Review of Air/Fuel

Induction and
Exhaust
Electronic Fuel Injection System
From Lecture Notes by Lec Anosh Ali
 Air-Fuel Combustion
• The engine gets its power by burning a mixture
of air and fuel in the combustion chamber
• Fuel injection is a system for introducing fuel into
internal combustion engines, and into
automotive engines, in particular
• On diesel engines, fuel injection is a necessity,
while on petrol engines fuel injection is an
alternative to the carburetor
 Air-Fuel Combustion
• Petrol cannot be used in the engine in liquid
form, and must be mixed with air to obtain
oxygen to form a combustible mixture
• The liquid fuel has to be atomised so that each
little droplet of fuel can be surrounded by air with
enough oxygen to completely burn the fuel
 Air-Fuel Combustion
• With an ideal mixture of air and fuel and complete
combustion taking place, full power would be obtained
from the fuel. The engine’s exhaust would be clean, and
pollution of the atmosphere would be reduced
• For a petrol engine, the most suitable ratio of air to fuel is
approximately 15:1, by mass – that is 15 kg of air to 1 kg
of petrol
• The air–fuel ratio for complete combustion is known as
the stoichiometric ratio, and is actually 14.7:1 (by mass)
 Air-Fuel Combustion
• Rich mixture - If there is too much fuel for the air in the
engine’s cylinders, combustion will not be complete and
some fuel will remain unburnt and will be exhausted into
the atmosphere as gas and will cause air pollution
• Weak mixture - If there is not enough fuel for the air in
the engine’s cylinders, combustion could cause hard
starting, poor combustion and loss of power
 Carburators vs EFI
• Electronic fuel injection (EFI) replaced carburetors back
in the mid-1980s as the preferred method for supplying
air and fuel to engines
• The basic difference is that a carburetor uses intake
vacuum and a pressure drop in the narrow part of the
carburetor throat (venturi) to siphon fuel from the
carburetor fuel bowl into the engine whereas fuel
injection atomizes the fuel through a small nozzle under
high pressure to spray it directly into the engine
SINGLE BARREL CARBURETTOR
BASIC CARBURETTOR FUEL SYSTEM
SIMPLE CARBURETTOR
CARBURETTOR VENTURI
DOWNDRAFT CARBURETTOR
IDLE SYSTEM OF A CARBURETTOR
 Carburettor
• A choke valve is sometimes installed in the
carburetor of internal combustion engines
• Its purpose is to restrict the flow of air, thereby
enriching the fuel-air mixture while starting the
engine 
Carburettor
 Advantages of Carburetor
• Carburetors do last longer than fuel
injection systems
• Carburetors are also much simpler to
install than fuel injection systems, because
there are no electrical components or
return lines to the fuel tank
• The carburetor is currently much less
expensive than the electronic fuel injection
systems
 Drawbacks of Carburetor
• It cannot monitor the air to fuel ratio for each
individual cylinder
• The twists and turns of the intake runners can
also cause the air and fuel mixture to separate
as if flows to the cylinders, resulting in uneven
fuel mixtures between cylinders
• The centre cylinders typically run slightly richer
than the end cylinders, which makes tuning for
peak fuel economy, performance and emissions
more difficult with a carburettor
 EFI Systems
• EFI systems use injectors to spray the fuel
• There are two different systems:
– throttle-body injection (also called single-point injection)
– multipoint injection
• In both systems, the injectors are electronically
controlled
 Throttle Body Injection

• A simple explanation of throttle body injection is

a computer controlled carburettor
• These systems can use a single or multiple
injectors located above the throttle body that
inject fuel according to PCM commands
 Throttle Body Injection

• With Throttle Body Injection (TBI), one or two

injectors mounted in the throttle body spray fuel
into the intake manifold
• Fuel pressure is created by an electric fuel pump
(usually mounted in or near the fuel tank), and
the pressure is controlled by a regulator
mounted on the throttle body
• Fuel is sprayed into the engine when the engine
computer energizes the injector(s), which occurs
in a rapid series of short bursts rather than a
continuous stream
 Multipoint Injection
• Multipoint injection is the most commonly used and is
further divided into
– Indirect sprays fuel into the intake valve port
– Direct Injection sprays fuel directly into the
combustion chamber
• Both systems have an injector for each cylinder
Multipoint Injection
EFI System
BASIC EFI SYSTEM
 EFI Sub Systems
• An EFI system can be considered as having
three subsystems, each of which has a number
of components. These subsystems are:
– Fuel supply system
– Air intake system
– Electronic control system
 EFI Components
Some parts supply fuel to the engine and other parts supply
air. These are:
Fuel tank – to store the fuel
Fuel pump – to provide pressure for the system
Filter – to protect the injectors
Fuel rail – to supply the injectors with fuel
Injectors – to spray fuel into the intake valve ports
Pressure regulator – to provide a regulated pressure in the
system
 EFI Components
Air cleaner and ducting – to provide clean air and carry it to
the intake manifold
Throttle body – to control the flow of air to the engine by
means of a throttle valve
Airflow meter – to measure air entering the engine
Plenum, or air, chamber – to dampen the flow of air
Intake manifold – to carry the air to the cylinders
 EFI Components
• There is an electronic control unit (ECU). This is
a micro-computer that receives signals from a
number of sensors, processes them and uses
the results to operate the injectors
ECU SIGNAL SOURCES
Air Intake System
Electronic Control Unit
Electronic Control Unit
 COMPONENTS OF AN ELECTRONIC
CONTROL SYSTEM
• The engine electronic control unit (ECU) is given
different names by the vehicle and component
manufacturers like engine control module
(ECM), or as a power control module (PCM)
 COMPONENTS OF AN ELECTRONIC
CONTROL SYSTEM
Sensors
• Intake air temperature sensor - The density of air
varies with temperature, so changes in
temperature could affect the ratio of air to fuel
(ratio by mass). A sensor in the air intake senses
it and sends the signals to the ECU
• Atmospheric pressure sensor - The mass of air
varies with altitude, and also to some extent with
weather conditions. Signals sent to the ECU
allow it to adjust the fuel quantity to suit the
density of air
 COMPONENTS OF AN ELECTRONIC
CONTROL SYSTEM
Sensors
• Coolant temperature sensor - The engine needs
a richer mixture when starting and when cold.
Signals from this sensor allow the ECU to make
suitable adjustments
• Engine RPM sensor - This sends the engine
speed to the ECU. Changes in engine speed
indicate changes in engine load and the ECU can
make adjustments for this. The ECU also adjusts
the ignition timing to suit the engine speed
 COMPONENTS OF AN ELECTRONIC
CONTROL SYSTEM
Sensors
• Knock sensor - Under certain operating conditions
irregular combustion within the combustion
chamber can produce detonation, or knocking,
which is harmful to the engine. If detonation is
sensed, the ECU acts to prevent this by retarding
the ignition and/or providing a richer fuel mixture
 COMPONENTS OF AN ELECTRONIC
CONTROL SYSTEM
Sensors
• Vacuum sensor - This is used in the intake
system to sense manifold pressure
• Oxygen sensor - Located in the exhaust manifold,
this sensor detects oxygen in the exhaust gases.
If the air–fuel mixture is correct, there will be
good combustion in the cylinders and there will
be little or no oxygen present in the exhaust
gases. With poor combustion, oxygen will be
present
 Benefits of EFI System
• Fuel injection generally increases engine fuel efficiency
due to improved cylinder-to-cylinder fuel distribution of
multi-point fuel injection, less fuel is needed for the same
power output
• Exhaust emissions are cleaner because the more
precise and accurate fuel metering reduces the
concentration of toxic combustion byproducts leaving the
engine
• More accurate adjustment to account for extremes of
ambient temperatures and changes in air pressure
• Easier cold starting
• More stable idling
 Drawbacks of EFI System
• These systems are sophisticated and will cost
much more than a carburetor
• Installation is more complicated as it uses an
electrical component and custom cylinder head
configuration
Intake & Exhaust System
Lecture 07
Lec Anosh Ali
 INTRODUCTION
• Proper combustion requires the engine
to “breathe” properly
• Intake & Exhaust manifolds & Valve train
must all work together
 AIR FILTERING
• Gasoline must be mixed with air to form a
combustible mixture. Air movement into an
engine occurs due to low pressure (vacuum)
being created in the engine
• Air contains dirt and other materials that cannot
be allowed to reach the engine
 AIR FILTERING
• An air cleaner and filter are used to
remove contaminants from the air
• The three main jobs of the air cleaner and
filter include
1. Clean the air before it is mixed with fuel
2. Silence intake noise
3. Act as a flame arrester in case of a backfire
 AIR FILTERING
• Paper air filter
­ Most common type
­ Chemically treated paper stock
­ Traps dust, dirt, and carbon
­ Particles larger than 10 to 25 microns in size
–Oil wetted polyurethane type
- Offer minimal airflow restriction
- Very high dirt capacity
• Air filters are rated
- Efficiency, flow, and capacity
 Manifolds
• Two kinds of manifolds used in the
engine’s breathing system are Intake
manifold and Exhaust manifold
• Designed to provide a uniform air-fuel
mixture to cylinders
- Must be properly designed and sized
 INTAKE MANIFOLD
–Intake manifolds are made from
Cast Iron, Aluminum, Plastic
• Many intake manifolds are
constructed in two parts
– Lower intake Manifold - attaches
to the cylinder heads and
includes
passages from the intake ports
– An upper manifold - usually
called the plenum, connects to
the lower unit. The throttle body
attaches to the upper intake
 Parts to the manifold
• Plenum
- The plenum is the big usually circular part
of the manifold
- All of the runners are fed by the plenum
- Plenum size should be 50-70% of the actual
engine displacement
 Runners
• The runners stem from the plenum and
are connected to the cylinder head
• They have a tapered shape starting large
at the plenum and gradually get smaller
near the cylinder head
• Short runners and wide are optimal for
higher engine function and Long and
narrow runners are optimal for low-mid
rpm function
 Throttle Body or Throttle Plate
• Controls the air flow into the intake plenum
• Size of the throttle body effects the speed
at which the air enters
• The air velocity should be kept at
approximately 300 ft/sec for smooth
throttle response
Intake Manifold
 Intake Manifold
• The intake manifold is also called an inlet
manifold
• Smooth engine operation can only occur
when each combustion chamber produces
the same pressure as every other chamber
in the engine
 Intake Manifold (TBI)
• Manifold sizes and shapes represent a
compromise
– They must have a cross section large enough to
allow charge flow for maximum power
– The cross section must be small enough that the flow
velocities of the charge will be high enough to keep
the fuel droplets in suspension. This is required so
that equal mixtures reach each cylinder
 Intake Manifold (Port Fuel
Injection)
• The size and shape of port fuel-injected engine intake
manifolds can be optimized because the only thing in the
manifold is air
• The fuel injector is located in the intake manifold about 3
to 4 in. (70 to 100 mm) from the intake valve
• The runner length and shape are designed for tuning only
• Intake manifold runners are tuned to improve engine
performance
- Long runners build low-RPM torque
- Shorter runners provide maximum high-RPM power
EXHAUST SYSTEM
Exhaust System Fundamentals
• The exhaust system is designed to
collect high-temperature spent gases
from the individual head exhaust ports
and direct them through various exhaust
system components into the atmosphere
• The hot gases are sent to an exhaust
pipe, then to a catalytic converter, to the
muffler, to a resonator, and on to the
tailpipe, where
they are vented to the atmosphere
Exhaust System Fundamentals

• Exhaust system functions

- Carries burned exhaust gases away from the
passenger compartment
- Keep the exhaust noise at a minimum
- Provide the least possible amount of restriction or
backpressure
–Exhaust system flow
- Not severely affected by bends in the pipe
 Exhaust System Components
• Exhaust Manifold
- to collect high-temperature spent gases from the individual
head exhaust ports and direct them into a single outlet
connected to the exhaust system
• Exhaust pipes
- Header, exhaust, and intermediate pipe
• Muffler
- Tubes and chambers to smooth vibrations of air
• Resonator
- Second muffler in line with primary muffler
• Catalytic converters
- Contain catalysts to reduce engine emissions
• Muffler hangers
- Support the muffler and pipes
Exhaust System Components
 Exhaust Manifold
• Made of cast iron, nodular iron,
stainless steel or heavy gauge
steel
• Engineered for size, flow,
silencing
• Proper tuning of the exhaust
manifold (headers) creates a
vacuum that assists in air/fuel
mixture induction into the
cylinder
 Exhaust Manifold
• Mounted to exhaust ports of cylinder head

• Exhaust temperature
- Related to the amount of load on the engine
- Under full-power conditions, the temperature
of an exhaust manifold can exceed 1,500°F
(815°C)
 EXHAUST PIPE
• Made from Stainless
steel, zinc-plated
• Double wall
construction prevents
“ringing”
• Sealing by
- Steel composition
Gasket/Washer
- Ball Shaped flange
against exhaust manifold
flange
 Catalytic Converter
• A catalytic converter
(reactor) is a device
installed in the
exhaust line (usually
before the muffler) to
significantly lower
emission levels of
hydrocarbons, carbon
monoxide and in the
case of some
converters, oxides of
nitrogen
 Muffler
• When the exhaust valve opens, it rapidly
releases high-pressure gas
• This sends a strong air pressure wave through
the atmosphere inside the exhaust system,
which produces a sound we call an explosion
• In an engine, the pulses are released one after
another. The explosions come so fast that they
blend together in a steady roar
• Sound is air vibration
• When the vibrations are large, the sound is loud
 Muffler
• The muffler catches the large bursts of
high-pressure exhaust
gas from the cylinder, smoothing out the
pressure pulses and allowing them to be
released at an even and constant rate
• It does this through the use of perforated
tubes within the muffler chamber
• The smooth flowing gases are released
to the tailpipe
 Resonator
• For even better sound control, some cars
use additional devices called resonators.
They may be located before or after the
muffler
 Tailpipe

• A tailpipe conducts
exhaust gases from
the muffler to
- beneath the rear
bumper
- released at the side
of the vehicle
 Hangers
• The muffler and tailpipe are supported with
brackets, called hangers, which help to
isolate the exhaust noise from the rest of
the vehicle
 Exhaust System
• To reduce the emission of oxides of nitrogen (NOx),
engines have been equipped with exhaust gas
recirculation (EGR) valves
• From 1973 until recently, they are used on almost all
vehicles
• Most EGR valves are mounted on the intake manifold
• On engines with EGR systems, the EGR valve opens at
speeds above idle on a warm engine. When open, the
valve allows a small portion of the exhaust gas (5% to
10%) to enter the intake manifold
• Because of the efficiency of computer-controlled fuel
injection, some newer engines do not require an EGR
system to meet emission standards
• These engines’ variable valve timing to close the exhaust
valve sooner than normal, trapping some exhaust in the
cylinder, is an alternative to using an EGR valve
Video
 Why Turbo/Supercharger??
• Volumetric efficiency is a measure of how well an engine
breathes
• It is a comparison of the actual volume of air-fuel mixture drawn
into an engine to the theoretical maximum volume that could be
drawn in
• It decreases as engine speed increases due to the shorter
amount of time for the cylinders to be filled with air during the
intake stroke
• For naturally aspirated engines
- At high speed, it may drop to as low as 50%
- A new engine is about 85% efficient
- A race engine usually has 95% or better volumetric efficiency
Need for Turbo/Supercharger??

• With either turbochargers or superchargers,

engines can easily achieve more than 100%
volumetric efficiency
• Many vehicles are equipped with a
supercharger or a turbocharger from the
factory to increase power
• A turbocharger is used on race engines to
overcome 100% volumetric efficiency
Need for Turbo/Supercharger??
• The greater the density of an air-fuel charge
forced into a cylinder, the greater the force it
produces when ignited, and the greater the
engine power
• A better way to increase air density is to use
some type of air pump such as a turbocharger
or supercharger
• Forced induction systems use an air pump to
pack a denser air-fuel charge into the cylinders
Need for Turbo/Supercharger??
• Pumping air into the intake system under pressure
forces it through the bends and restrictions of the air
intake system at a greater speed than it would travel
under normal atmospheric pressure
• This added pressure allows more air to enter the
intake port before the intake valve closes
• By increasing the airflow into the intake, more fuel
can be mixed with the air while still maintaining the
same air-fuel ratio
 Supercharger
• A supercharger is an engine-driven air
pump that supplies more than the normal
amount of air into the intake manifold and
boosts engine torque and power
• A supercharger provides an instantaneous
increase in power without any delay
 Turbocharger

• The major disadvantage of a supercharger is

it takes some of the engine power to drive
the unit
• In some installations, as much as 20% of the
engine power is used by a mechanical
supercharger
• A turbocharger uses the heat of the
exhaust to power a turbine wheel and
therefore does not directly reduce engine
power
Turbocharger
Turbocharger