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Automotive Fuel Injection Systems Information
 

Automotive technology is evolving at an astounding rate. It is important for the car owner and the automotive technician to have useful resources and news about the development of the integral systems that make the automobile work. This fwicki was created to provide useful news, videos, and information about fuel injection technologies.



A Cutaway View Of A Fuel Injector

Fuel injection is a means of metering fuel into an internal combustion engine. In modern automotive applications, fuel metering is one of several functions performed by an "engine management system". For gasoline engines, carburetors were the predominant method to meter fuel before the widespread use of fuel injection. However, a wide variety of injection systems have existed since the earliest usage of the internal combustion engine.

The primary functional difference between carburetors and fuel injection is that fuel injection atomizes the fuel by forcibly pumping it through a small nozzle under high pressure, while a carburetor relies on the vacuum created by intake air rushing through it to add the fuel to the airstream.

The fuel injector is only a nozzle and a valve: the power to inject the fuel comes from further back in the fuel supply, from a pump or a pressure container.

The fuel injector acts as the fuel-dispensing nozzle. It injects liquid fuel directly into the engine's air stream. In almost all cases this requires an external pump. The pump and injector are only two of several components in a complete fuel injection system.

Periodically, fuel injectors need to be serviced or replaced. The following tips will help the technician or mechanic understand general procedures involved in replacing fuel injectors:

How To Remove And Re-Install Fuel Injectors:

The following is a general overview of how to remove and replace worn or damaged fuel injectors. This process is not recommended for the novice or intermediate mechanic or automotive technician. If you are unsure about any of the steps and techniques listed below, be sure to consult a professional auto repair technician. Due to the complexity of most fuel injection systems, it is advisable to enlist the help of a certified automotive repair technician. The example given below is a general approach and your particular make and model vehicle may require specific variations of the following procedures.

Pre-Removal Steps And Techniques:

  • Relieve the fuel-line pressure. Remove the fuel pump assembly access cover. Disconnect the electrical connector by pressing down on the tab and pulling forward. Try to start the car, it should not start.
  • Disconnect battery negative terminal.


  • Performance Packages Add Power
  • Remove the rear intercooler pipe completely and stuff clean rags into the top of the turbo and the open IC pipe.
  • Disconnect the Y-pipe from the throttle body. This may require loosening or removing the two intercooler pipes attached to it, depending on your setup, and the air by-pass hose.
  • Remove the bolt holding the oil supply line near the rear turbo for more working space.
  • Remove the accelerator cable bracket and set aside. Note the tension of the cable and/or the location of the bolts in the bracket for the installation later.
  • Remove the two bolts that hold the 3-plug bracket on the passenger side of the plenum.
  • Remove the two bolts holding the fuel injector harness to the plenum.
  • Remove the passenger-side bolt from the EGR pipe (it comes up from the rear cat near the oxygen sensor). Loosen (but do not remove) the driver-side EGR pipe bolt, and slide the metal gasket downward. Securely attach a wire to the gasket, then remove the remaining EGR pipe bolt. Set the gasket aside, it can be reused.
  • Carefully remove the two bolts attaching the rear of the plenum to the brackets.
  • Remove the three bolts from the plenum front, the two long bolts from the plenum top, and the two nuts from the plenum front sides. The plenum may pop a little with the release of pressure.
  • Carefully lift the plenum straight up to clear the front studs then tilt toward the passenger side. Prop it up. The fuel pressure regulator hose will probably slide off the throttle body, but the rest of the hoses (including the clutch vacuum assist hose on the right side of plenum) should allow enough length to move the plenum around without a problem.
  • Fuel Injection System Performance Parts

    EFI Performance Kit
  • Cover the intake manifold with a clean rag. Be sure to protect the intake manifold opening, do not allow any object to drop into the intake. Now is a good time to replace the gasket if it needs it.
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Removal Steps And Techniques:

  • Remove the PCV hose from the driver's side of the valve covers.
  • Disconnect the rear EGO sensor electrical connection near the middle of the front rail.
  • Drain a little coolant, just a few ounces, into a clean container. Remove the overflow tube from the radiator fluid filler neck.
  • Remove the hoses from the fuel pressure regulator. Remove the vacuum hose and re-attach it to the tube on the throttle body. Slide off the fuel return line hose and set aside.
  • Remove the bolt that clamps down the high-pressure supply line a few inches from the from rail.
  • Disconnect the 3 electrical connectors from the 3-plug bracket that you removed earlier from the passenger-side of the plenum.


  • Video Tip: Freeing A Stuck Fuel Injector
  • Remove the 4 bolts that secure the two fuel rails to the manifold. Be careful to not let any of the 4 insulators fall off. They are grooved to fit into the rail on top and the manifold on the bottom. Just lift the each rail up a little and slide out each insulator. The injectors should come up with the rails and the fuel injector insulators will either be attached to the injector base or remain in the manifold.
  • Gently slide each injector from the rail with a slight twisting motion. Some fuel may drain out.
  • Retrieve any injector insulators that remain in the manifold if you are going to replace them. Forceps work well for this.
  • Disconnect the injectors from the wiring harness. Pry off each retaining clip. It may help to place your left thumb lightly over the clip while you pry it out with the thin-blade of a pocket knife.
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Installation:
Before installing the new injectors, test each injector for electrical resistance across the terminals. The standard is 2 to 3 Ohms.

  • Connect the new injectors into the wiring harness.
  • Place the injector insulators into the manifold recessed areas. You could also slide the insulators onto the injectors, however, you may find it easier to ensure good alignment by putting them into the manifold first.
  • Slide the injectors into the rail with a slight twisting motion. First, apply a very small amount of clean motor oil on the o-ring and top of the grommet. A Q-tip will work fine for this purpose. Be sure that no oil gets into the injector.
  • Roughly align the injectors with the holes in the manifold. Don't press down yet.
  • Add the four rail bolts and insulators. Don't drop the insulators into the manifold.
  • Now simultaneously align and insert all six injectors. Take your time and re-check continuously. Keep pressing down until the rails fit tightly to their insulators and the injectors are seated on their insulators.
  • Tighten the four rail bolts using a torque wrench applying 10-13 N-m (7-9 ft-lbs). Be careful not to strip the threads.
  • Re-connect the coolant overflow tube.
  • Re-attach the high-pressure fuel supply line bracket.
  • Re-attach the fuel return line hose to the fuel pressure regulator.
  • Connect the PCV hose and the 3 connectors on the bracket that sits on the passenger's side of the plenum and re-connect the rear EGO sensor.

Post-Installation:

  • Clean the plenum-to-manifold gasket if required or replace it.
  • Lower the plenum onto the manifold studs. Do NOT attach bolts or nuts at this time. The plenum will have to be loose for the next step.
  • Bolt the plenum to the rear two stays first. You may need to apply your weight or tap the plenum with your fist to get the holes to line up. Be sure to re-attach the grounding cable and oil pipe bracket with the driver-side stay. Insert the two bolts by hand and tighten but do not torque down.


  • Video Tip: Fuel Injection Diagnostics



  • With the wire still attached to the EGR pipe gasket, insert the driver-side bolt through the EGR pipe and gasket and into the plenum. Tighten a little by hand. Remove the wire, slide the gasket around, and insert the other bolt. The two EGR bolts can now be tightened (18 N-m).
  • Install the forward plenum bolts and the two nuts. Torque the two rear stay bolts, the front five bolts and two nuts to 18 N-m.
  • Now proceed with pre-removal steps 8 to 3 above (in reverse order). Be sure to check the fuel pressure regulator hose and the other vacuum hoses.
  • Re-connect the fuel pump electrical connector.
  • Re-connect the battery negative terminal. The disconnected battery reset the ECU.
  • Start the car and let it idle for a few minutes and check for leaks or other problems.
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Description: News and information about fuel injection systems. This fwicki also contains video and media content for installing and maintaining fuel injection systems on cars, trucks, and motorcycles.
Tags: fuel injection / Edelbrock / Holley / Enderle fuel injection / Bosch fuel injection / Hilborn fuel injection / fuel injection part / electronic fuel injection / fuel injection system / K N fuel Injection performance parts / FIPK Air Intake
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Fuel Injection System Benefits:

The benefits of owning a fuel injected vehicle are many. Operational benefits to the driver of a fuel-injected car include smoother and more dependable engine response during quick throttle transitions, easier and more dependable engine starting, better operation at extremely high or low ambient temperatures, reduced maintenance intervals, and increased fuel efficiency.

An engine's air/fuel ratio must be accurately controlled under all operating conditions to achieve the desired engine performance, emissions, drive ability, and fuel economy. Modern electronic fuel injection systems meter fuel very accurately

Fuel System Parts and Service

Fuel System Maintenance Requires Quality Parts
and precisely, and closed loop fuel control based on feedback from an oxygen sensor (or "O2 sensor") lets fuel-injected engines run considerably cleaner than comparable carbureted engines. Properly-designed fuel injection systems can react faster and more precisely to rapidly changing inputs such as rapid throttle movements, and can tailor fuel distribution to closely match the engine's needs across a wider range of operating conditions such as load, ambient temperature, operating temperature, fuel quality, and altitude (i.e., barometric pressure).

The process of determining the amount of fuel, and its delivery into the engine, are known as fuel metering. Early injection systems used mechanical methods to meter fuel (non electronic, or mechanical fuel injection). Modern systems are nearly all electronic, and use an electronic solenoid (the injector) to inject the fuel. An electronic engine control unit calculates the mass of fuel to inject.

Modern fuel injection schemes follow much the same setup. There is a mass airflow sensor or manifold absolute pressure sensor at the intake, typically mounted either in the air tube feeding from the air filter box to the throttle body, or mounted directly to the throttle body itself. The mass airflow sensor does exactly what it's namesake implies; it senses the mass of the air that flows past it, giving the computer an accurate idea of how much air is entering the engine. The next component in line is the Throttle Body. The throttle body has a throttle position sensor mounted onto it, typically on the butterfly valve of the


Video Tip: Identifying Fuel Injector Pump Noise
throttle body. The throttle position sensor (TPS) reports to the computer the position of the throttle butterfly valve, which the ECM uses to calculate the load upon the engine. The fuel system consists of a fuel pump (typically mounted in-tank), a fuel pressure regulator, fuel lines (composed of either high strength plastic, metal, or reinforced rubber), a fuel rail that the injectors connect to, and the fuel injector(s). There is a coolant temperature sensor that reports the engine temperature to the ECM, which the engine uses to calculate the proper fuel ratio required. In sequential fuel injection systems there is a camshaft position sensor, which the ECM uses to determine which fuel injector to fire. The last component is the oxygen sensor. After the vehicle has warmed up, it uses the signal from the oxygen sensor to perform fine tuning of the fuel trim.

In contrast to an EFI system, a carburetor directs the induction air through a venturi, which generates a minute difference in air pressure. The minute air pressure differences both emulsify (premix fuel with air) the fuel, and then acts as the force to push the mixture from the carburetor nozzle into the induction air stream. As more air enters the engine, a greater pressure difference is generated, and more fuel is metered into the engine. A carburetor is a self-contained fuel metering system, and is cost competitive when compared to a complete EFI system.

An EFI system requires several peripheral components in addition to the injector(s), in order to duplicate all the functions of a carburetor. A point worth noting during times of fuel metering repair is that early EFI systems are prone to diagnostic ambiguity. A single carburetor replacement can accomplish what might require numerous repair attempts to identify which one of the several EFI system components is malfunctioning. Newer EFI systems since the advent of OBD II diagnostic

Fuel Injected V8

Fuel Injection Is Synonymous With Performance
systems, can be very easy to diagnose due to the increased ability to monitor the real time data streams from the individual sensors. This gives the diagnosing technician real time feedback as to the cause of the drive ability concern, and can dramatically shorten the number of diagnostic steps required to ascertain the cause of failure, something which isn't as simple to do with a carburetor. On the other hand, EFI systems require little regular maintenance; a carburetor typically requires seasonal and/or altitude adjustments.

Multi-Point Fuel Injection:

Multi-point fuel injection injects fuel into the intake port just upstream of the cylinder's intake valve, rather than at a central point within an intake manifold, referred to as SPFI, or single point fuel injection. MPFI systems can be sequential, in which injection is timed to coincide with each cylinder's intake stroke, batched, in which fuel is injected to the cylinders in groups, without precise synchronization to any particular cylinder's intake stroke, or simultaneous, in which fuel is injected at the same time to all the cylinders. All modern EFI systems utilize sequential MPFI. Some Toyotas and other Japanese cars from the 1970s to the early 1990s used an application of the Bosch multipoint L-Jetronic system manufactured under license by DENSO.

 

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