Sylvie Willis
Ford's dual fuel tank system, used in its F150 and larger F-Series trucks, employs two separate tanks: a primary and a secondary tank. This setup offers benefits such as improved weight distribution and increased mileage. The fuel first enters the primary tank, then moves to the secondary tank once the vehicle is in motion, before finally reaching the engine. The secondary tank also serves to replace the wasted energy of the primary tank. In addition, Ford has utilized fuel injection systems in its vehicles, with the introduction of the Ford EEC-III single-point fuel injection system in 1980, which played a role in the transition from carburettors to fuel injection in the early 1990s.
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What You'll Learn
Ford dual fuel tanks have a primary and secondary tank
The dual fuel tank system increases fuel efficiency, allowing trucks to carry more fuel and travel farther. This ensures that the engine does not shut down due to a lack of fuel. Additionally, dual tanks assist in weight distribution, preventing truck imbalance during hard turns. They also offer backup fuel, enhancing vehicle rigidity, confidence, and road safety.
The dual tank system includes a fuel pressure regulator, which uses a diaphragm to control fuel compression caused by the fuel injector. One pass of the tank drives the diaphragm, while the other is connected to the vacuum in the intake manifold. When fuel levels are low and the truck is in extreme conditions, the fuel reservoirs, formed by fuel delivery assemblies, prevent the fuel barrier.
While dual fuel tanks offer benefits, they also have drawbacks. They are more expensive to produce and maintain due to the additional tank, valve systems, automatic switches, and fuel pumps. This complexity led Ford to transition back to single tanks with in-tank fuel pumps and larger capacities.
Ford vehicles with dual fuel tanks include the Ford F-150 and larger F-Series Trucks from 1987 to 1996, as well as the 1997 Ford F-350.
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Fuel moves from the primary to the secondary tank, then to the engine
Ford's dual fuel tank system involves a primary and a secondary tank. The fuel first moves to the primary tank, and once the vehicle is running, it moves to the secondary tank. From there, the fuel is sent to the engine.
The primary tank receives fuel from the filler pipe, and a vent line and discharge line work alongside the pipe throughout the process. The two tanks operate independently but simultaneously. The secondary tank replaces the wasted energy of the primary tank. When the ignition is turned off or the vehicle speed drops below 120 ppm, the fuel pump becomes inactive, which is controlled by the powertrain control module.
The dual fuel tank system offers benefits such as improved weight distribution and increased mileage. However, it is more expensive than a single tank system and requires more maintenance due to the additional tank.
In terms of the fuel injection process, fuel injection atomizes the fuel through a small nozzle under high pressure. This process is controlled by an engine control unit, which determines the appropriate amount of fuel to be supplied and controls the fuel flow accordingly. The fuel is then sprayed into the engine with the help of a nozzle that is operated by a solenoid-needle valve.
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Dual tanks offer better weight distribution and mileage
Dual fuel tanks have several advantages over single tanks, including better weight distribution and mileage. This system, used by Ford in the past, features a primary and secondary tank. The fuel first moves to the primary tank, and once the vehicle is running, it moves into the secondary tank, from where it is sent to the engine.
The dual tank system offers better weight distribution by allowing for more flexibility in tank placement. With two smaller tanks, weight can be distributed more evenly across the vehicle, improving handling and stability. This is particularly beneficial for larger vehicles such as trucks, where weight distribution is critical for safety and manoeuvrability.
Additionally, dual tanks provide increased mileage. The secondary tank replaces the wasted energy of the primary tank, ensuring that fuel is used more efficiently. This is especially advantageous for vehicles with poor fuel economy, as the extra tank capacity allows for longer distances to be travelled without refuelling.
The dual tank system also includes a fuel pressure regulator, which controls fuel compression caused by the fuel injector. This regulator, driven by one pass of the tank, maintains optimal fuel pressure and returns excess fuel to the tank. This further contributes to efficient fuel usage, reducing waste and maximising mileage.
While dual fuel tanks offer these benefits, they have largely been replaced by single tanks due to their higher cost and complexity. Maintaining two tanks can be more challenging and expensive, and modern vehicles often achieve sufficient mileage and weight distribution with single tanks. However, for certain applications, dual tanks can still offer advantages, particularly in larger or fuel-inefficient vehicles.
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Dual tanks are costly and complex to maintain
Dual-tank fuel systems, such as those found in some Ford vehicles, offer certain advantages such as improved weight distribution and increased mileage. However, they also come with their own set of challenges, particularly when it comes to cost and maintenance.
One of the main drawbacks of dual-tank systems is the added complexity they introduce. With two separate tanks to manage, the maintenance burden is inherently higher compared to a single-tank setup. This complexity is further exacerbated by the presence of additional components unique to dual-tank systems, such as the fuel pressure regulator, the shuttle selector valve, and the supply check valve.
The fuel pressure regulator, for instance, plays a critical role in controlling fuel compression caused by the fuel injector. It utilizes a diaphragm to regulate fuel pressure, with one side sensing fuel pressure and the other connected to the intake manifold vacuum. While this component is essential for the proper functioning of the fuel injection system, it also represents an additional maintenance concern. The regulator requires periodic servicing, and any issues with it can lead to problems with fuel delivery and engine performance.
Another challenge with dual-tank systems is the potential for fuel cross-flow between the tanks. This can result in unexpected fuel level discrepancies, as observed by some Ford vehicle owners. In certain cases, it may even be necessary to simultaneously switch the fuel source, fuel return, and fuel level sender, adding to the maintenance complexity.
Furthermore, the cost of maintaining dual tanks can be significantly higher than that of a single tank. The presence of two tanks means double the maintenance requirements, including the need for regular fuel filter replacements and potential repairs or replacements of tank components. This increased cost can be a significant deterrent for vehicle owners, especially when compared to the relatively simpler and more cost-effective single-tank systems.
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Fuel injection atomises fuel under high pressure
Ford's dual-tank fuel injection system uses two tanks: a primary and a secondary tank. The fuel first moves to the primary tank and then to the secondary tank once the vehicle is running. From the secondary tank, the fuel is delivered to the engine.
Fuel injection is operated by spraying pressurised fuel into the engine. Fuel injection atomises fuel through a small nozzle under high pressure. The atomisation of fuel refers to the process of breaking down the fuel into fine particles. The atomisation effect of heavy fuel can be improved by applying direct injection (DI) technology, which reduces fuel loss.
The direct injector assembly includes three parts: a fuel injector, a premixing chamber, and an air-assisted injector. Fuel is first ejected through the outlet of the fuel injector into the premixing chamber and then delivered by the air-assisted injector into the constant volume chamber or engine cylinder. The fuel spray characteristics directly affect the combustion performance of the engine.
In a common-rail system, fuel from the fuel tank is supplied to a common header (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. The fuel is sprayed with the help of a nozzle that is opened and closed with a solenoid-operated needle valve.
The main purpose of the fuel injection system is to deliver fuel into the engine cylinders while precisely controlling the injection timing, fuel atomisation, and other parameters. Modern injection systems reach very high injection pressures and utilise sophisticated electronic control methods. The performance of diesel engines is heavily influenced by their injection system design.
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Frequently asked questions
The dual fuel tank system has a primary and a secondary tank. There is a connecting pipe between the tanks. The fuel first moves to the primary tank and then to the secondary tank. From the secondary tank, the fuel gets into the engine.
The Fuel Pressure Regulator controls the fuel compression caused by the fuel injector. It uses a diaphragm to function. Nominal fuel pressure is established by a spring preload applied to the diaphragm.
Carburetion relies on suction created by intake air accelerated through a Venturi tube to draw fuel into the airstream. Fuel injection, on the other hand, atomizes the fuel through a small nozzle under high pressure.
There are two types of manifold injection systems: multi-point (or port) and single-point (or throttle body) injection.
