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Fuel System, Description: General

The engine uses an injection system where fuel is injected into each cylinder via separate unit injectors. Each unit injector is driven by the engine's camshaft and consists of a pump and valve parts. The fuel pump delivers fuel from the tank to the unit injectors. The injection process involves four phases - filling, spill, injection, and pressure reduction. The control unit receives sensor inputs and calculates the timing and duration of electric pulses to the injectors to control the amount and timing of fuel injection for each cylinder.

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267 views7 pages

Fuel System, Description: General

The engine uses an injection system where fuel is injected into each cylinder via separate unit injectors. Each unit injector is driven by the engine's camshaft and consists of a pump and valve parts. The fuel pump delivers fuel from the tank to the unit injectors. The injection process involves four phases - filling, spill, injection, and pressure reduction. The control unit receives sensor inputs and calculates the timing and duration of electric pulses to the injectors to control the amount and timing of fuel injection for each cylinder.

Uploaded by

Astrit Strati
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Fuel system, description

General
The engine has an injection system where the fuel is injected into the combustion compartments via separate
injection pumps for each cylinder. The injection pressure may be as high as 1500 bar.
The fuel is delivered from the tank via the primary filter by the fuel pump via the secondary filter to the supply
channel for the unit injectors.
From the unit injectors, the fuel is delivered through the pressure (delivery) lines to the injectors.
Return fuel from the unit pumps passes via a channel in the cylinder block to the overflow valve which is placed
in the outlet from the cylinder head's fuel channel.
The overflow valve controls the feed pressure in the fuel system. Opening pressure is approx. 3.5 bar.
The high feed pressure ensures filling of the unit injectors.
The fuel pump has a very high flow and excess fuel helps to cool the unit pumps.
After the overflow valve, the fuel passes via a cooler to the tank.

Figure 1
Unit pump, description
The injector pumps are driven by the engine's camshaft. Each pump consists of two main parts: the pump part
and the valve part with solenoid valve.
Function
It's easiest to divide the events in the unit injector in four phases.
Filling phase
Filling takes place all the time that the piston moves down. The fuel valve is open since the solenoid valve is not
supplied with voltage. Therefore, fuel can be sucked from the feed channel through the open valve and into the
pump cylinder.

Figure 1 Filling phase for unit pump


1. Solenoid valve
2. Fuel valve
3. Pump piston
4. Injector
Spill phase
The pump piston is on its way up. As long as the solenoid valve isn't supplied with voltage, the fuel valve
remains open and fuel flows in return to the feed channel.
Figure 2 Spill phase for unit pump

Injection phase
The pump piston is still on its way up. The solenoid valve is now supplied with voltage from the control unit and
the valve closes. Since fuel cannot flow through the valve, the pressure increases rapidly so that the injector
needle lifts and injection takes place. Injection continues for as long as the valve is closed and the pump piston
moves up.
Injection timing depends on when in time the electric pulse arrives (when the fuel valve closes). The amount of
fuel is determined by the length (duration) of the electric pulse. It's the control unit that decides the pulse's
duration and timing via information it receives from the control system.
Figure 3 Injection phase for unit pump

Pressure reduction phase


The pump piston is still on its way up. The control unit terminates the electric pulse when the engine has
received the fuel amount that it needs at exactly that point in time. The fuel valve opens and the fuel in the
pump part can once again flow in return to the feed channel.

Figure 4 Pressure reduction phase for unit pump


Summary
The pump piston always sucks the same amount of fuel as it pumps out of the injector. It's only when the fuel
valve is closed that pressure builds up and injection takes place.
The electric pulse's duration and its timing determines the injected fuel amount and when injection takes place.

Unit injectors, description


The injector's lower sleeve with injector nozzle is shaped to give even fuel dispersion, despite the angle of the
unit injector, and thus the injector nozzle has to face in one way only.
The injector nozzle has six holes.

Figure 1

Control unit, description


The control unit (E-ECU) is the central part in the injection system.
The control unit (A) is located on the intermediate wall outside the engine compartment and is mounted in
brackets with rubber dampers.
The control unit receives continuous information from the throttle pedal and from a number of sensors on the
engine and "calculates" the fuel amount and timing for fuel injection into the cylinders.
Control signals to the unit pumps run via shielded electrical cables.
Since the control unit, through the flywheel sensor, senses the engine's rpm and also differences in rpm during
the revolution, it ensures that each unit pump receives the correct amount of fuel.
The control unit stores information if a problem or malfunction should occur, or if anything in the system is
abnormal.
Even sporadic malfunctions are stored in the control unit and can be traced at a later time.
Control unit's sensors
Figure 1
Fuel system's sensors
1. SE2203, combined sensor for engine oil pressure and engine oil temperature
2. SE2306, fuel temperature sensor
3. SE2507, Charge-air temperature sensor
4. SE2508, sensor for boost pressure, located on induction manifold
5. SE2606, coolant temperature sensor
6. SE2701, combined sensor for flywheel position and rpm
7. SE2703, camshaft position sensor
In the control system, there's also a sensor for atmospheric pressure and, on the air filter there's a sensor for
induction air temperature as well as a monitor for clogged air filter.

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