Ameer Randolph
An in-tank fuel pump is a type of fuel pump that is located inside the fuel tank of a vehicle. Its primary function is to deliver fuel from the tank to the engine, where it is burned to produce power. There are three main types of fuel pumps: mechanical, electric, and high-pressure. Mechanical pumps are driven by the camshaft or a special shaft driven by the crankshaft, while electric pumps are powered by the vehicle's battery and are usually located inside the fuel tank for safety reasons. The pump may also include a filter to catch any sediment or contaminants in the fuel. In addition, there is often a sending unit that measures the fuel level and sends this information to the fuel gauge on the dashboard. Overall, the in-tank fuel pump plays a crucial role in ensuring that fuel is consistently and efficiently delivered to the engine to maintain optimal performance.
| Characteristics | Values |
|---|---|
| Types | Mechanical, Electric, and High-Pressure |
| Function | Moves gasoline from the fuel tank to the engine |
| Location | Inside the fuel tank |
| Components | Fuel pump motor, Impeller, Fuel filter, Sending unit, Wiring harness |
| Operation | Draws fuel into the pump and pushes it out to the engine |
| Pressure | Operates at pressures above 200 Pascals |
| Fuel Level | Maintains consistent flow even at low fuel levels |
| Safety | Located away from the engine, Includes a fuel filter to prevent impurities |
| Power Source | Vehicle's battery |
| Regulation | Electronic Control Unit (ECU) regulates output pressure, volume, and incoming fuel |
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What You'll Learn
Electric fuel pumps
An in-tank electric fuel pump is a type of fuel pump that is located inside the fuel tank of a vehicle. It is responsible for delivering fuel from the tank to the engine, where it is burned to produce power. The electric fuel pump assembly consists of several components that work together to deliver fuel from the tank to the engine.
The electric motor is the heart of the fuel pump assembly. It drives the impeller and creates the pressure required to deliver fuel to the engine. The impeller is a small propeller-like device that is connected to the motor. As the motor spins, the impeller creates a low-pressure area that draws fuel into the pump and a high-pressure area that pushes fuel out of the pump and into the fuel lines.
The fuel filter is located on the inlet side of the pump and helps to remove any debris or contaminants that may be present in the fuel. Contaminants like dirt, debris, and other impurities can clog the fuel filter or damage the fuel pump. Over time, this can cause the fuel pump to wear out or fail prematurely.
One of the key advantages of an in-tank electric fuel pump is its ability to provide a consistent flow of fuel to the engine, even when the fuel level in the tank is low. It operates quietly and efficiently, and the vehicle's battery provides the current required to run the fuel pump. An electronic control unit (ECU) assists in regulating the output pressure and volume of the gasoline, metering the incoming fuel from the tank, and improving fuel economy and power.
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Mechanical fuel pumps
A mechanical fuel pump is typically driven by the camshaft or by a special shaft driven by the crankshaft. It is mounted to the head, with a nylon spacer between the head and the pump, and a hole for a pushrod to go through. As the camshaft turns, a cam passes under a pivoted lever and forces it up at one end. The other end of the lever is linked to a rubber diaphragm, which forms the floor of a chamber in the pump and moves down with the lever.
The diaphragm moves up and down, creating a pumping action and a vacuum in the fuel line on the input side of the pump. This draws fuel through a one-way valve into the pump and then pushes it into the carburettor. The carburettor takes the fuel it needs, and the return spring pushes the diaphragm back up to deliver the fuel.
Over time, the rubber diaphragm in a mechanical fuel pump can dry out and lose its elasticity, reducing the amount of fuel pumped and causing the engine to run dry. This can sometimes be addressed by adjusting the nylon spacer to make the stroke of the rod longer.
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High-pressure fuel pumps
In-tank fuel pumps are used to draw fuel out of the tank and supply it to the engine. They can be mechanical or electric. Mechanical pumps are driven by the camshaft or crankshaft, while electric pumps are usually placed inside the fuel tank.
The high-pressure pump receives fuel from the low-pressure circuit, where the fuel is initially drawn from the tank by an electrical fuel pump. The fuel is then pumped through high-pressure fuel lines into the fuel distribution pipe (also known as the rail). From there, the fuel reaches the relevant cylinders through connected electrical high-pressure injection valves.
The engine control unit plays a crucial role in monitoring and regulating fuel pressure in the high-pressure circuit. This unit ensures that the pressure remains within an appropriate range, typically between 50 and 350 bar, depending on the specific system configuration.
It is important to note that repairing or replacing high-pressure fuel pumps should only be performed by trained specialists due to the potential risks involved.
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Fuel injection systems
The two main functional principles of mixture formation systems for internal combustion engines are internal and external. A fuel injection system that uses external mixture formation is called a manifold injection system. There are two types of manifold injection systems: multi-point (or port) and single-point (or throttle body) injection.
Internal mixture formation systems can be separated into several different varieties of direct and indirect injection. The most common is the common-rail injection, a variety of direct injection. In a common-rail system, fuel from the fuel tank is supplied to a common header (called the accumulator) and then sent through tubing to the injectors, which inject it into the combustion chambers. The accumulator has a high-pressure relief valve to maintain pressure and return excess fuel to the fuel tank.
Direct injection means that the fuel is injected into the main combustion chamber of each cylinder. The air and fuel are mixed only inside the combustion chamber. Therefore, only air is sucked into the engine during the intake stroke. The injection scheme is always intermittent (either sequential or cylinder-individual). This can be done either with a blast of air or hydraulically, with the latter method being more common in automotive engines.
In petrol engines, fuel injection systems are always indirect, with petrol being injected into the inlet manifold or inlet port rather than directly into the combustion chambers. This ensures that the fuel is well mixed with the air before it enters the chamber. Many diesel engines, however, use direct injection, where diesel is injected directly into the cylinder filled with compressed air.
The earliest fuel injection systems were mechanically controlled and often called Petrol Injection (PI for short), with the fuel flow controlled by a mechanical regulator assembly. These systems were mechanically complex and had poor responses to backing off the throttle. Mechanical systems have now been largely superseded by electronic fuel injection (known as EFi for short) due to the increasing reliability and decreasing costs of electronic control systems.
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Fuel filters
The most common type of pump has a cylindrical filter holder and a disc filter. To access the filter, the top of the pump is unscrewed, and the filter is removed. Mechanical pumps often have a removable top covering the filter, which can be made of glass. The filter is usually held in place by a central screw or nut. Once the top is removed, the filter can be lifted out. In some cases, there may be a flexible fuel pipe connected to the top, which should be left intact.
SU mechanical pumps, commonly found in British-built cars, have two main types: the AUF 800 and AUF 700. The AUF 800 has a filter, while the AUF 700 does not. The AUF 800's inlet and outlet pipes are positioned side by side on top, facing opposite directions. To access the filter, the right-angled 'elbow' connectors must be unscrewed.
The actual filter is a small gauze disc between two rubber seals. It should be carefully removed with a pin and cleaned. During reassembly, it is crucial to ensure that the gasket between the main pump parts remains in the same position. Additionally, the valve should be placed with the straight strip on top.
A blocked fuel pump filter can cause significant issues, including intermittent engine cut-off, especially at high speeds, and even complete engine failure. Therefore, regular cleaning and maintenance of the fuel pump filter are essential to ensure the smooth operation of the vehicle.
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Frequently asked questions
An in-tank fuel pump is a component used in liquid-fuelled engines to transfer fuel from the fuel tank to the carburettor or fuel injector.
An in-tank fuel pump draws fuel from the tank through a pipe to the carburettor. The pump may be mechanical or electric. A mechanical pump is driven by the camshaft or crankshaft, while an electric pump uses a DC motor in the pump assembly to draw fuel from the tank.
In-tank fuel pumps are used because they can be smaller and shielded to reduce noise. They also benefit from head pressure, which assists the pump in pushing fuel. Additionally, submerging the pump in fuel cools the pump and reduces the risk of fire.
