Fuel Systems
Fuel Systems
Fuel Systems
Service
PIERBURG
Technical
Market Service
Hamburger Strasse 15
D-41540 Dormagen
Phone +49 21 33 - 2 67 - 1 00
Fax
+49 21 33 - 2 67 - 1 11
Phone +49 21 33 - 2 67 - 1 67
Fax
+49 21 33 - 2 67 - 1 11
Untere Neckarstrasse
D-74172 Neckarsulm
Phone +49 71 32 - 33 33 33
Fax
+49 71 32 - 33 28 64
info@msi-motor-service.com
www.msi-motor-service.com
8.40002.57.0
04/03
technical.servicePG@msi-motor-service.com
Fuel Systems
Components and solutions for
universal applications
Fuel Systems
Table of Contents
Introduction........................................................................................4
1.1
1.2
1.3
1.4
1.5
1.6
Components..........................................................................................8
3.1
3.2
3.2.1
3.2.2
3.2.2.1
3.2.3
3.2.4
3.2.5
3.3
3.4
3.5
3.6
3.7
3.7.1
3.7.2
Overview ......................................................................................8
Electric all-purpose fuel pumps (EFP) ...........................................8
Type E1F .......................................................................................9
Type E1S .....................................................................................10
Comments on pre-feeder pumps.................................................10
Type E3L .....................................................................................11
Accessories for pumps................................................................12
Safety shut-off (12 V operation)..................................................13
Non-return valve (NRV) ...............................................................14
Fuel cut-off valve (COV/ECOV).....................................................15
Fuel vapor separator (FVS)..........................................................16
Pressure relief valve (PRV) ..........................................................17
Additional accessories for fuel systems ......................................18
Selections from our catalog Tools & Testing Instruments........18
Specialist trade items .................................................................18
2 | Fuel Systems
Preface .........................................................................................4
Pictograms and symbols...............................................................4
Explanation of terms.....................................................................5
General notes ...............................................................................5
Product liability ............................................................................5
General notes on safety ................................................................6
Fuel Systems
Table of Contents
10 Contact Information.......................................................................37
Fuel Systems | 3
Fuel Systems
Introduction
1 Introduction
Please note:
This brochure is intended only for
qualied personnel.
- safety regulations,
- accident prevention regulations and
- guidelines and accepted rules of
technology (such as standards).
1.1 Preface
Typically gasoline (petrol) or diesel
fuel is required for the operation of
combustion engines.
In addition to that, fuels are also used
for heat generation, as is the case with
heating oil. The fuels must be stored,
transported, transferred and supplied
to the motor or heating system.
The components used to accomplish
this are referred to in general as
fuel systems. For mass production
vehicles these systems as well as the
corresponding components are
developed and tested for specialized applications. For small series or
Please note:
Information regarding fuel
systems for injection engines can be
found in our brochure Service Tips &
Info - Fuel Supply for Injection
Engines
4 | Fuel Systems
Fuel Systems
Introduction
Abbreviation
ACF
Term
Activated carbon lter
Denition
Absorber for hydrocarbons in the tank ventilation system.
ACF valve
COV / ECOV
Cut-off valve
DCOV
DV
Diaphragm valve
E1F
E1S
Periphery pump
E3L
Screw pump
EFP
FVS
A volume with a xed or variable return, in which vapor is returned and the
fuel is degassed
Inline
In-line pump
Intank
In-tank pump
MFP
NRV
Non-return valve
For installation in the feed and return lines. Prevents lines from running empty
PRV
Fuel Systems | 5
Fuel Systems
Introduction
6 | Fuel Systems
Fuel Systems
Most Common Fuel Systems
carburetor
Figure 1
non-return valve
mechanical fuel pump
fuel tank
Figure 2
fuel lter
pulsation damper
fuel pressure regulator
fuell distributor
non-return valve
pre-feeder pump
(in tank)
fuel tank
Figure 3
Fuel Systems | 7
Fuel Systems
Components
3 Components
Components for fuel systems are
described below.
3.1 Overview
In addition to the electric fuel pump
(EFP) as the primary component, there
are additional components which
improve the safety and function of the
engine fuel supply.
In certain cases, for example, they can
eliminate hot start problems.
Which components are to be used
where depends on the specic
application. For further details, see
Chapter 4, Common Applications.
Term
Model/Type
Order No.
Fuel pump
E1F
Table 3.2.1
Fuel pump
E1S
7.21088.62.0
Fuel pump
E3L
7.22782.50.0
for 6 mm connection
7.20469.51.0
for 8 mm connection
7.20234.52.0
electric
7.22386.50.0
4.05284.50.0
4.07303.12.0
7.20925.51.0
without return
7.20726.50.0 *
7.20726.51.0 *
7.20726.52.0 *
7.21182.50.0
8 | Fuel Systems
Fuel Systems
Components
Stat. P at
Q = 0 l/h
Flow
Rate
[bar]
[l/h]
[bar]
[A]
Max.
Suction
Head
[mm]
0.270.38
95
0.10
38
133.5
84.5
M 2.00
500
500
Curve
7.21440.51.0 1
System
Pressure
Current
Draw
at
12
7.21440.53.0 2
12*
0.440.57
100
0.15
38
133.5
84.5
M 2.05
7.21440.63.0 2
24
0.440.57
100
0.15
38
134.2
84.5
M 1.35
500
7.21440.78.0 3
12
> 1.85
95
1.00
38
141.5
91.0
12
M 4.30
500
7.21440.68.0 3
24
> 1.85
95
1.00
38
139.5
90.5
M 3.00
500
E
4.8
120
I (12 V)
Q [l/h]
2.4
60
I (24 V)
I [A]
3.6
90
C
1.2
30
3
0
D
A
0
0
0.2
0.4
5
0.6
0.8
10
1.0
15
1.2
1.4
20
1.6
1.8
2.0
p [bar]
p [psi]
25
Figure 4
Fuel Systems | 9
Fuel Systems
Components
Stat. P at
Q=0 l/h
Flow
Rate
System
Pressure
Current
Draw
[V]
[bar]
[l/h]
[bar]
[A]
Max.
Suction
Head
[mm]
12
75
0.24
38
100
75.3
9.5
19
2.00
at
7.21088.62.0
400
Q
I
200
100
0
0
54.5
I [A]
Q [l/h]
300
0.1
0.2
2
0.3
3
0.4
5
p [bar]
p [psi]
Figure 5
Electric fuel pump, type E1S, dimensions and characteristic curve (including prelter)
10 | Fuel Systems
This prevents a vacuum from occurring on the intake side of the main
pump.
Flow pumps are the typical choice for
pre-feeder pumps. They are not selfpriming and must therefore be placed
in the tank.
Installation example, see
section 4.6
Fuel Systems
Components
[Volt]
[bar]
Flow
Rate
at
[l/h]
12
280120
7.22782.50.0
B
C
Q [l/h]
System
Pressure
- 4.00
[bar]
43.5 199.5
Current
Draw
[A]
Max.
Suction
Head
[mm]
156
8.00
500
360
18
320
16
280
14
240
12
200
10
160
I [A]
120
I
80
40
54.5
0
0
7
10
11
12
13
14
15
16
U [V]
Q = ow ratee; U = voltage; I = current input
Figure 6
Electric fuel pump, type E3L, dimensions and characteristic curves (at 1.8 bar, 20C)
Fuel Systems | 11
Fuel Systems
Components
Modell/Type/Comment
Figure
7
Order No.
Suspension
sound-proof
4.05303.50.0
4.07414.87.0
Rocker element
Reducing piece
10
4.07414.86.0
Safety shut-off
for E1F
11
4.05288.50.0
61.5
57
38
6.7
10
Figure 7
Fixing clamp
(included with the E1F order)
Figure 8
Suspension, sound-proof
(4.05303.50.0)
8 mm
22
15
M6
35
Figure 9
Rocker element
(4.07414.87.0)
6 mm
12 | Fuel Systems
Fuel Systems
Components
ignition coll
ignition distributor
4
15
to terminal 15 (12V)
red
black
green
relay
12 V
brown
brown
3
5 6
4
7
Pin
Cable
Terminal on Relay
No.
Color
No.
red
30
black
31b
brown
31
red
15
green
87
Fuel Systems | 13
Fuel Systems
Components
18
14 | Fuel Systems
61.5
2.5
2.5
20
20
62
20
20
18
2.5
2.5
6
7
Fuel Systems
Components
Connection 1
Connection 2
Technical data
Rated voltage
Pull-in voltage
Connections
Flow rate at 0.3 bar
Length
12
[V]
8
[V]
2, 8 [mm]
<_ 100 [l/h]
78.5 [mm]
Connection 2
Connection 3
Connection 1
Technical data
Rated voltage
Pull-in voltage
Connections
Flow rate at 0.3 bar
Length
12
[V]
8
[V]
3, 8 [mm]
<_ 100 [l/h]
85
[mm]
Fuel Systems | 15
Fuel Systems
Components
Variant 2
(metal)
R
7
Variant 1
(plastic)
Variant 3
(metal)
Variant 4
(metal)
16 | Fuel Systems
Fuel Systems
Components
33
33
9
52
9
42
42
52
7
Fuel Systems | 17
Fuel Systems
Components
Quantity
Order No.
T-piece 6 mm
10 units
4.07413.99.0
Y-piece 6 mm
10 units
4.07413.98.0
Tee 8 mm
10 units
4.07414.01.0
Y-piece 8 mm
10 units
4.07414.00.0
20 m
4.07371.05.0
20 m
4.07371.06.0
4.00005.01.0
Filter sieve
4.00030.80.0
Figure 24 Filter sieve
DS-K 6L
DS-K 8L
sealing rings
tank wall
DS-K 6L
DS-K 8L
sealing rings
18 | Fuel Systems
Fuel Systems
Common Applications
4 Common Applications
In sections 4.2 to 4.9 of this chapter, the most common applications
and installation scenarios for fuel
system pumps and components are
described, taken from the range of
applications of our customers.
Fuel Systems | 19
Fuel Systems
Common Applications
20 | Fuel Systems
Application-specic notes:
The return can be run parallel to the
supply line.
The discharge into the tank should be
via a bulkhead tting
(see section 3.7).
If possible it should be mounted on
a cover for the tank (for example the
cover of the tank sensor).
The outlet for the fuel return line
should be down below the normal
level in the tank. If no fuel vapor
separator is used, the return must be
calibrated with a jet so as to ensure
the fuel supply even at at full load.
The mechanical Pump can be bypassed or removed. If it is removed,
the opening on the engine side must
be sealed oil-tight.
If it is bypassed, the inlet and outlet
should be connected with a piece of
hose to prevent contamination from
getting in.
air lter
carburetor
mechanical
fuel pump
fuel tank
Fuel Systems
Common Applications
fuel vapor
separator
non-return valve
pressure
relief valve
carburetor
lter sieve
fuel tank
electric fuel
pump (E1F)
non-return valve
mechanical
fuel pump
non-return valve
pressuree relief
valve
carburetor
lter sieve
fuel tank
electric fuel
pump (E1F)
non-return valve
Fuel Systems | 21
Fuel Systems
Common Applications
non-return valve
lter sieve
electric fuel
pump (E1F)
fuel tank
pressure relief
valve
carburetor
non-return valve
non-return valve
Figure 30 Carburetor engine with two E1F electric fuel pumps (gasoline engine)
fuel vapor
separator
pressure relief
valve
non-return valve
lter sieve
fuel tank
carburetor
non-return
valve
main pump
Figure 31 Fuel system with an E1F as a switchable backup pump (emergency pump)
Application-specic note:
The backup pump muss be connected
so that both pumps can draw and
deliver freely.
Fuel Systems
Common Applications
non-return valve
Figure 32 Diesel engine with in-line injection pump and attached pre-feeder pump (MFP)
non-return valve
fuel stage
lter (provided by the
customer)
fuel tank
lter sieve
E1F as a pre-feeder pump
Figure 33 Diesel engine with in-line injection pump and attached pre-feeder pump (E1F)
drive switch
17
19
19
+30
15
15
17
50
fuse holder
with fuse
starter glow switch
Fuel Systems | 23
Fuel Systems
Common Applications
lter sieve
non-return valve
E1F (connected
in parallel)
auxiliary tank
E1F (connected
in parallel)
non-return valve
fuel tank
24 | Fuel Systems
Fuel Systems
Common Applications
lter sieve
non-return
valve
heating oiltank
Fuel Systems | 25
Fuel Systems
Information on Other Documents
Catalogs
- Fuel supply article no. 8.40002.47.0
- Tools & Testing Instruments
article no. 50 003 931-02
- MSI Training Program
article no. 50 003 646
Brochures
- Service, Tips & Info Fuel Supply for
Injection Engines
article no. 8.40002.37.0
Products information PI
- PI 0005 Fuel pressure tester
- PI 0007 Add-ons for the fuel
pressure tester
- PI 0013 Electric fuel pump E1F
- PI 0014 Fuel pump tester
- PI 0015 Electric in-tank fuel pump
E1S
- PI 0016 Diesel-resistant electric
universal pump E3L (for system
pressures up to 4 bar)
Service Information SI
- SI 0016A Safety shut-off for
electric fuel pumps
- SI 0044 Fuel non-return valves
- SI 0062 Installation of an electric
fuel pump E1F to replace a mechanical fuel pump.
- SI 0063 Installation of an electric
fuel pump E1F as a backup pump
26 | Fuel Systems
Fuel Systems
Tools and Testing Equipment
Fuel Systems | 27
Fuel Systems
Frequently Asked Questions
Questions
Answers
Additional Information
SI 0062, 0063
Section 4.1 General notes
SI 0062, 0063
Section 4.1 General notes
SI 0062, 0063
SI 0016/A
Section 3.2.5
SI 0062, 0063
Chapter 4. Common
Applications
28 | Fuel Systems
Fuel Systems
Frequently Asked Questions
Answers
Additional Information
Questions
SI 0062, 0063
Section 4.1 General notes
No.
Publication 003/2002
A pump solution for antique
cars
SI 0062, 0063
Section 4.1 General notes
Fuel Systems | 29
Fuel Systems
Troubleshooting Tips
8 Troubleshooting Tips
Below you will nd a table with tips
for troubleshooting. This table only
Malfunctions in injection engines with standard equipment are handled in our brochure
Service Tips & Information, Fuel
Supply for Injection Engines.
30 | Fuel Systems
Malfunction
No ow from the pump
Possible Cause
Voltage supply to the
EFP is faulty.
Remedy/Comments
Visual inspection.
Test the voltage
supply.
Bad fuse.
Electrical malfunction
in the pump.
Fuel Systems
Troubleshooting Tips
Possible Cause
Remedy/Comments
Symptom
Filter clogged.
Improper installation.
Resonance
Commutator deposit
Unsuitable medium to be
pumped (see section 8.2.5).
Malfunction
Possible Cause
Remedy/Comments
Fuel leaks.
Amount of fuel/combustion
material too low.
Fuel Systems | 31
Fuel Systems
Troubleshooting Tips
Malfunction
The carburetor is ooding.
Possible Cause
The pump pressure is too high
(oat needle valve is
overpressured) or the
oat is too small.
Remedy/Comments
Use a pump with lower pressure.
Install a return line. Install a
pressure relief valve or fuel
vapor separator with a pressure
relief valve.
Repair the carburetor.
Fuel is sprayed from the carburetor Foaming of the fuel in the oat
in the lter, and the engine
chamber as a result of too fast
oods.
supply ow.
Engine misres,
stops.
Engine misres.
32 | Fuel Systems
Fuel Systems
Troubleshooting Tips
Remedy:
Only use fuels which meet the
applicable stadards (such as
DIN EN 14214) at the time of
their use.
Biofuels may only be used in
systems if all components/
devices of these systems have been
approved for biofuels.
Fuel Systems | 33
Fuel Systems
MSI Training Program
Language
50 003 648
German
50 003 646
English
34 | Fuel Systems
Fuel Systems
MSI Training Program
Fuel Systems | 35
Fuel Systems
MSI Training Program
36 | Fuel Systems
Fuel Systems
Contact Information
10 Contact Information
Please note:
Local contact information for Pierburg
products can be found on our Web site
www.msi-motor-service.com
under Contact > Contacts world-wide
or by calling us.
Product information (PI) and service
information (SI) are found on the
Pierburg CD (article no. 8.40002.62.0)
or as a collection in Folder I.
They can also be downloaded free of
charge from our Web site
www.msi-motor-service.com
Fuel Systems | 37
Fuel Systems
Notes
38 | Fuel Systems
Fuel Systems
Notes
Fuel Systems | 39
KOLBENSCHMIDT
Service
PIERBURG
Technical
Market Service
Hamburger Strasse 15
D-41540 Dormagen
Phone +49 21 33 - 2 67 - 1 00
Fax
+49 21 33 - 2 67 - 1 11
Phone +49 21 33 - 2 67 - 1 67
Fax
+49 21 33 - 2 67 - 1 11
Untere Neckarstrasse
D-74172 Neckarsulm
Phone +49 71 32 - 33 33 33
Fax
+49 71 32 - 33 28 64
info@msi-motor-service.com
www.msi-motor-service.com
8.40002.57.0
04/03
technical.servicePG@msi-motor-service.com
Fuel Systems
Components and solutions for
universal applications