FUEL SYSTEM MAINTENANCE

PRIMARY PURPOSE OF FUEL SYSTEM

The fuel system delivers clean fuel, at the right
time and in the right quantity, to meet the engine
horsepower demand.

The system system components match fuel

delivery to engine horsepower demand by
altering how much fuel is injected, and when it is
injected.

These function are handled by the heart of the

fuel system, the fuel injection pump.
 TYPES OF FUEL SYSTEM

Pump and Lines

Electronic Unit Injection

COMPONENTS & FUEL FLOW

Pump & lines Fuel System

 FUEL TANK

The fuel tank stores fuel. Fuel begins to flow when you turn
the key to start the engine. As you turn the key, a solenoid is
actuated, which turns on the transfer pump.
Fuels may contain water/sediment which require pretreatment
before delivery to the fuel injection system.Fuel storage tanks
should be constructed on an angle so water and sediment will
settle in the low end. Water in the fuel tanks can also lead to
the growth of bacteria.
 WATER SEPARATOR

The water must be drained off before the rated water capacity
of the unit is reached. All additional water will pass through
the separator.
 FUEL TRANSFER PUMP

The primary purpose of the fuel transfer pump is to keep an

adequate supply of clean fuel in the injection pump.
 SECONDARY FUEL FILTER

Secondary fuel filters screen minute particles & contaminants

from the fuel, which could damage nozzles or plugged injectors.
 NO BYPASS VALVE

Unlike oil filters, the fuel filters have no bypass valves. If the
filters get clogged, fuel flow stops and the entire engine will
not run. This protect the engine from dirty fuel.
 PRIMING PUMP

Most final fuel filters incorporate a fuel priming pump in the

base. You can use the pump to prime the system if you have
removed the fuel pump housing for a major service.
 PRIMING PUMP

The pump is also used to prime the fuel system after changing
the fuel filter. This is to eliminate air in the system and to
produce a solid and pressurized fuel in the system.
 FUEL LINE/GALLERY

Fuel exits the final filter and flows into the fuel gallery within
the injection pump housing.
 FUEL INJECTION PUMP HOUSING

Pumps in the housing measure and pressurize the fuel. Also,

attached in the housing are timing advanced unit, mechanical
governor, and fuel ratio control.
 ELECTRONIC CONTROL MODULE

On an EUI system, the mechanical governor, timing advance,

and fuel ratio control are replaced by electronics.
 HIGH PRESSURE FUEL LINES

On pump and lines systems, steel high pressure fuel lines

connect fuel injection pumps to nozzles.
 HIGH PRESSURE FUEL LINES

The high pressure side of the fuel system consists of the high
pressure lines and the nozzles. Proper quantities of pressurized
fuel travel through the high pressure fuel lines to the fuel
nozzles.
 FUEL NOZZLES

Proper quantities of pressurized fuel travel through the high

pressure fuel lines to the fuel nozzles.
 TYPES OF NOZZLES

Capsule type for PC engines

Ball peen type for DI engines

 NOZZLES/UNIT INJECTORS

Nozzles/ UI have valve that opens when fuel pressure gets

high enough. When the valves opens, fuel is atomized and
sprayed into the combustion chamber. At the end of injection,
there is rapid pressure drop, which closes the valves.
 FUEL RETURN LINE

The return line:

1. Direct excess fuel back to the tank
2. Removes air from the fuel
3. Cools the fuel by keeping it in motion.
 FUEL SHUTOFF

Every fuel system has either electronic or manual methods of

turning off the fuel supply.
 COMBUSTION CHAMBER DESIGN

The design affects fuel efficiency and engine performance.

Piston design and the injection method determine how
quickly and completely the fuel burns.
TYPES OF COMBUSTION CHAMBER DESIGN

Combustion chamber design:

1. Pre-combustion Design
2. Direct Injection Design
 PC COMBUSTION CHAMBER

In a PC system, the nozzles inject fuel into a pre-combustion

chamber where it ignites. This forces the remaining fuel into
the main chamber, where full combustion takes places. In
some engines, glow plugs are used to warm the air when
staring the engine.
HYDRAULIC ACTUATED ELECTRONIC CONTROLLED
UNIT INJECTION

EUI systems use a fuel tank, primary fuel filter, hydraulic

pump, transfer pump, final fuel filter, and a fuel return line.
 ELECTRONIC UNIT INJECTOR

The fuel injection pump, high pressure lines, and nozzles are
replaced by a single component called a unit injectors.
 SENSORS & SOLENOIDS

Fuel in the manifold enters the injector, which meters,

pressurizes, and injects the fuel.
 EUI SOLENOID

Electronic unit injector can be recognized by the solenoid

attached near the top.
EUI system use an electronic control module (ECM) to
house some of the electronics and programming information.
 FUEL SYSTEM CONTROL COMPONENTS

Fuel ratio control

Timing Advance Governor

A timing advance unit controls when fuel is injected. And the

governor controls how much fuel is delivered to the engine, or
duration.
ELECTRONIC CONTROL MODULE
ELECTRONIC CONTROL MODULE
ELECTRONIC CONTROL MODULE