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

2. Systems
Fuel Delivery System

3. 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

4. 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

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

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

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

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

9. 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

10. 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

11. FDM
Return Line Fuel
WORKING OF FUEL TANK

12. 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

13. 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

14. 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

15. FDM
Return Line Fuel
WORKING OF FUEL TANK

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

17. 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

18. 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

19. FUEL STORAGE AND FILLING SYSTEM
FDM
FUEL STORAGE AND FILLING SYSTEM

20. 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

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

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

23. In Car Repairs
Fuel Sender Unit Replacement

24. 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

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