FUEL DELIVERY SYSTEM Copyright © MILE 2011 MILE / XUV500 / IC / VER 01 / JUL 2011

Systems Fuel Delivery System

System Components Wiring Harness Fuel Gauge Nut Plastic FDM Fuel Delivery Module Secondary Fuel Delivery Module Primary Gasket FDM Fuel Lines on Tank Fuel Tank Assy Heat Shield Fuel Tank Screw Heat Shield FUEL STORAGE SYSTEM

XUV5OO Fuel System Only For Export Vent Pipe on Tank Gravity Vent Valve Foam Pads Blow Molded Shell Inlet Check Valve Secondary Side Primary Side Heat Shield Spacer FUEL STORAGE SYSTEM

XUV500 Fuel System Step 1: Assemble Heat Shield to Fuel Tank Heat Shield Spacer Screw Heat Shield Tightening Torque of Screw Heat Shield: 3 +0.5 N.m

Method Of Assembly Step 1: Assemble Heat Shield to Fuel Tank Heat Shield Spacer Screw Heat Shield Tightening Torque of Screw Heat Shield: 3 +0.5 N.m

Method Of Assembly Step 4: Connect the Transfer Connector to the Fuel Delivery Module Primary and Assemble with the Fuel Tank

Method Of Assembly Step 5: Connect the Nut Plastic FDM to the Fuel Tank: Tightening Torque: 85 ± 5 N.m

Method Of Assembly Common: 10 litres Secondary Side: 28 Litres Primary Side: 32 Litres During Filling, Fuel gets filled first in the primary side, overflows to the secondary. During Draining, Fuel gets drained first in the secondary then in the primary FUEL TANK FILLING

Operating Principle Return Line Fuel Fuel Flowing Through Restricted Opening Return Line fuel from the engine enters the chamber as shown where two restricted openings are provided to create suction pressure. One opening helps in suction pressure causes fuel to suck from secondary to primary side. The other opening helps in creating suction from primary to primary side when the fuel falls below the reservoir level. WORKING OF FUEL TANK

FDM Return Line Fuel WORKING OF FUEL TANK

Fuel Flowing into the Reservoir Secondary Side FDM Return Line Fuel Fuel Flowing into the Reservoir Secondary Side FDM Return Line Fuel Suction of Fuel From Secondary Side WORKING OF FUEL TANK – TRANSFER OF FUEL FROM SECONDARY SIDE TO PRIMARY SIDE

FDM LOW FUEL CONDITION- WHEN THE FUEL FALLS BELOW RESERVOIR Return Line Fuel LOW FUEL CONDITION- WHEN THE FUEL FALLS BELOW RESERVOIR Fuel Flowing into the Reservoir Return Line Fuel FUEL SUCTION FROM PRIMARY TO PRIMARY SIDE-LOW FUEL CONDITIONS

SAFETY VALVE ON FDM – TO RELEIVE EXCESS PRESSURE ACROSS THE FUEL LINE Return Line Fuel SAFETY VALVE ON FDM – TO RELEIVE EXCESS PRESSURE ACROSS THE FUEL LINE Pressure Relief Valve When the Pressure across the fuel line is higher, the relief valve opens and allows the fuel to go through valve and store in the reservoir

FDM Return Line Fuel WORKING OF FUEL TANK

FDM Cluster L2 L1 L1+L2 R2 R1 GAUGING OF FUEL TANK

FUEL TANK BEHAVIOUR IN ROLL OVER CONDITIONS FDM Gravity Vent Valve Functions: To Prevent Overfilling of the advertised capacity – Requirement in Export Vehicles Will act as additional Venting during Filling During Roll over Conditions, this valve will close there by preventing fuel leakage FUEL TANK BEHAVIOUR IN ROLL OVER CONDITIONS

FDM Assy Filler Neck Gasket Filler Neck Assy Filler Neck Cap Locking Filler Pipe Nozzle Guide Pipe Ventilator Fuel Tank Filler Pipe Assy Filler Neck Gasket Filler Pipe Clamp Filler Pipe Cap Locking Filler Pipe Worm Clamp Heat Shield Hose Fuel Filler Hose Fuel Filler Filler Pipe FUEL FILLING SYSTEM

FUEL STORAGE AND FILLING SYSTEM FDM FUEL STORAGE AND FILLING SYSTEM

FILTER Temperature Sensor Fuel Filter Brkt Fuel Line Clamp Inlet Port Outlet Port Fuel Lines on Engine Clip Fuel Line 2 way Water Level Sensor Clip Fuel Line 5 way Fuel Lines Underbody FUEL HANDLING SYSTEM

FUEL STORAGE, FILLING AND HANDLING SYSTEM W201 FUEL SYSTEM FUEL STORAEG FUEL STORAGE, FILLING AND HANDLING SYSTEM

FDM VIEW Engineering Advantages over Existing Design: Plastic Fuel Tank meets stringent crash requirements 2. Plastic Fuel Tank can take complicated shapes and takes full usage of packaging space available

In Car Repairs Fuel Sender Unit Replacement

Replacement of Sender Unit Maintenance to be carried out in the system Fuel Tank Servicing interval to be defined Fuel Delivery Module Servicing Interval to be defined Specification Fuel Tank Refilling Capacity : 70 litres Fuel Filling Rate : 55 lpm Fuel Filter Service Interval: 20,000 kms Special Tools: For Assembling and Removing Fuel Delivery Module

Thank You Copyright © MILE 2011 MILE / XUV500 / FUEL/ VER 01 / JUL 2011