Motor vehicle fuel system and operation

A motor vehicle fuel system is a critical component that manages the storage,
delivery, and combustion of fuel in an internal combustion engine. The
primary goal of the fuel system is to ensure that the engine receives the
correct amount of fuel at the right time for efficient and smooth operation.
The main components of a typical motor vehicle fuel system include the fuel
tank, fuel pump, fuel filter, fuel injectors (or carburetor), and associated fuel
lines.

Here's a brief overview of the key components and the general operation of a
motor vehicle fuel system:

1. Fuel Tank:

 The fuel tank is a container that holds the vehicle's fuel, usually
gasoline or diesel.

 It is often located at the rear of the vehicle for safety reasons.

2. Fuel Pump:

 The fuel pump is responsible for drawing fuel from the tank and
delivering it to the engine.

 In modern vehicles, fuel pumps are often electric and are located
inside the fuel tank.

3. Fuel Filter:

 The fuel filter is positioned in the fuel line to remove impurities

and contaminants from the fuel before it reaches the engine.

 Clean fuel is essential for the proper functioning of the engine and
fuel injectors.

4. Fuel Lines:

 Fuel lines connect the fuel tank to the engine, allowing the flow of
fuel from the tank to the fuel injectors or carburetor.
 5. Fuel Injectors or Carburetor:

 In modern vehicles, fuel injection systems are more common. Fuel

injectors spray fuel directly into the combustion chamber of each
cylinder.

 In older vehicles, a carburetor may be used to mix air and fuel

before delivering it to the engine.

6. Fuel Pressure Regulator:

 The fuel pressure regulator helps maintain a consistent fuel

pressure in the fuel system.

 It ensures that the correct amount of fuel is delivered to the

engine under various operating conditions.

7. Engine Control Unit (ECU):

 The ECU, also known as the engine control module (ECM),

manages the fuel injection timing and duration based on various
inputs such as engine speed, load, and temperature.

 The ECU optimizes fuel delivery for performance, efficiency, and

emissions control.

Operation:

1. Fuel Intake: The fuel system begins with fuel being drawn from the tank
through the fuel pump.

2. Fuel Filtration: The fuel passes through the fuel filter to remove
impurities.

3. Fuel Injection or Carburetion: In fuel-injected systems, fuel is sprayed

directly into the combustion chamber by fuel injectors. In carbureted
systems, the carburetor mixes air and fuel before delivering it to the
engine.

4. Combustion: The fuel-air mixture is ignited in the combustion chamber,

resulting in the release of energy.
 5. Exhaust: After combustion, the exhaust gases are expelled through the
exhaust system.

Overall, the motor vehicle fuel system plays a crucial role in the efficient and
reliable operation of an internal combustion engine, contributing to the
vehicle's performance and fuel efficiency.

Types of fuel pump

MECHANICA L PETROL PUMP

Function

This is to transfer fuel from a low-level tank to a carburetor float chamber at

higher level, at a rate greater than the maximum rate of engine fuel
consumption.

Most pumps are capable of delivering up to a height of 2 m but about 0-45 m

is the usual requirement.

Advantages of Mechanical Fuel Pumps:

1. Simplicity: Mechanical fuel pumps are relatively simple devices with

fewer components compared to electric fuel pumps. This simplicity can
make them easier to maintain and repair.

2. Reliability: Mechanical fuel pumps can be robust and reliable in certain

applications. They are less prone to electrical issues that can affect
electric fuel pumps.

3. No Electricity Required: Mechanical fuel pumps do not rely on

electrical power to operate. This can be an advantage in situations
where electrical systems may be compromised.
 4. Cost: In some cases, mechanical fuel pumps can be more cost-effective
than their electric counterparts. This can be a consideration in budget-
conscious applications.

5. Lower Heat Generation: Mechanical fuel pumps generally generate less

heat during operation compared to electric fuel pumps. This can be
beneficial in terms of reducing the risk of vapor lock.

Disadvantages of Mechanical Fuel Pumps:

1. Lower Pressure and Flow Rates: Mechanical fuel pumps typically

provide lower fuel pressure and flow rates compared to electric fuel
pumps. This limitation can impact performance in high-performance or
fuel-injected systems.

2. Engine Driven: Mechanical fuel pumps are usually driven by the

engine's camshaft. This means they are directly tied to engine speed,
and their performance can be affected by engine RPM.

3. Limited Mounting Options: Mechanical fuel pumps are often limited in

terms of mounting options due to their need to be close to the engine
and mechanically driven. Electric fuel pumps offer more flexibility in
placement.

4. Vibration and Noise: Mechanical fuel pumps can produce vibrations

and noise, especially at high engine speeds. This may not be as
noticeable in noisy environments, but it can be a consideration for
comfort in certain applications.

5. Vapor Lock Potential: In some conditions, mechanical fuel pumps can

contribute to vapor lock, especially in high-temperature environments.
Vapor lock occurs when the fuel in the system turns to vapor before
reaching the engine, disrupting the fuel delivery.
Construction
The pump is bolted to the side of the engine and is operated by an eccentric on the engine camshaft.
Meta l pipes are used to connect the pump to the tank and to the float chamber. The pump is an
assembly of die-castings which form a sediment chamber and a pumping chamber, the incoming petrol
first passing through a fine wire-gauze filter. The pumping chamber has a flexible wall in the form of a
rubberized fabric diaphragm which is moved inward by the action of a spring, and outward by the action
of a link arm.

This link arm is mounted upon the same pivot as the rocker arm and the two normally act as a solid
lever, a contact face being formed on each. The rocker arm is spring-loaded in such a way that it always
maintains contact with the camshaft eccentric. Opposed disc-type, spring-loaded valves are fitted to
control the flow of petrol into an d out of the pumping chamber, the movement of the fuel being caused
by the pressure changes resulting from the movement of the diaphragm. It is important to note that,
although the rocker arm always maintains contact with the eccentric, it may not always be able to move
the link arm.

OPERATION

a. Intake stroke.

As the engine camshaft rotates, the eccentric lifts the rocker arm which forces the link arm and the
diaphragm down, and compresses the diaphragm spring. This outward movement of the diaphragm
increases the volume of the chamber and so reduces the pressure inside it.

The difference between this pressure and the higher atmospheric pressure in the tank forces petrol to
flow from the tank, open the inlet valve against its spring, and fill the chamber. The outlet valve is held
closed by both its spring and the pressure difference. When the chamber is full the pressures are
equalized and the inlet valve is closed by its spring.

b. Delivery stroke.

Continued camshaft rotation removes the lifting force from the rocker arm but its spring causes it to
maintain contact with the eccentric. The link arm and the diaphragm are now forced up by the
diaphragm spring. This reduces the volume of the chamber and therefore increases the pressure on the
petrol inside it. The inlet valve is closed more firmly to its seat and the difference between the pressure
in the chamber and atmospheric pressure in the float chamber opens the outlet valve and forces petrol
to flow into the float chamber.

(b) Idling stroke.

When the float chamber is filled to its correct level, delivery is stopped by the action of the float-
operated needle valve. This prevents the pump diaphragm spring extending and the diaphragm and link
arm are held in their down position. Under these conditions the rocker arm follows the eccentric, but its
face cannot contact the face of the link arm. The diaphragm cannot therefore be moved, and the pump
idles until such time as the float needle valve

ELECTRICAL PETROL PUMP

Advantages of Electrical Fuel Pumps:

1. High Pressure and Flow Rates: Electric fuel pumps can provide higher fuel pressure and flow
rates compared to mechanical fuel pumps. This is especially important for fuel injection systems
that require precise control over fuel delivery.

2. Variable Speed Operation: Electric fuel pumps can operate at variable speeds, adjusting to the
engine's fuel demand. This dynamic control enhances fuel efficiency and engine performance.

3. Remote Mounting Options: Electric fuel pumps can be mounted at various locations in the
vehicle, including inside the fuel tank. This flexibility in mounting options allows for better
packaging and design possibilities.

4. Quieter Operation: Electric fuel pumps generally produce less noise and vibration compared to
mechanical fuel pumps. This contributes to a quieter and more comfortable driving experience.
 5. Less Susceptible to Vapor Lock: Electric fuel pumps are less prone to vapor lock issues compared
to some mechanical fuel pumps. Vapor lock occurs when the fuel in the system turns to vapor
before reaching the engine, causing disruptions in fuel delivery.

Disadvantages of Electrical Fuel Pumps:

1. Dependence on Electricity: Electric fuel pumps rely on the vehicle's electrical system to operate.
If there's an electrical failure or issue, it can lead to a loss of fuel delivery and engine
performance.

2. Complexity: Electric fuel pumps are generally more complex than mechanical fuel pumps, with
additional electronic components. This complexity can make them more challenging to
troubleshoot and repair.

3. Heat Generation: Electric fuel pumps can generate more heat during operation compared to
mechanical fuel pumps. In-tank electric pumps are immersed in the fuel, which helps dissipate
some of the heat, but excess heat can still be a concern.

4. Cost: Electric fuel pumps are often more expensive than mechanical fuel pumps. The initial cost
of the pump and potential replacement costs can be higher.

5. Reliability Concerns in Certain Environments: In some off-road or extreme environments, where

vehicles may experience excessive vibrations or extreme temperatures, there can be concerns
about the reliability of electric fuel pumps. Specialized designs or protective measures may be
needed.

Construction

The pump-chamber action is similar to that of the mechanical pump but the valves are not spring-
loaded. The diaphragm is moved outward from the chamber by the action of an electromagnet which
attracts an iron disc attached to the diaphragm. The operation of the magnet is controlled by toggle-
operated contacts activated by a link rod also attached to the diaphragm. The link rod is centralized by a
set of non-magnetic rollers, and the diaphragm is moved into the chamber by a spring. The flow of
battery current to the unit is controlled by the ignition switch.
Operation

(a) Intake stroke.

When the contact points are closed and the ignition is switched on, battery current is passed
through the electromagnet to earth, so energizing the magnet and attracting to it the iron disc
attached to the diaphragm. The diaphragm is drawn outward from the chamber, compressing its
spring and increasing the volume of the chamber. A pressure reduction is caused and the difference
between this pressure and the higher atmospheric pressure in the tank forces petrol to flow from
the tank, open the inlet valve, and fill the chamber r - passing through a filter before passing
through the inlet valve. As the chamber is filled the pressures equalize and the inlet valve is closed
by gravity. As the diaphragm reaches the full extent of its outward movement, the attached link rod
throws over the toggle and the contacts are opened in one quick movement.

(b) Delivery stroke.

When the contacts are separated, the current cannot energize the electromagnet and the
diaphragm spring therefore forces the diaphragm back into the chamber. The chamber volume is
reduced and the pressure on the petrol inside it increased. This closes the inlet valve more firmly to
its seat and the pressure difference between the chamber and the float chamber opens the outlet
valve and forces petrol into the float chamber.

(c) Idling stroke.

When the float chamber is full the float needle valve stops delivery by holding the diaphragm in its
outward position. The link rod has thrown over the toggle and therefore the electromagnet cannot
be energized. When the petrol level falls and the needle valve opens again the delivery is made, the
link arm moves the toggle to close the contacts, and the intake stroke is started again.