DTS-Fi TRG NOTE FS

Chapter 5 Fuel System & EMS Fuel System & EMS 5 Chapter
Sensors & Actuators Located on Vehicle

A DTS-Fi Engine Management System
Throttle Body
Introduction TPS Sensor Injector Fuel Pump
The purpose of the fuel system is to supply the engine with a combustible Engine Control Malfunction
mixture of air & fuel. This mixture is the air fuel mixture. It is burned in Unit (ECU) Indicator Lamp
the engine to produce power.
The Fuel System is made up of two smaller systems or sub systems. These
12 11 10
are the Fuel Supply System & the Fuel Metering System.
Diagnostic Tool 13 9 Oil Pressure
The Fuel Supply System delivers fuel from the tank to the Fuel Metering Connecting Port Sensor
System. The metering system either uses a carburettor or a fuel injection
system. It measures out or ‘Meters’ the amount of fuel needed by the
engine. This is the fuel that mixes with the air entering the engine to
form the air fuel mixture. The air enters the engine through the air filter
or air intake system.
14 8
This chapter describes the Fuel Injection System which is controlled by

Electronic Control Unit (ECU).
1 7
Air Filter 2 6 Crank Angle

IR Sensor Sensor
3 4 5
Roll Over Engine Oil

Sensor Temp. Sensor
Intake Air Manifold Engine Temp.
Temp. Sensor Pressure Sensor Sensor
Continued
Pulsar DTS-Fi Training Notes 62 Dealer Development Center Dealer Development Center 63 Pulsar DTS-Fi Training Notes
1 Air Filter IR Sensor B EMS Layout

It is located on the non cleaner side of air filter assembly.
2 Roll Over Sensor

It is located below air filter box & fitted on chassis.
ROLL OVER
DIGNOSTIC
SENSOR
SWITCH
3 Intake Air Temperature Sensor
It is located in between air filter & throttle body. It is fixed on
connecting tube.
4 Manifold Pressure Sensor INPUT
SENSOR
It is located in ECU and is connected to intake manifold through
MAP
IGNITION
rubber pipe.
ELECTRONIC
CONTROL
Engine Temperature Sensor
UNIT
BATTERY
5 OUTPUT
It is fitted on cylinder head which is located on LH side of engine.
ENGINE TEMPERATURE SENSOR

6 Engine Oil Temperature Sensor
It is fitted on magneto side crankcase and located on LH bottom
CRANK ANGLE SENSOR

MANIFOLD PRESSURE
engine side.
INTAKE AIR TEMPERATURE SENSOR

THROTTLE POSITION SENSOR
7 Crank Angle Sensor
MALFUNCTION INDICATOR
It is fitted inside the magneto cover & is located on LH side of the
engine.
FUEL PUMP MODULE
SPARK PLUGS
8 Oil Pressure Sensor
INJECTOR
AIR
It is fitted on oil cooler body & located on LH side of the oil cooler.
9 Malfunction Indicator Lamp

It is located on speedometer & is displayed with ( ) icon.
10 Fuel Pump
It is fitted inside the petrol tank.
11 Injector
It is fitted on the intake manifold.
FUEL
FUEL LEVEL
12 Throttle Body TPS Sensor
It is fitted on throttle body & is located from LH side of the engine.
13 Engine Control Unit (ECU)

It is fitted behind air filter box on chassis.
14 Diagnostic Tool Connecting Port

It is located below pillion seat.
C Working of System Fuel Pump Fuel Injector
Function Function
To draw the fuel from the fuel tank and push it along the fuel lines to To inject the fuel into the intake manifold until the electric signal from solenoids is cut off by ECU.
the injector rail and keeping a constant pressure in the system. Also
the fuel pump needs to ensure a high level of fuel flowing through the
fuel line thus maintaining constant fuel delivery pressure. Construction
Fuel Supply
Rail ‘O’ Ring Seal

Electric Connection
Construction
Integral Filter
Fuel Pump Module
Assembly
Fuel Pump Mounting

Bracket Fuel Pressure Regulator
Coil
Fuel Pump Return Spring
Fuel Strainer
Rubber Gasket for Armature

Sealing on to Petrol Tank
Pressurized Fuel out to Regulator Connected Washer

Fuel Filter in a ‘T’ Joint Valve Needle
Fuel Filter to Injector Fuel to Injector Manifold ‘O’ Ring
Pintle Protection Cap
Pintle
Working
The fuel is pumped from the fuel tank by a roller cell pump through a fuel filter into a fuel rail at the Working The injector internal movement is restricted just
end of which is a fuel pressure regulator. to < 0.1 mm. Also period that an injector
The fuel injector supplies the fuel in the form of
remains open is very low (between 1.5 & 10
In order to keep the injector pressure differential constant despite variations of inlet manifold a spray from the injector pintle which is located
milliseconds). Thus the opening & closing time
depression with load, the fuel pressure regulator senses the difference between pumping pressure & on intake manifold.
is critical for accurate fuel metering.
that of the inlet manifold. Excess fuel is returned to the fuel tank, the continuous flushing keeps the The injector have the nozzles which are opened
fuel cool & avoids formation of pockets of fuel vapor. & closed by solenoid wound (coil) in the The fuel spray mixes with the incoming air as
injector body. both move towards the inlet valve giving a
The fuel pump is lubricated & cooled by the fuel flowing through the motor, including the brushes precisely metered combustion mixture.
and across the armature hence it is important that never run the pump without adequate fuel inside When the windings are energized the armature
the fuel tank. is attracted due to magnetism and compresses
the spring which lifts the needle valve. Thus
The fuel filter strains impurities out of the fuel. This is an important measure in preventing the fuel pintle automises the fuel into a fine spray form
pump, fuel injector nozzles from clogging. with a pressure about 2.5 bars (36 lbf / in2)
until the electric signal in the solenoid is cut off
Fuel Pump Resistance = 2.7 + 0.1 Ohms by the ECU.
Engine Control Unit - ECU Engine Control Unit - ECU
Introduction Working
The automotive engine has two power generation systems named as ‘Carburetion System’ & The ignition & fuel injection is controlled by a single control unit named as ‘ECU’.
‘Ignition System’ respectively.
In ECU the inputs from various sensors are fed into a signal processor circuits to ensure that all
The Carburettor supplies atomized / vaporized air fuel mixture to the engine maintaining the desired outputs to the computer are in the form of digital pulses.
air fuel ratio as per engine requirement.
These inputs received may be steady or slowly varying voltages. These are said to be in analogue
The Ignition system supplies electric igniting spark at the spark plug tip as per precise engine form & which are converted into equivalent digital valves by an analogue to digital (AD) converter.
demand (timing) to burn the compressed air fuel mixture inside the combustion chamber.
The digital output are fed to the input / output rail for transporting to the main heart of the
However these 2 systems like Carburetion and Ignition has been dealt separately. computer. Thus the ECU collects all signals, calculates them & process them to actuators to delivery
precise ignition advance timing & fuel injection requirement for the engine at various load & speed
In digital ignition circuits a microprocessor is used in the CDI unit. This microprocessor is capable of conditions.
controlling various tasks. Hence it was logical to use this spare capacity for controlling fueling also.
Thus then developed a digital electronic control system for fuel injection & combined it with the Set of Various Sensors
digital ignition control to form a single unit controller. This unit is named as “Electronic Control A sensor is a device which detects or measures a quantity, usually in electrical form so that it may
Unit”. be used in measurement or control.
The analogue signal processing is added to the sensor, this improves the resistance to
Function interference.
To collects information from various sensors and ensure that a correct quantity fuel is injected into
the intake manifold at precise time considering various engine load and speed conditions. Set of Various Actuators
Actuators is a general term used to describe a control mechanism i.e. a device that converts
It is brain of the engine and controls various devices. Also it controls / supports on vehicle
electrical signals into mechanical movement e.g. -
diagnostic instrument for diagnosing the problem in fuel injection system.
• Fuel injector
• Fuel pump
Construction
• Solenoid starter relay
It consists of a micro computer A - D Convertor (Analog to Digital) and I - O Unit (Input - Output).
Input signals are received from Signals given to operate

various set of Sensors following Actuators
Sensors Actuators
Analogue to Digital - (A~D)
• Throttle position
Signal Processing (SP)
• Intake air temperature

• Fuel pump
• Manifold pressure sensor
Engine • Fuel injector
• Engine oil temperature
Control Unit
• Engine temperature
ECU • It also supports
• Oil pressure to Diagnostic
• Vehicle inclination angle trouble codes
assessment.
• Engine RPM
• Crankshaft position
Throttle Position Sensor Intake Air Temperature Sensor
Function Function
To measure the exact position of the To measure the temperature of air entering inside the intake manifold and communicate this
throttle valve opening and to send this information to ECU.
measurement signal in voltage form to
ECU.
Coupler
Construction
Construction
End It is a thick nickel film coated thermistor
The throttle body has a throttle valve mounted on mounted on top of the connecting tube,
the intake manifold. The throttle valve is connected near the throttle body end.
by accelerator cable & its opening and closing is
controlled by accelerator twist grip mounted on RH
side of handle bar. The throttle position sensor
mounted on the throttle valve continuously reports Insert into
the throttle position to the ECU. Connecting
Tube upto
This is a rotary throttle position sensor having a this Flange
variable resistor also called as a potentiometer. Face
Internally it has a coil resistance wire in the form of
a half circle. One end connects to the ground and
other end is connected to a 5 volt source from ECU.
The wiper blade has a contact that rides on the coil
& connects to the throttle valve shaft.
Also the position of the throttle valve is important in Integral
controlling the idling rpm. Protection / Sensor
Shield for Tip
Sensor
Working
RESISTANCE COIL
Upon acceleration the throttle valve CLOSED THROTTLE
position changes. The wiper type blades

moves over the coil winding as it is
pivoted directly on the throttle valve shaft. Working Throttle Orientation Air Filter
When the air passes into the connecting tube its Body End Lug End
Throttle position at zero (closed) OUTPUT
temperature is sensed by the IAT sensor. Its
VOLTAGE
position
WIPER PIVOT TO ECU resistance varies quickly with the change in air
When the throttle valve is closed, the BLADE
temperature.
blade is at the grounded end of the coil.
A small voltage signal is send to ECU at
The response of thick film sensor is almost linear.
this position which senses that the throttle
position is at zero. WIDE OPEN THROTTLE
It has a sensitivity of about 2 ohm / OC and it has
5 VOLTS
FROM ECU a Positive Temperature Coefficient (PTC)
Further movement of throttle position characteristic.
As the throttle valve moves towards the
open position, the wiper type blade IAT Sensor
swings towards 5 volt end of the coil. Fits Here
This sends an increasing voltage signal to
the ECU. Thus the continuously charging
voltage regularly communicates the ECU
the exact position of the throttle valve.
Manifold Pressure Sensor Engine Temperature Sensor
Function Function
To measure the intake air pressure in the To measure the engine / engine oil temperature up to 2000C.
manifold which results from engine load and
speed variation. This measured signal send to
ECU, & thus ECU injects the precise amount of Construction
fuel through injector. The principal methods of temperature measurement is done
by thermistor.
Thermistor is constructed of semi conductor material such

as cobalt or nickel oxides and is encapsulated in a brass
sleeve for mechanical protection.
Construction
The manifold pressure sensor is located Working
inside the ECU. To sense the intake manifold The thermistors are semi conductor resistors which change their resistance valve with temperature.
pressure it is connected to the intake The resistance decreases with an increase in engine temperature as it has a negative temperature
manifold with a rubber pipe. The intake coefficient (NTC) & vice versa.
opening on ECU often corporate a vapour
The characteristic of engine temperature is represented graphically. (The values does not match
trap to prevent petrol fumes reaching the
exactly, it is just a representation for understanding).
sensor.
This NTC type thermistor is used to measure the engine temperature in engine management system.
200
Working 180
Thermister Resistance (Ohm)

Inlet manifold vacuum gives the measure of 160
engine load. Engine load is proportional to
140
manifold pressure. In high load condition it
produces high pressure and lower load conditions 120
produces lower pressure. The manifold pressure
100
sensor is located inside the ECU and is
connected to the manifold through a rubber pipe. 80
60
The map sensor senses the pressure (vacuum)
and the changes in the intake manifold. This 40
collective information is then given to ECU. Thus
20
ECU determines the precise fuel injection from NTC
injector. 0
O
Temp. C Thermistor
0 10 20 30 40 50 60 70 80 90 100
If map sensor is not working or there is leakage
due to pipe breakage or circlip missing etc., NTC Thermistor Characteristic
malfunction indicator glows.
Roll Over Sensor Crank Angle Sensor
Function Function
To send the ignition cut off signal to ECU for To communicate the ECU how fast the crankshaft is
shutting down the engine if the bike exceeds rotating per minute & help ECU in delivering precise
the inclination angle beyond 600 on either of fuel metering & ignition spark advance.
the side.
Main Switch
Construction Construction
Sensor The roll over sensor is a sealed sensor unit and A magnetic sensor located in magneto
that contains moving weight which is suspended cover facing towards square notched /
freely on a shaft. This is mounted below the air square block on the rotor periphery.
filter box onto the chassis.
Please note, even if roll over sensor is not

connected (coupler open) the vehicle does not
start (to ensure safety) & the malfunction will be
shown on speedometer.
Working
As the rotor rotates the notched square blocks on the
Magnet
rotor periphery causes voltage pulses in the sensor.
These pulses are send to the ECU. The ECU counts
the number of pulses per second & understands at
what rpm the engine is operating and accordingly
Working precise fuel metering & ignition spark advance is
The moving weights are suspended freely. controlled.
When the vehicle leans down on either of the
LH / RH side the position of these weights There are 23 square notches / square blocks on the
60 O
60
changes. The change of position of the rotor outer periphery and are placed equidistance.
O
weights is sensed by the sensor. If the

x 0 At a particular location there is wide gap seen between
inclination angle exceeds beyond 600 to the
2 square notches / square blocks. This can also be
vertical the sensor will give signal to ECU to
determined as square notch missing.
cut off the ignition system.
This missing square notch area represents the BTDC
This is a useful safety feature because
position. At this BTDC position voltage pulse is sensed
inclination angle exceeding 600 indicates that
by the crank angle sensor and is communicated to
the rider has dropped the bike or is involved y
ECU.
in an accident. Thus safety of the bike and
rider is ensured. ECU uses this information to control ignition spark
advance.
Malfunction Indicator Light D Fuel Injection Advantages over Carburetion
When certain troubles develop in the Advantages of Fuel Injection

electronic control system, the ECU
• Increased power output per unit of
stores in its memory or number or
displacement.
trouble code for each fault. This
• Higher torque at low engine rpm.
turns a Malfunction Red Indicator Malfunction
Light ( ) on the speedometer Indicator Symbol • Improved cold start, warm up and
(next to Hi-beam light). sudden acceleration (No chance of
wetting intake manifold).
This alerts the driver that there is • Lower fuel consumption.
some problem & repair / service in • Overall superb drive-ability.
needed. • Lower maintenance cost.
• Communicates malfunctioning of fuel
If a single sensor or its harness part injection system, if any.
fails the ECU may substitute a value
• Low emission level.
for failed sensor. This allows the Diagnostic Tool Diagnostic Tool Application
engine to appear to run normal. A
Diagnostic Chart or Flash Code
fault that turns on the malfunction
indicator light may also put the Flash
Code
Malfunction
Code
Description Limitations of Carburettor
engine into its limp-in mode. This • Restricted air flow due to venturi design causes
69 P0112 Inlet air temp output short to ground
means that limited operation power loss (volumetric efficiency is limited).
71 P0113 Inlet air temp output short to 5 V supply or open
strategy (LOS) chip in the ECU has
15 P0117 Engine temp sensor output short to ground • As intake manifold contains combustible
taken over. It provides basic
instructions to the microprocessor if
14 P0118 Engine temp sensor output short to 5 V or open mixture, danger of back fire from the cylinder
a part of the electronic system fails.
49 P0563 Battery voltage greater than 16 V into the manifold is always there.
22 P0122 Throttle position sensor output open or shorted to ground
The engine runs but with fixed • At high altitude or in warm weather, possibility
21 P0123 Throttle position sensor short to 5 V
ignition timing and air fuel ratio. The of vapor lock.
29 P0231 Fuel pump output open or shorted to ground
injector pulse width does not • After burning noise in silencer on sudden
change. This allows the vehicle to 32 P0232 Fuel pump output short to 12 V
deceleration.
be driven but with greatly reduced 31 P0232 Fuel pump output short to 12 V
16 P0261 Fuel injector output open or shorted to ground • Does not support sudden acceleration.
performance. The benefit of this is
the vehicle can be limp-in for 17 P0262 Fuel injector short to 12 V • Difficult cold starting & requires choke for
service instead of being towed or 64 P1351 Ignition coil 1 primary output short to ground starting.
transported into a cargo. 42 P0351 Ignition coil 1 primary output short to 12 V • In cold conditions, fuel wets the wall of the
78 P1352 Ignition coil 2 primary output short to ground induction manifold causing running difficulties.
The technician can retrieve the 87 P0352 Ignition coil 2 primary output short to 12 V
• Difficult cold starting & requires choke for
stored trouble code from ECU 98 P1650 Malfunction indicator lamp open or short to ground
starting.
memory using the diagnostic tool. 99 P0650 Malfunction indicator lamp short to 12 V
To use the code the technician can 12 P1654 Tachometer output open or short to ground
• Inconsistence in fuel efficiency.
refer the Diagnostic Chart or the 11 P0654 Tachometer output short to 12 V • Maintenance cost is reasonably more.
Flash Code. This chart explains 19 P0335 Crank sensor mis-synchronous • High emission level.
where lies the problem and its 79 P1335 Crank sensor open
probable cause. 34 P0107 Map sensor output open or ground
33 P0108 Map sensor output short to 12 V
33 P0108 Map sensor short to 5 V
23 P1500 Roll over sensor on
E Part Inspection Parameters Intake Air Temperature :

• IAT sensor cracked / broken
Injector : • IAT sensor tip coating given away / dent mark.
• Sealing of fuel pipe when connected • IAT Internal protection / shield for sensor broken / cracked.
• IAT sensor flange broken / cracked
• Locked clip for upper body cap / Intake nozzel
• IAT sensor coupler / socket matching lug broken
• 'O' rings cut / missing / bulged / damaged
• IAT sensor coupler /socket matching male pins broken / bend
• Injector body cracked / damaged
• Nozzel holes blocked / chocked / gummy deposits
Throttle Body :
• Injector female coupler self locking damaged / loose fitment • Throttle body cracked / distorted damaged
• Electrical male couplers bend / Twisted / Broken / Dislocated • Air passage clear / blocked / clogged
• Free movement of butterfly
Intake ManifoId : • Idle adjuster screw loose / tight fitted
• Sealed plug with aluminum washer for MAP sensor. • Proper fitment of throttle position sensor
• MAP sensor vacuum sensing hole clear / clogged. • Throttle cable outer stopper bend / distorted
• Proper fitment of rubber pipe with perfect fitment of circlip. • Throttle cable pulley free movement
• Mating surface with head - No scratch / Dent Mark. • Throttle cable pulley free from casting flashes
• Injector fitting bore - No scratch / Dent. • Throttle cable pulley return spring having adequate tension / broken / slipped out
• Injector fitment stay support threads Ok / Damaged • Throttle position sensor body crack / damaged
• Manifold body cracked / damaged. • Throttle position sensor coupler / socket fitment locking lug broken
• Throttle position sensor coupler male pins broken / bend
• Groove on manifold body for proper fitment and sealing of connecting tube.
• Throttle position sensor tamper proff screw Ok / damaged
• Carbon soot formation on intake manifold side and air filter side
Connecting Tube :
(Not to clean soot deposited at the interface of butterfly blade and bore of throttle body)
• No Crack / Puncture
• No deformation at IAT sensor fitment location. Fuel Pump Assembly :
• Groove for clamp fitment • Proper fitment of gasket / no leakage between pump assly and petrol tank.
• Groove for tube internal fitment in air filter box assembly. • Pump regulator connections intact / loose / crimping given away.
• Locating lug / cut mark intact. • White perforated connecting tube from pump to rail properly sealed / criclip intacted
• Petrol strainer clogged / blocked / torned / damaged
Air Filter Assembly : • Pressure regulator pipe connecting to rail - sealed / no leakage
• Body cracked / distored • Rails bend / damaged / clogged
• Air filter assly mounting hangers on chassis hole oblonged / cracked. • Supply wire from pump to regulator coating given away / cracked / open
• Bedded nuts in the body tight sealed / Not rotating. • Pump holding bracket screw intact / bracket bend / twisted.
• Drain tube upper semi circle type cap intact / Broken / Cracked • Sedimentation on base plate of pump assly.
• Drain tube passage clear / clogged
Fuel Filter and Fuel Pipes :
• Dummy hole above drain tube plugged.
• Fuel filter body cracked / leakage from Body
• Air intake duct sealed / loose fitted / Not sealed.
• Fuel filter colour becoming blackish
• IR Sensor fitment Ok / Not Ok (Arrow pointing toward intake duct)
• Fuel filter chocked / blocked
• IR sensor gasket leakage / Ok
• Fuel pipes fitting mouth flaring / Cut marks / Bulged
• IR sensor wires intact / cracked
• Fuel pipes Ok / Punctured
• Bracket fitted with phillips screw for side pannel locking Ok / Not Ok • Fuel pipe mounting clips having adequate tension / loose fitting.
Fuel Tank Cap : Notes :

• Paint pealed OFf / Chipped OFF
• Locking mechanism operating smooth / operating sticky / Not operating
• Internal parts in Petrol Tank cap as below Ok / Not Ok
- Springs
- Paper Gasket
- Air path special gallery washers
- Collar
• Inner side rubber seal intact / cracked / damaged
• Petrol tank cap operating in Pivot pin smoothly.
Petrol Tank :
• Paint finish - Ok / Dull / Paint over flow / Paint chipping Off
• External damages - Scratches / dent / damaged
• Leakages from - Seam welding joint / Fuel tank unit mounting - Fuel Pump
Mounting, Tank unit mounting - Petrol cap mouth
• Welding of sub brackets given away
• Petrol tank rusty internally
G Dos & Don'ts Oil Cooler Engine Temperature Sensor (ETS)
Do’s Don’ts Do’s Don’ts

Always prime a new oil Do not continue to run the Assemble the ETS only after Do not pre-assemble the
cooler by starting the engine engine without removing the engine has been ETS on to the cylinder head
and loosening the oil pipe trapped air in the oil mounted on the chassis. as it is vulnerable to
banjo on the Crankcase LH passages. damage.
to remove trapped air.
Always use new copper Do not fit used copper Use only a open end wrench Do not use a socket for
coated washers when the oil coated washers for the oil to tighten the sensor. tighten / torque the sensor.
cooler banjos at the clutch cooler banjos as these may Prevent any contact with the Prevent any contact with the
cover are removed. result into poor sealing sensor socket area. sensor socket area.
causing oil leakage.
Ensure that ‘O’ rings are Do not re-use removed or De-greasing the sensor tip Do not toss the sensor
fitted at each end of the oil damaged ‘O’ ring’s for the using pure petrol before around or handle it roughly
cooler connecting banjos banjos at the oil cooler as fitment. as it can get damaged
prior to fitment. these may result into poor permanently.
sealing causing oil leakage.
Inspect the oil cooler pipes Do not let the oil cooler Remove the ETS first if the Do not connect or dis-
especially at the crimped hang by itself, supported engine has to be removed connect the ETS with the
region for signs of leakage, only by the oil pipes, when from chassis for any reason. ignition switch in ‘ON’ or
cracks if any. assembling or disassembling power ‘ON’ condition.
from the chassis.
Handle the oil cooler assly. Do not over tighten the During fitment of the ETS Do not store the ETS with
very carefully to prevent wiring securing nuts & bolts wiring harness coupler, other parts in bin for any
damage to the delicate coupled to the oil cooler / oil ensure that it clicks and reasons what so-ever.
cooling fins and which are pressure sensor as it will locks positively in place.
not repairable. damage sensor & wire.
ETS to be stored in a dust

free environment when
dismantled. It should be
placed in clean polythene
bag & should be handled
minimum to avoid damages.
Engine Oil Temperature Sensor (EOT) Injector
Do’s Don’ts Do’s

Fit the EOT sensor only after Do not remove the engine While installing the injector in During fitment of the injectors
the engine is fitted onto the with the EOT sensor fitted as the intake manifold, apply a wiring harness coupler, ensure
chassis to prevent damage it can get damaged. light coat of MoS2 grease on that it clicks & locks positively
to it. the injector nozzle side ‘O’ in place.
ring.
Ensure correct tightening Do not overtighten the single While assembling a new ‘O’ Use only recommended
torque for the Philips screw wiring harness wire, which ring, apply a light coat of solvents like pure and clean
of the single wiring harness needs to be coupled to the MoS2 grease and roll it into petrol for cleaning of injector.
wire. EOT sensor as it will place.
damage it.
Ensure that the single wiring Do not loosen the crankcase Injector to be stored in a Use only the original
harness wire is aligned oil drain bolt with a open dust free environment when recommended ‘O’ rings for
properly / prevented from end spanner or ring spanner dismantled. It should be the injector sealing. Replace
rotating, when tightening the when the engine is still on placed in clean polythene ‘O’ rings if found damaged.
Philips head screw of the the chassis. Use a deep bag & should be handled
EOT sensor. Ensure proper socket spanner. minimum to avoid damages.
cap fitment.
Use a new copper coated Do not re-use the old copper

washer when re-fitting the
EOT sensor.
coated washer of the EOT
sensor as this may result Don’ts
into poor sealing causing oil
leakage. Do not use a plier to pull the Do not use a screw driver or
injector out. Assembly and any other sharp object for
Disassembly should be done ‘O’ ring removal.
by hand gently.
EOT to be stored in a dust Do not connect or dis-
free environment when connect the EOT sensor with
dismantled. It should be the ignition switch in ‘ON’ or
placed in clean polythene power ‘ON’ position.
bag & should be handled Do not bend the injector Do not use a injector if it
minimum to avoid damages. from side to side while has been dropped or has
pulling it out, as this may fallen down.
damage it.
Continued
Injector Intake Air Temperature Sensor (IAT)
Don’ts Do’s Don’ts

Do not clean the injector in • Do not interchange the ‘O’ Use a light coat of 3 bond Do not immerse the sensor
any solvent, like kerosene, rings of the injector. 1521 B/C based adhesive or in any kind of solvent and
diesel, CTC, Acetone. equivalent, to the sensor attempt to clean it.
• Do not use ‘Similar’ or fitment area to prevent it
non-standard ‘O’ rings. from loosening / coming off.
Do not use a brush with Do not store the injectors During fitment of the sensor Do not attempt to clean the
bristles, which can jam or with other parts in bin for wiring harness coupler, sensor using compressed air.
block the injector nozzle any reason what-so-ever. ensure that it clicks and
holes. locks positively in place.
Do not attempt to clean / Do not attempt to open the IAT to be stored in a dust Do not allow the adhesive to
clear the nozzle holes of the injector or dismantle it any free environment when trickle on to the sensor tip.
injector using fine wires etc. way. dismantled. It should be
Do not attempt to clean the Do not connect or dis- Do not use a dropped IAT
injector nozzle hole by connect the injector with the sensor.
blowing compressed air at / ignition switch in ‘ON’ or
through it. power ‘ON’ condition.
Do not connect or disco-

nnect the IAT sensor with
the ignition switch in ‘ON’ or
power ‘ON’ condition.
Air Filter IR Sensor Fuel Filter & Fuel Pipes
Do’s Don’ts Do’s Don’ts

During fitment of IR sensor Do not use a dropped IR Inspect the IN and OUT Do not reuse the old fuel
ensure that the arrow mark sensor. connections to the fuel filter filter.
UP
is facing ‘UP’ towards intake at the periodic service

duct. interval.
Ensure proper fitment of Do not connect or disco-

gasket for perfect sealing of nnect the Air Filter IR sensor Replace the fuel filter after Do not attempt to clean the
IR sensor on air filter assly. with the ignition switch in every 5000 kms. or Earlier if fuel filter by blowing in the
‘ON’ or power ‘ON’ the fuel quality is suspected. compressed air as it will
condition. damage it.
Blow compressed air gently Do not immerse the sensor

to clean IR sensor. in any kind of solvent and
attempt to clean it. Replace the entire rubber Do not let a vehicle run with
fuel pipes once in every a leaking fuel filter.
30,000 kms.
Manifold Pressure Sensor
Do’s Don’ts Replace the fuel filter if there

is any darkening of the inner
Do not cut and reuse the
rubber fuel pipes.
element is seen.
Replace the hosepipe if any Do not route the rubber
external cracks are seen or if hose pipe in such a manner
any physical damage has that it gets pinched or
occurred or Replace at every kinked.
10,000 kms periodically.
Always ensure that the Do not apply any grease or

retaining spring clip is fitted oil to fit the hose pipe either
on both ends of the hose at the intake manifold end or
pipe (At intake manifold and the ECU end.
ECU) for perfect sealing.
Do not fix the rubber hose

pipe partly which may cause
leakage in intake manifold.
Fuel Pump Assembly H Know It On Your Finger Tip
While installing the injector in Use a light coat of 3 bond

Do’s Don’ts the intake manifold, apply a
light coat of MoS2 grease on
1521 B/C based adhesive or
equivalent, to the sensor
the injector nozzle side ‘O’ fitment area to prevent it
Replace the rubber gasket if Do not remove the strainer ring. from loosening / coming off.
there is any fuel leakage from the fuel pump assly for
from the sealing area cleaning purposes.
interface with petrol tank.
While assembling a new ‘O’ During fitment of IR sensor

ring, apply a light coat of ensure that the arrow mark is
Tighten the fuel pump Do not dismantle the fuel MoS2 grease and roll it into UP
facing ‘UP’ towards intake
assembly rubber gasket in a pump body or regulator or place. duct.
diagonal manner (criss-cross any other part from the
pattern). pump assembly as these
parts are not serviceable.
Assemble the fuel pump Do not remove corrugated Injector to be stored in a Tighten the fuel pump assly.
assly in a cleaned petrol transparent pipe connecting dust free environment when rubber gasket in a diagonal
dismantled. It should be manner (criss-cross pattern).
tank which is free from dust the pump to the outlet tube, placed in clean polythene
& dirt or cleaning solvents as these are non removable bag and should be handled
that could affect pump type. minimum to avoid damages.
performance or damage its
internal parts.
Do not remove the electrical

Fuel pump assembly to be connections / couplers of the
stored in a dust free fuel pump.
environment when
dismantled. It should be
Do not use a cut/deformed
or damaged rubber gasket
for fitment of the fuel pump
assembly.
Note :
Do not dry run the vehicle as the fuel inside the tank helps in lubrication and cooling of the
pump.
Chapter 5 Fuel System & EMS
6
I Evaluate Yourself
Evaluate yourself
1. The rotary throttle position sensor having a variable resistor is also called as -
Chapter Engine & Transmission
a. Resistance Meter b Potentiometer c. Voltmeter
2. When the throttle valve is wide opened and the wiper blade in the TPS swings towards 5 volt end of the A Removal of Engine from Frame 94
coil. This sends -
a. Increasing voltage signal to the ECU. B Dismantling Engine 97
b. Decreasing voltage signal to the ECU c. a & b are correct.
3. Where is the MAP sensor located - C Dismantling of Sub Assemblies 105

a. Inside the intake manifold b. Inside the ECU c. Inside the BCU
D Parts Inspection Parameters 110
4. Upon engine starting the engine, the intake manifold vacum gives the measure of engine load. This load
is proportional to manifold pressure. In high load condition -
a. It produces low pressure b. It produces high pressure c. All above are incorrect. E Service Data - Engine 113
5. The ECU receives input from sensors in a steady or slowly varying voltages. These are in analogue form Assembling of Sub Assemblies
& which are converted into equivalent digital valves by a -
F 115
a. Digital to analogue converter b. Analogue to digital converter c. AC to DC converter
G Assembling Engine 121
6. Actuators converts electrical signals into mechanical movements of a device-
a. True b. False Know It On Your Finger Tip
H 129
7. Following are actuators -
• Throttle position sensor • Roll over sensor I Evaluate Yourself 131
• Crank angle sensor • Engine oil temperature sensor
a. True b. False
8. Flash code and malfunction code are similar -

a. True b. False
9. The malfunction code for Inlet air temp output short to ground is -
a. PO 112 b. PO 113 c. PO 117
10. Flash code for fuel injector output open or shorted to ground -
a. PO 261 b. PO 262 c. 16
11. To measure the temperature of air entering inside the intake manifold which sensor is used
Key Learning Points
a. Intake air temperature sensor b. Intake manifold pressure sensor c. Both above are correct
After reading this chapter you should be able to understand..
12. The injector sprays the fuel inside the manifold at a pressure of about - • Correct Dismantling & Assembling procedure of the engine as per standard
a. 2.5 bar b. 36 lbf/m2 c. Both above are correct
guideline & precautions to be followed.
13. During deceleration the fuel injection system stops injecting fuel
• Dismantling & Assembling of various sub assemblies of engine.
a. True b. False
14. Fuel pump is lubricated and cooled by the petrol flowing through the pump assly - • Inspection of various engine components.
a. True b. False
• Understanding of standard & service limits of the engine parts.
15. While fitting the IR sensor on the air filter the arrow on IR sensor should face towards -
a. Air intake duct b. Opposite to air intake duct c. All above are correct

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Chapter 5 Fuel System & EMS Fuel System & EMS 5 Chapter

Sensors & Actuators Located on Vehicle

the engine to produce power.

This chapter describes the Fuel Injection System which is controlled by

Air Filter 2 6 Crank Angle

Roll Over Engine Oil

1 Air Filter IR Sensor B EMS Layout

2 Roll Over Sensor

4 Manifold Pressure Sensor INPUT

ENGINE TEMPERATURE SENSOR

CRANK ANGLE SENSOR

INTAKE AIR TEMPERATURE SENSOR

FUEL PUMP MODULE

9 Malfunction Indicator Lamp

13 Engine Control Unit (ECU)

14 Diagnostic Tool Connecting Port

C Working of System Fuel Pump Fuel Injector

Rail ‘O’ Ring Seal

Fuel Pump Mounting

Rubber Gasket for Armature

Pressurized Fuel out to Regulator Connected Washer

Engine Control Unit - ECU Engine Control Unit - ECU

Input signals are received from Signals given to operate

• Intake air temperature

Throttle Position Sensor Intake Air Temperature Sensor

Upon acceleration the throttle valve CLOSED THROTTLE

position changes. The wiper type blades

Manifold Pressure Sensor Engine Temperature Sensor

Thermistor is constructed of semi conductor material such

Thermister Resistance (Ohm)

Roll Over Sensor Crank Angle Sensor

Please note, even if roll over sensor is not

weights is sensed by the sensor. If the

Malfunction Indicator Light D Fuel Injection Advantages over Carburetion

When certain troubles develop in the Advantages of Fuel Injection

E Part Inspection Parameters Intake Air Temperature :

Fuel Tank Cap : Notes :

G Dos & Don'ts Oil Cooler Engine Temperature Sensor (ETS)

Do’s Don’ts Do’s Don’ts

ETS to be stored in a dust

Engine Oil Temperature Sensor (EOT) Injector

Do’s Don’ts Do’s

Use a new copper coated Do not re-use the old copper

Injector Intake Air Temperature Sensor (IAT)

Don’ts Do’s Don’ts

Do not connect or disco-

Air Filter IR Sensor Fuel Filter & Fuel Pipes

Do’s Don’ts Do’s Don’ts

is facing ‘UP’ towards intake at the periodic service

Ensure proper fitment of Do not connect or disco-

Blow compressed air gently Do not immerse the sensor

Manifold Pressure Sensor

Do’s Don’ts Replace the fuel filter if there

Always ensure that the Do not apply any grease or

Do not fix the rubber hose

Fuel Pump Assembly H Know It On Your Finger Tip

While installing the injector in Use a light coat of 3 bond