into the combustion chambers.
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 Injectors for CRDI
▪ The injectors used in Common Rail systems are
triggered externally by an Electronic Diesel Control,
(EDC) unit.
▪ EDC controls all the engine injection parameters
including the pressure in the fuel rail and the timing
and duration of injection.
▪ Some common rail injectors are controlled by a
magnetic solenoid on the injector.

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 Injectors for CRDI
▪ In some injectors, hydraulic force from the pressure in
the system is used to open and close the injector, but
the available pressure is controlled by the solenoid
triggered by the Electronic Diesel Control unit.
▪ Some injectors use Piezo crystal wafers to actuate the
injectors.
▪ These crystals expand rapidly when connected to an
electric field.
▪ In a Piezo inline injector, the actuator is built into the
injector body very close to the jet needle and uses no
mechanical parts to switch injector needles.

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 Injectors for CRDI
▪ The electronic diesel control
unit precisely meters the
amount of fuel injected, and
improves atomization of the
fuel by controlling the injector
pulsations.
▪ This results in quieter, more
fuel efficient engines; cleaner
operation; and more power
output.

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 ELECTRONIC FUEL
INJECTION SYSTEM
(EFI)

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 Electronic fuel injection system
(EFI)
▪ In the electronic controlled engine system, sensors
detect the state of the engine, and all information from
the sensors is sent to Engine Control Unit (ECU).
▪ According to the information from sensors, ECU
calculates injection volume and ignition timing.
▪ ECU also controls idle rotating speed by means of the
idle speed control valve (ISCV).

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 EFI
▪ ECU gathers information from sensors about the engine,
and then controls actuators for Electronic Fuel Injection
(EFI), Electronic Spark Advance (ESA) and Idle Speed
Control (ISC), according to that information.
▪ And there is “SELF DIAGNOSIS” function in this system.
▪ If there is problem with the electronic part of this
system (that means, in the sensors, the wire harness
and ECU itself) The ECU detects the problem part and
memorize it.
▪ When technicians check the “self diagnosis code”, they
can identify the problem easily.

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 EFI

ECU

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 Types of EFI
▪ Based on location and number of injector
o Throttle body (single point injection)
o Port (multi point injection)

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 Types of EFI
▪ Based on mixture formation
o External (manifold/indirect injection)
o Internal (direct injection)

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 Fuel Injection System

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 EFI
Advantages
▪ Improved Atomization
▪ Better fuel flow
▪ Smoother idle
▪ Improved fuel economy
▪ Lower emissions
▪ Better cold weather drivability
▪ Increased engine power
▪ Simpler

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 EFI
Engine Throttle Valve

▪ Controls air flow and gasoline to power engine.

▪ When butterfly valve is closed it restricts air-flow and the resulting
flow of fuel into the engine.
▪ When accelerator is pressed, the air-flow is increased in the intake
manifold.
▪ Engine sensors detect the resulting changes and increase fuel flow
through the injectors.
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 EFI
Electronic Fuel Injection uses various engine sensors and control
module to regulate the opening and closing of injector valve.
▪ Fuel delivery system

▪ Air induction system

▪ Sensor system

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▪ Computer control system
 Fuel Delivery system
•Electrical Fuel Pump draws fuel from
tank and forces it into the regulator.

•Pressure Regulator controls the amount

of pressure that enters the injector and any
extra fuel is returned to the fuel tank.

•Fuel Injector is simply a coil or solenoid

operated valve.
• Spring pressure holds the injector closed.
•When engaged, the injector sprays fuel
into the engine.
Injector Pulse Width indicates the time each
Injector is energized (Kept Open).
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1/16/2023
 Air Induction System

•Air filter

•Throttle valve

•Sensors

•Connecting ducts

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 Sensor System

▪ Monitors engine operating condition and reports this information

to ECM (computer).
▪ Sensors are electrical devices that change resistance or voltage
with change in condition such as temperature, pressure and position.

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 Computer Control System
▪ Uses electrical data from the sensors to control the operation of
the fuel injectors.
▪ Engine Control Module (ECM)- “Brain” of the electronic fuel
injection.

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 sensors
▪ Converts a physical/chemical condition into an
electrical signal
▪ Is a transducer: to change from one form to
another
Sensor requirements
o High reliability
o Low manufacturing cost
o Severe operating conditions
o Low volume
o High accuracy
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 Engine Sensors
Oxygen Sensor
▪ Measures the oxygen content in engine
exhaust.
▪ Mounted on the exhaust system before
the catalytic converter.
▪ Voltage out-put of O2 sensor changes
with the change in oxygen content of
exhaust.
▪ Lean mixture decreases the voltage
▪ Rich mixture increases the voltage
▪ Signal is sent to ECM and the ECM
changes the time that an injector is open
or close.

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 Oxygen Sensor
Open Loop
▪ When the electronic injection system doesn’t use the
input from the engine exhaust.
▪ System operates on information stored in the computer
(PROM).
▪ Computer ignores the sensors when the engine is cold.

Closed Loop
▪ Ones engine reaches the operating temperature,
computer uses information from oxygen sensor and the
other sensors.

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 Manifold Absolute Pressure Sensor (MAP)
▪ Measures the pressure, or vacuum
inside the engine intake manifold.
▪ Manifold pressure = Engine load
▪ High pressure (low intake
vacuum) = High load = Rich
mixture
▪ Low pressure (high intake
vacuum) = Little load = Lean
mixture
▪ Computer senses the change in
resistance and alters the fuel
mixture

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 Throttle Position Sensor (TPS)
▪ Variable resister connected to
the throttle plate.
▪ Change in throttle angle =
change in resistance.
▪ Based on the resistance,
ECM richens or leans the
mixture.

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 Engine Temperature Sensor

▪ Monitors the operating temperature

of the engine.
▪ Exposed to engine coolant.
▪ Engine cold = Low Resistance = Rich
Mixture
▪ Engine Hot = High Resistance = Lean
Mixture.

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 Mass Air Flow Sensor (MAF)

▪ Measures the amount of outside air entering the engine.

▪ Contains an air flap or door that operates a variable resistor.
▪ Helps computer to determine how much fuel is needed.
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 Inlet Air Temperature Sensor

▪ Measures the temperature of air entering the engine.

▪ Cold air (more dense) = More fuel for proper AF ratio.
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 Crankshaft Position Sensor

▪ Detects engine speed.

▪ Changes injector timing and duration
▪ Higher engine speed = More fuel

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 Water temperature sensor

▪ Detects the temperature of coolant

▪ Made of thermistor
▪ Signal is used for;
o Injection correction during;
o starting,
o after start,
o warm up,
o acceleration and deceleration

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 Engine Sensors

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 Engine Idle Speed Control
Fast Idle Thermo Valve
▪ Thermo wax plunger
expands and shrinks as the
engine warms up or cools
down.
▪ The thermo valve opens
when cold to allow air to
by-pass the throttle valve
▪ This extra air increases
engine idle speed to prevent
cold engine stalling.

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 Engine Idle Speed Control
Idle Air Control Motor (IAC)

▪ Computer opens the valve when temperature sensor signals

a cold engine.
▪ Open = More Air = Increased Idle Speed.
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 Throttle Body Injection
▪ Uses one or two injectors.
▪ Injectors (pulse) spray fuel into
the top of throttle body air horn.
▪ Atomized fuel mixes with air and
drawn into the engine.
▪ Fuel pressure regulator is spring
loaded and is part of the housing.
▪ Fuel is being injected whenever
the engine is running, also called
CIS: Continuous Injection
System.

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 EFI
EFI Multi port Injection System
▪ Injector is pressed into the
runner(Port) in the intake
manifold.
▪ Injector sprays towards an
engine intake valve.
▪ Each cylinder has it’s own
injector
EFI Direct fuel Injection System
▪ Injectors are pressed into the
combustion chamber and spray
fuel directly into the combustion
chamber.
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