Mercedes Mullins
The fuel system in modern cars is a complex combination of components and electronics. Once you fill up the tank with gasoline, the system is ready to start. The fuel pump is then used to draw fuel from the fuel tank through the fuel lines and into the fuel injectors, which spray the fuel into the combustion chamber. The pump may be mechanical or electric, in which case it is usually next to or inside the fuel tank. Fuel lines can be made from a variety of materials, including stainless steel, aluminium, coated steel tube, rubber, nylon, or PTFE-lined hose. It is important to keep fuel lines away from moving parts and suspension pinch points, and to ensure clamps are tight to avoid abrasion and fuel line droop.
Characteristics and Values of Internal Fuel Pumps
| Characteristics | Values |
|---|---|
| Hose Internal Diameter | 6mm, 8mm, 10mm, 12mm, 15mm, 19mm |
| Hose Type | Low-pressure (carburettors), High-pressure (fuel injection) |
| Hose Material | Plain rubber, Stainless-steel over-braid |
| Hose Connection | Push-on, Hose clips, Swaged |
| Hose Durability | Nylon tubing, Braided hose, PTFE-lined hose |
| Hose Fittings | JIC/AN fittings, Screw-on |
| Fuel Pump Location | In-tank, In-engine bay |
| Fuel Pump Type | In-line, Mechanical, Electrical |
| Fuel Flow | One-way valve, Check valve |
| Fuel System | Single-pipe, Supply and return pipes |
| Fuel Filter | Paper, Wire, Plastic gauze, Bowl |
| Fuel Sampling Kit | Push-on hose, Threaded male/male, Threaded male/female |
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What You'll Learn
- Fuel lines can be made from a variety of materials, including nylon, rubber, braided stainless steel, and PTFE
- The internal fuel pump is usually located inside the fuel tank, where it remains submerged and cooled
- In-line fuel pumps are gravity-fed and must be positioned below the fuel level
- The fuel pump draws petrol out of the tank through a pipe to the carburettor, where it is mixed with air
- The pump may be mechanical or electric, and it sends petrol continuously through a circuit of pipes
Fuel lines can be made from a variety of materials, including nylon, rubber, braided stainless steel, and PTFE
Fuel lines are an essential component of a car's fuel system, delivering fuel from the tank to the engine. They can be made from different materials, each with its own advantages and considerations:
Nylon Fuel Lines
While information on nylon fuel lines is scarce, they are a type of fuel line available in the market.
Rubber Fuel Lines
Rubber fuel lines are commonly used, offering flexibility and ease of installation. They are available in various internal diameters to fit different vehicle applications. However, they are susceptible to degradation over time, especially with the increasing ethanol content in pump fuel, which can lead to premature replacement.
Braided Stainless Steel Fuel Lines
Braided stainless steel fuel lines offer enhanced protection against impact, abrasion, and cuts. They are ideal for street and racing applications where compatibility with E85, gasoline, or methanol fuel is required. Additionally, the stainless steel outer braid safeguards the inner liner, which is typically made of PTFE.
PTFE Fuel Lines
PTFE, or polytetrafluoroethylene, fuel lines offer several advantages. They provide outstanding flow capacity and are easier to route in tight spaces due to their smaller outer diameter compared to rubber braided lines. PTFE fuel lines also deliver extended service life as they are resistant to hardening, micro-fracturing, and fuel vapor permeation, minimizing fuel odour in the vehicle storage area.
When choosing the right fuel line material, it is important to consider the specific requirements of your vehicle, including fuel compatibility, performance, and regulatory compliance. Additionally, proper sizing, securing methods, and protection from heat are crucial factors in ensuring the fuel system functions optimally.
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The internal fuel pump is usually located inside the fuel tank, where it remains submerged and cooled
In vehicles with fuel injection, the primary fuel pump is typically found inside the fuel tank. This primary fuel pump is responsible for drawing fuel from the reservoir and transferring it towards the engine. The reservoir is a crucial component as it stores all the usable fuel in the vehicle, and it must always be kept full. The fuel pump assembly includes parts such as the fuel level float, level sensor, pressure regulator, fuel level sender, strainers, impeller, and armature.
The armature is a key component of the fuel pump, enabling it to rotate the impeller and draw fuel from the reservoir. This process ensures a consistent and steady supply of fuel at the required pressure for efficient engine operation. The fuel pump's location inside the fuel tank helps prevent overheating, extending its lifespan and ensuring reliable performance.
Additionally, modern vehicles with gasoline direct injection (GDI) systems often feature a secondary high-pressure fuel pump. This second pump is typically mounted near the fuel rail within the engine compartment. The purpose of this high-pressure pump is to increase fuel pressure to the extremely high levels demanded by GDI systems, facilitating more precise fuel delivery directly into the combustion chamber.
Accessing the fuel pump for maintenance or repairs can vary depending on the vehicle model. Some vehicles provide convenient access through a fuel pump access door located underneath the rear seat, eliminating the need to remove the entire fuel tank. However, other vehicles may require disconnecting various components, such as electrical connections, fuel lines, or even the exhaust system, to reach the fuel pump.
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In-line fuel pumps are gravity-fed and must be positioned below the fuel level
In-line fuel pumps are an integral part of any vehicle's fuel system, ensuring the smooth delivery of fuel from the tank to the engine. When it comes to in-line fuel pumps, their positioning is crucial as they rely on gravity to feed fuel to the engine. Here's an in-depth look at why in-line fuel pumps must be positioned below the fuel level:
In-line fuel pumps, also known as gravity-fed fuel pumps, operate on the basic principle of using gravity to facilitate the flow of fuel. This means that the fuel tank needs to be positioned higher than the engine for the system to work effectively. By placing the fuel tank above the engine, gravity naturally pulls the fuel downwards, allowing it to flow smoothly towards the engine. This setup is commonly seen in high-wing aircraft, such as the Cessna 172, where the fuel tanks are mounted in the wings, taking advantage of gravity to feed fuel to the engines.
The positioning of the fuel tank relative to the engine is critical for the optimal functioning of a gravity-fed fuel system. The higher the fuel tank is positioned above the engine, the greater the gravitational force assisting the fuel flow. This relationship is often calculated using the elevation between the tank and the engine, with each foot of elevation resulting in approximately 0.5 psi of fuel pressure. Therefore, ensuring that the fuel tank is higher than the engine is essential for the gravity-fed system to work as intended.
In some cases, a booster pump or backup pump may be installed alongside the main fuel pump to augment the gravity-fed system. This is particularly common in pump-fed, low-wing aircraft where the fuel tanks cannot be positioned high enough above the engine to rely solely on gravity. The booster pump provides additional pressure to ensure the fuel reaches the engine, and its performance can be monitored through a fuel pressure gauge.
It is worth noting that while gravity-fed fuel systems are simple and efficient, they may not be suitable for all aircraft designs, especially low-wing types. In such cases, a fuel pump system becomes necessary, adding complexity to the overall design. Additionally, gravity-fed systems may require a bypass system to allow surplus fuel to return to the tank, maintaining the proper fuel pressure and preventing issues like flooding.
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The fuel pump draws petrol out of the tank through a pipe to the carburettor, where it is mixed with air
The fuel pump is an essential component of a car's fuel system, responsible for drawing petrol out of the tank and delivering it to the engine, where it is burned to power the vehicle. The pump ensures a consistent supply of fuel, enabling the engine to run smoothly. Here's a detailed overview of the process:
The fuel pump draws petrol out of the tank through a pipe, known as the fuel line. This process involves creating suction to draw the fuel along the fuel pipe and into the pump through a one-way valve. The fuel line can be made from various materials, including metal, rubber, nylon, or braided hose with a stainless steel or nylon exterior. Metal, specifically stainless steel, aluminium, or coated steel tube, is the most common material used by manufacturers due to its durability. However, other materials like rubber or nylon are more cost-effective and easier to install.
The fuel pump pushes the petrol through the fuel line towards the carburettor. The carburettor is a device that mixes the petrol with air to create a combustible mixture. This mixture is precisely calibrated to ensure the engine receives the optimal ratio of fuel to air at all times. Both the petrol and air are filtered before entering the carburettor to remove any impurities. The mixture then continues on its journey through the fuel line.
In some fuel systems, the petrol circulates continuously through a complete circuit of pipes, from the tank to the carburettor and back again. The carburettor draws off the petrol-air mixture as needed. This type of system is known as a supply and return pipe system and is found in some cars. However, single-pipe systems are more commonly used.
Finally, the petrol-air mixture reaches the engine, where it is burned to generate power. The engine sucks in the mixture from the carburettor, and the combustion process occurs in the engine's combustion chambers. This process releases the energy required to propel the vehicle forward. The fuel pump plays a vital role in ensuring a steady flow of fuel to make this process efficient and reliable.
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The pump may be mechanical or electric, and it sends petrol continuously through a circuit of pipes
A fuel pump is a component used in liquid-fuelled engines, such as petrol or diesel engines, to transfer the fuel from the fuel tank to the carburetor or fuel injector. The pump may be mechanical or electric, and it sends petrol continuously through a circuit of pipes.
Carbureted engines often use low-pressure mechanical pumps that are mounted on the engine. Fuel injected engines use either electric fuel pumps mounted inside the fuel tank or high-pressure mechanical pumps mounted on the engine. Some engines do not use any fuel pump at all. A low-pressure fuel supply used by a carbureted engine can be achieved through a gravity feed system, i.e. by simply mounting the tank higher than the carburetor. This method is commonly used in carbureted motorcycles, where the tank is usually directly above the engine. On engines that use a carburetor, a mechanical fuel pump is typically used to transfer fuel from the fuel tank into the carburetor. These fuel pumps operate at a relatively low fuel pressure of 10–15 psi (0.7–1.0 bar).
In fuel-injected petrol engines, an electric fuel pump is typically located inside the fuel tank. For older port injection and throttle-body injection systems, this "in-tank" fuel pump transports the fuel from the fuel tank to the engine, as well as pressurising the fuel to typically 40–60 psi (3–4 bar). While for direct-injection systems, the in-tank fuel pump transports the fuel to the engine, where a separate fuel pump pressurises the fuel to a much higher pressure. Since the electric pump does not require mechanical power from the engine, it can be located anywhere between the engine and the fuel tank.
Pumps for modern direct-injection engines operate at a much higher pressure, up to 30,000 psi (2,100 bar). They have configurations such as common rail radial piston, common rail two-piston radial, inline, port and helix, and metering unit. Injection pumps are fuel-lubricated, which prevents oil from contaminating the fuel. Port and Helix pumps are most commonly used in marine diesel engines because of their simplicity, reliability, and ability to be scaled up in proportion to the engine size.
The lines that come from an internal fuel pump are typically made of metal or rubber. Metal lines, usually made from stainless steel, aluminium, or coated steel tube, hold up better than any soft material. Rubber fuel hoses, on the other hand, are easy to install and are typically connected using standard barbed fittings and fuel line hose clamps. However, rubber hoses have some downsides and should not be used to plumb an entire fuel system as they start degrading as soon as they come into contact with fuel.
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Frequently asked questions
Fuel lines can be made from a variety of materials, including nylon, rubber, braided stainless or braided nylon, and PTFE. Most cars come with metal lines, usually made from stainless, aluminium or coated steel tube, as they hold up better than any soft material.
There are two types of fuel systems: one with both supply and return pipes, and the other with a single-pipe. The former has petrol circulating continuously, from which the carburettor draws off whatever it needs. The single-pipe system is more common, where the fuel is pumped along a pipe from the tank and mixed with air in the carburettor.
Internal fuel pumps are quieter and safer than external pumps. In the event of a leak, the fuel is contained within a sealed tank, reducing the risk of a fire. They are also submerged in fuel, which keeps them cool, unlike mechanical pumps that heat up while running.
