10/5/13

Fuel Injection System Components

DieselNet Technology Guide Diesel Fuel Injection

www.DieselNet.com. Copyright Ecopoint Inc. Revision 2013.06

Fuel Injection System Components

Hannu Jskelinen, Magdi K. Khair
This is a preview of the paper, limited to some initial content. Full access requires DieselNet subscription. Please log in to view the complete version of this paper.
Abstract: The fuel injection system can be divided into low-pressure and high-pressure sides. The low-pressure components include the fuel tank, fuel supply pump and fuel filter. The high-pressure side components include a high pressure pump, accumulator, fuel injector and fuel injector nozzle. A number of injection nozzle designs and different actuation methods have been developed for use with different types of fuel injection systems. Low-Pressure Side Components Overview Fuel Tank and Fuel Supply Pump Fuel Filter Fuel Heaters & Coolers High-Pressure Side Components Overview High Pressure Pump Accumulator Fuel Injector and Fuel Injection Nozzle Fuel Metering Nozzle Needle Control Actuators

1. Low-Pressure Side Components

1.1 Overview
In order for the fuel injection system to fulfill its purpose, fuel must be transferred to it from the fuel tank. This is the role of the low-pressure fuel system components. The low pressure side of the fuel system consists of a number of components including the fuel tank, one or more fuel supply pumps and one or more fuel filters. In addition, many fuel systems contain coolers and/or heaters to better control fuel temperature. Figure 1 illustrates two examples of schematics for low pressure fuel systems, one for a
www.dieselnet.com/tech/diesel_fi_comp.php#hpintro 1/5

10/5/13

Fuel Injection System Components

heavy-duty diesel truck and one for a light-duty diesel passenger car [CRC 2007][CRC 2008].
Fuel return Injector pump supply Fuel return Injector pump supply Secondary fuel filter Fuel pump Fuel filter

Thermostatic control

Primary fuel filter Fuel tank Fuel pump

Fuel tank

MY 2003 Caterpillar C12

fuel system in an International truck

MY 2005 Volkswagen Passat

with 2.0 L TDI engine fuel system

Figure 1. Examples of Low Pressure Fuel Systems for Heavy-Duty and Light-Duty Diesel Vehicles

1.2 Fuel Tank and Fuel Supply Pump

The fuel tank is a reservoir that holds the fuel supply and helps maintain its temperature at a level below its flash point. The fuel tank also serves as an important means of dissipating heat from the fuel that is returned from the engine [Bosch 1971]. The fuel tank should be corrosion-resistant and leakproof to pressures of at least 30 kPa. It must also use some means to prevent excessive pressure accumulation such as a vent or a safety valve. The fuel supply pump, often referred to as the lift pump, is responsible for drawing fuel from the tank and delivering it to the high pressure pump. Modern day fuel pumps can be electrically or mechanically driven by the engine. Using an electrically driven fuel pump allows the pump to be placed anywhere in the fuel system including inside the fuel tank. Pumps driven by the engine are attached to the engine. Some fuel pumps may be incorporated into units that serve other functions. For example, so called tandem pumps are units that incorporate a fuel pump and a vacuum pump for the brake booster. Some fuel systems, such as those based on a distributor type pump, incorporate a mechanically driven supply pump and the high pressure pump in one unit. Fuel pumps are commonly sized to deliver more fuel than is consumed by the engine at any particular operating system. This extra fuel flow can serve a number of important functions including providing extra fuel to help to cool injectors, pumps and other engine components and maintaining a more constant temperature of the fuel in the entire fuel system. Also, the excess fuel that is heated by its contact with hot engine components can be returned to the tank or fuel filter to improve the vehicles low temperature operability.

1.3 Fuel Filter

www.dieselnet.com/tech/diesel_fi_comp.php#hpintro 2/5

10/5/13

Fuel Injection System Components

Trouble-free operation of a diesel injection system is possible only with filtered fuel. Fuel filters help reduce damage and premature wear from contaminants by retaining very fine particles and water to prevent them from entering the fuel injection system. As shown in Figure 1, fuel systems can contain one or more stages of filtration. In many cases, a course screen is also located at the fuel intake located in the fuel tank. Two stage filter system typically uses a primary filter on the inlet side of the fuel transfer pump and a secondary filter on the outlet side. The primary filter is required to remove larger particles. The secondary filter is required to withstand higher pressures and remove smaller particles that can damage the engine components. One-stage systems remove larger and smaller particles in a single filter. Filters can be a box-type or replacement element design, as shown in Figure 2. The box-type filter is that which can be completely replaced as needed and does not require cleaning. Filters with a replaceable element have to be thoroughly cleaned when replacing elements and care must be taken to avoid any dirt residue that could migrate to the intricate parts of the fuel injection system. Filters can be constructed of metal or plastic.

Figure 2. Two Types of Fuel Filters

(a) Box type; (b) Element type

Common materials for modern fuel filter elements are synthetic fibres and/or cellulose. Micro glass fibres can also be used but because of the risk of migration of small glass fibre pieces broken off from the main element into critical fuel system components, their use in some applications is avoided
[Petiteaux 2009]. In the past, pleated paper, packed cotton thread, wood chips, a mixture of packed

cotton thread and wood fibres and wound cotton have also been used [Brady 1996]. The degree of filtration required depends on the specific application. In general, when two filters are used in series, the primary filter retains particles down to about 10 - 30 m, while the secondary filter is capable of retaining particles greater than 2-10 m. As fuel systems evolve, clearances and stresses on high pressure components increase and the need for clean fuel becomes event more critical. Both the capability of fuel filters to keep up with demands for cleaner fuel [Salvador 2009] as well as methods quantifying acceptable fuel contamination levels have needed to evolve [van Stockhausen 2009]. In addition to keeping solid particles out of the fuel supply and injection equipment, water in fuel must
www.dieselnet.com/tech/diesel_fi_comp.php#hpintro 3/5

10/5/13

Fuel Injection System Components

also be prevented from entering critical fuel injection system components. Free water can damage fuel lubricated components in the fuel injection system. Water can also freeze in cold temperature conditions and ice may block small fuel injection system passages thus cutting off the fuel supply to the rest of the fuel injection system. Water can be removed from the fuel using two common approaches. The incoming fuel can be subject to centrifugal forces that separates the denser water from the fuel. Much better removal efficiencies can be achieved with a filter media that separates water. Figure 3 shows a filter using a combination of media-type and centrifugal approaches.

Figure 3. Fuel Filter Equipped with Water Separator

Different water separation media operate under different principles. Hydrophobic barrier media, such as silicone treated cellulose, rejects water and causes it to bead up on the upstream surface. As the beads become larger, they run down the face of the element into a cup under the force of gravity. Hydrophilic depth coalescing media, such as glass micro-fibre, has a high affinity for water. The water in the fuel associates with the glass fibres and over time as more water enters from the upstream side, massive droplets are formed. The water moves through the filter with the fuel and on the downstream side, falls out of the fuel flow into a collection cup. Increased use of surface active fuel additives and fuel components such as biodiesel have rendered conventional separating media less effective and filter manufacturers have needed to develop new approaches such as composite media and ultra-high surface area coalescing media [Stanfel 2009]
[Pangestu 2009][Bessee 2009]. Methods of quantifying fuel/water separation performance have also been

affected [Stone 2009].

www.dieselnet.com/tech/diesel_fi_comp.php#hpintro

4/5

10/5/13

Fuel Injection System Components

Fuel filters can also contain additional features such as fuel heaters, thermal diverter valves, de-aerators, water-in-fuel sensors, filter change indicators. A fuel preheater helps minimize the accumulation of wax crystals that can form in the fuel as it cools to low temperatures. Common heating methods use electric heaters, engine coolant or recirculated fuel. Two approaches that use warm return fuel to heat the incoming fuel are shown in Figure 1. Fuel overflow and leak-off fuel returning to the tank also carries air and fuel vapor. The presence of gaseous substances in the fuel can cause difficulties in starting as well as normal engine operation in high temperature environments. Therefore, bleeder valves and de-aerators are used to rid the fuel supply of vapors and air to ensure trouble-free engine operation.

References
Bessee, G.B., Hutzler, S., 2009. The effects of diesel fuel additives and water separation performance, SAE Technical Paper 2009-01-0868, doi:10.4271/2009-01-0868 Bosch, 1971. Fuel Injection Equipment for Diesel Engines - Fuel Injection Pumps PE and PF, Robert Bosch GmbH, 1st ed., 1971 Brady, R.N., 1996. M odern Diesel Technology, Vancouver Community College and HiTech Consulting Limited, Prentice Hall, Englewood Cliffs, New Jersey CRC, 2007. Evaluation Of Low Temperature Operability Performance Of Light-Duty Diesel Vehicles For North America, Coordinating Research Council, Inc., Atlanta, GA, CRC Report No. 649, http://www.crcao.com/reports/recentstudies2007/CRC%20649%20Complete%20Report.pdf CRC, 2008. Biodiesel Blend Low-Temperature Performance Validation, Coordinating Research Council, Inc., Atlanta, GA, CRC Report No. 650, http://www.crcao.org/reports/recentstudies2008/DP-2a-07/CRC%20650.pdf Pangestu, F.D., Stanfel, C.M ., 2009. M edia for water separation from biodiesel-ultra low sulfur diesel blends, SAE Technical Paper 2009-01-0871, doi:10.4271/2009-01-0871 Petiteaux, M ., 2009. Innovative Water Separation Technology and Electrostatic Discharge System Developed and Validated for the New Diesel Fuel Filtration M odule of the Future Ford Diesel F-Series, SAE Technical Paper 2009-01-1459, doi:10.4271/2009-01-1459 Salvador, C., 2009. Filtration technology challenges for common-rail diesel engine fuel systems, SAE Technical Paper 2009-010874, doi:10.4271/2009-01-0874 Stanfel, C.M ., 2009. Fuel filtration: protecting the diesel engine, Filtration + Separation, M ay/June 2009, 22-25 Stone, W., et al., 2009. Diesel fuel/water separation test methods - where we are and where we are going, SAE Technical Paper 2009-01-0875, doi:10.4271/2009-01-0875 van Stockhausen, A., et al., 2009. Procedure for determining the allowable particle contamination for diesel fuel injection equipment (FIE), SAE Technical Paper 2009-01-0870, doi:10.4271/2009-01-0870

###

www.dieselnet.com/tech/diesel_fi_comp.php#hpintro

5/5