Low Pressure Transfer Systems

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1 Chapter 7b Low Pressure Transfer Systems Automotive Diesel Technology Understanding & Servicing Contemporary Clean Diesel Technology Gus Wright

2 Low Pressure Transfer Layout of a low-pressure fuel transfer system for a Duramax 6.6L diesel. 2

3 System Components Typical components include: 1. Fuel tank(s) 2. Low-pressure fuel lines 3. Fuel level sending units and tank pickup 4. Fuel filters 5. Fuel-water separators and temperature regulators 6. Fuel transfer pumps 3

4 Air In Fuel Air in fuel causes the nozzle valve to impact the nozzle seat with high forces causing damage to the nozzle tip. Fuel containing air will not pressurize properly since air is eleastic 4

5 Air In Fuel This Volkswagen diesel uses clear plastic suction and fuel return lines to detect air entering and leaving the fuel system. 5

6 Air In Fuel The fuel filter of this Volkswagen diesel has a fuel vapor separator feature. Air and/or fuel vapor returns to the tank through the fuel return line. 6

7 Air In Fuel Using a site glass to check for air in the suction line. 7

8 Separating Water Fuel in Water Sensor Drain Valve Sediment Bowl Water will damage the fuel system corroding parts to leading to premature wear or seizure 8

9 Separating Water Water can enter through condensation or mixing with water leakage into fuel. 9

10 Fuel Tanks This plastic tank for a 2011 Dodge Ram shows basic tank connection tank vent, inlet, outlet, and fuel level sensor. Diesel engine fuel tanks are permitted to be vented to the atmosphere unlike gasoline systems. 10

11 Fuel Conditioning A horizontal fuel conditioning module (HFCM). The module pumps fuel, has a 10-micron primary filter, separates water from fuel, heats fuel, and has a fuel-water sensor. A drain valve is used to purge the module of contamination. A 4-micron secondary filter is located in the engine compartment. 11

12 Fuel Pick-up Fuel tank pick-ups are designed to draw both water and fuel out of the tank where it is separated upstream. 12

13 Fuel Conditioning An electric fuel heating element is located in the filter housing of this Powerstroke diesel. 13

14 Fuel Conditioning This fuel module for a 2003 Dodge Ram contains a cartridgetype filter, water in the fuel sensor and a fuel heater. 14

15 Fuel Conditioning Primary Filter Secondary Filter Priming Pump Fuel Pressure Sensor Water Drain Valve Fuel Heater Connection Water in Fuel Sensor A fuel conditioning module with two filters 15

16 Fuel Conditioning A float type water in fuel separator 16

17 Fuel Conditioning Fuel conditioning for a common rail 6.4L Powerstroke. Note the fuel cooler needed to reduce temperature of fuel returned to the tank. 17

18 Fuel Conditioning Location of the fuel cooler and cooling system components for the common rail fuel return on a Powerstroke 6.4L diesel. 18

19 Fuel Filters Location of primary and secondary fuel filters 19

20 Fuel Filters Comparing micro glass and paper p type filter media 20

21 Fuel Filters Fine abrasive particles are the greatest hazard to fuel systems because they can enter the spaces making up the operating clearances between moving parts. 21

22 Fuel Filters Measuring the efficiency of a fuel filter. The percentage of particles trapped, say 5 microns and above, is the proper measure of efficiency and not just micron sizing of the filter alone. 22

23 Fuel Filters Fuel flow through the filter of the 6.5L Chevy diesel. Note how water will separate and accumulate outside the filter in the housing where it settles to be drained. 23

24 Fuel Filters A two pass filter from a Chevy 6.5 Diesel 24

25 Priming Fuel Filters A secondary fuel filter for a DMX diesel. Note the vent plug which is loosened to purge air when priming. Filter must be purged of air after service. 25

26 Priming Priming a low pressure fuel system by applying vacuum to the fuel return system 26

27 Priming Inlet and outlet check valve of a piston type hand primer 27

28 Fuel Filters Measuring filter restriction with an electronic pressure transducer. This filter has a 0.1-psi pressure drop across the filter element. The resistance to fuel flow caused typically y by dirt is called restriction. 28

29 Fuel Filters Location of a fuel test port to measure filter outlet pressure 29

30 Test Points Low-pressure system inspection and test points for a LPowerstroke 6.7L 30

31 Test Points Common inspection and test points for evaluating the lowpressure fuel system on a common rail fuel system 31

32 Fuel Pumps A two stage transfer pump used by the early 7.3 Powerstroke 32

33 Fuel Pumps A diaphragm pump with a weep hole to prevent oil dilution from and internal fuel leak 33

34 Fuel Pumps An inline type fuel pump p 34

35 Fuel Pumps Pulse width modulated electric transfer pumps. Lengthening the pulse width increases fuel pressure and delivery volume. 35

36 Fuel Transfer Pumps Pump Vanes Inlet Filter Screen A vane type transfer pump located in the distributor head of this injection pump 36

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