SECTION 8A - FUEL SYSTEM
Service Precaution
General Description
Fuel Metering
Fuel Filter
Removal
Inspection
Installation
Inspection
In–Tank Fuel Filter
Fuel Pump Flow Test
Fuel Pump
Fuel Pump and Associated Parts
Removal
Installation
Fuel Tube / Quick – Connector Fittings
Precautions
Cautions During Work
Removal
Reuse of Quick–Connector
Assembling Advice
Fuel Pump Relay
General Description
Fuel Tank
Fuel Tank and Associated Parts
Removal
Installation
Fuel Gauge Unit
Removal and Installation
Fuel Filler Cap
General Description
Inspection
Main Data and Specifications
SERVICE PRECAUTION
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
HOLDE N will call out those f asten ers th at requir e a
replacement after removal. HOLDEN will also call
out the fasteners that require thread lockers or
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (Paints , greases,
or other corrosion inhibitors ) on threaded fast eners
or fastener joint interfaces. Generally, such
coatings adversely affect the fastener torque and
the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specifications.
Following these instructions can help you avoid
damage to parts and systems.
Techline
GENERAL DESCRIPTION
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Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(4) Fuel Pump and Sender Assembly
(5) Fuel Filter
(6) Fuel Rail Right
(7) Right Bank (Cyls # 1-3-5)
(8) Fuel Rail Left
(9) Left Bank (Cyls # 2-4-6)
(10) Fuel Pressure Regulator
(11) Common Chamber
(12) Cannister Purge Solenoid Valve
(13) Throttle Valve
(14) Canister
(15) Evap . Pipe
(16) 2 Way Val ve
CAUTION:
• Any time the fuel system is being worked on,
disconnect the negative battery cable except for
those tests where battery voltage is required.
• Always keep a dry chemical (Class B) fire
extinguisher near the work area.
• Replace all pipes with the same pipe and fittings that
were removed.
• Clean and inspect “O" rings. Replace if required.
• Always relieve the line pressure before servicing any
fuel system components.
• Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
• Adhere to all Notices and Cautions.
All petrol engines are designed to use only unleaded
gasoline. Unleaded petrol must be used for proper
emission control system operation.
Its use will also minimize spark plug fouling and extend
engine oil life. Using leaded petrol can damage the
emission control system and could result in loss of
emission warranty coverage.
All cars are equipped with an Evaporative Emission
Control System. The purpose of the system is to
minimize the escape of fuel vapors to the atmosphere.
FUEL METERING
The Powertrain Control Module (PCM) is in complete
control of thi s fue l de liv ery sy s tem du ri ng norm al dr iv in g
conditions.
The intake manifold function, like that of a diesel, is
used only to let air into the engine. The fuel is injected
by separate injectors that are mounted over the intake
manifold.
The Manifold Absolute Pressure (MAP) sensor
measures the changes in the intake manifold pressure
which result from engine load and speed changes,
which the MAP sensor converts to a voltage output.
This sensor generates the voltage to change
corresponding to the flow of the air drawn into the
engine.
The changing voltage is transformed into an electric
signal and provided to the PCM.
With receipt of the signals sent from the MAP sensor,
Intake Air Temperature sensor and others, the PCM
determines an appropriate fuel injection pulse width
feeding such information to the fuel injector valves to
effect an appropriate air/fuel ratio.
The Multiport Fuel Injection system utilizes an injection
system where the injectors turn on at every crankshaft
revolution. The PCM controls the injector on time so
that the co rrect a mount of fue l is m ete re d de pen din g o n
driving conditions.
Two interchangeable “O" rings are used on the injector
that must be replaced when the injectors are removed.
The fuel rail is a ttached to t he t op of the in take ma ni fol d
and supplies fuel to all the injectors.
Fuel is rec ir cul ated thr ou gh the r ail continuall y whi le the
engine is running. This removes air and vapors from the
fuel as well a s keeping the fuel c ool durin g hot weath er
operation.
The fuel pressure control valve that is mounted on the
fuel rail maintains a pressure differential across the
injectors under all operating conditions. It is
accomplished by controlling the amount of fuel that is
recirculated back to the fuel tank based on engine
demand.
See Section 6C1 “Driveability and Emission" for more
inform ati on and diagno si s.
FUEL FILTER
REMOVAL
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section 6C1 “Driveability and
Emission".
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1. Disconnect battery ground cable.
2. Remove Fuel filler cap(1).
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3. Disconnect fuel hoses(1) from fuel filter on both
engine side and fuel tank side.
4. Fuel filter fixing bolt(2).
• Remove the fuel filter fixing bolt(2) on fuel filter
holder.
5. Remove fuel filter(3).
INSPECTION
1. Replace the fuel filter if the fuel leaks from fuel filter
body or if the fuel filter body itself is damaged.
2. Replace the filter if it is clogged with dirt or
sediment.
3. Check the drain of receive rubber and if it is clogged
with dust, clean it up with air.
INSTALLATION
1. Install the fuel filter in the proper direction.
2. Install fuel filter holder fixing bolt.
3. Connect fuel hoses on engine side(1) and fuel tank
side(2).
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4. Install fuel filler cap
5. Connect the battery ground cable.
INSPECTION
After installation, start engine and check for fuel
leakage.
Legend
(1) Fuel Filler Cap
(2) Receiver Rubber Drain
Legend
(1) Fuel Hose
(2) Fuel Filter Fixing Bolt
(3) Fuel Filter
IN–TANK FUEL FILTER
The filter is located on the lower end of fuel pickup tube
in the fuel tank. It prevents dirt from entering the fuel
pipe and also stops water unless the filter is completely
submerged in the water. It is a selfcleaning type, not
requiring scheduled maintenance. Excess water and
sediment in the tank restricts fuel supply to the engine,
resulting in engine stoppage. In such a case, the tank
must be cleaned thoroughly.
FUEL PUMP FLOW TEST
If reduction of fuel supply is suspected, perform the
following checks.
1. Make sure that there is fuel in the tank.
2. With the engine running, check the fuel feed pipe
and hose from fuel tank to injector for evidence of
leakage. Retighten, if pipe or hose connection is
loose. Also, check pipes and hoses for squashing or
clogging.
3. Insert the hose from fuel feed pipe into a clean
container, and check for fuel pump flow rate.
4. Connect the pump relay terminals with a jumper
wire(1) as shown and start the fuel pump to
measure delivery.
140RX020
CAUTION: Never generate sparks when connecting
a jumper wire.
If th e meas ure v alue is ou t of s tandard, c onduct the
pressure test.
Pressure test
For the pressure test to the fuel system, see Section
6C1-83 “Fuel Control System Diagnosis".
Delivery Delivery
15 seconds 0.38 liters minimum
FUEL PUMP
FUEL PUMP AND ASSOCIATED PARTS
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REMOVAL
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section 6C1 “Driveability and
Emission".
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.
3. Support underneath of the fuel tank assembly (11)
with a lifter.
4. Remove fuel tank assembly(11). Refer to “Fuel Tank
Removal" in this section.
5. Remove Fuel Tube/Quick Connector (2).
NOTE: Handling of the fuel tube sure to refer “Fuel
Tube/Quick Connector Fittings" in this section.
6. Remove fuel pump and sender (FPAS) assembly (4)
fixing snap ring and remove the FPAS assembly.
NOTE: After removing pump assembly (4), cover fuel
tank to prevent any dust entering.
INSTALLATION
1. Install FPAS assembly(4).
2. Install Fuel Tube/Quick Connector (2).
NOTE: Handling of the fuel tube sure to refer “Fuel
Tube/Quick Connector Fittings" in this section.
3. Install fuel tank assembly(11). Refer to “Fuel Tank
Installation".
4. Fill the tank with fuel and tighten fuel filler cap.
5. Connect battery ground cable.
Legend
(1) Fuel Feed Port
(2) Fuel Tube/Quick Connector
(3) Fuel Return Port
(4) Fuel Pump and Sender Assembly
(5) Connector; Fuel Feed Pump
(6) Connector; Fuel Level Sensor
(7) Snap Ring
(8) Hose; Evaporative Fuel
(9) Hose; Air Breather
(10) Hose; Fuel Filler
(11) Fuel Tank Assembly
FUEL TUBE / QUICK – CONNECTOR FITTINGS
PRECAUTIONS
• Lighting of Fires Prohibited.
• Keep flames away from your work area to prevent the
inflammable from catching fire.
• Disconnect the battery negative cable to prevent
shorting during work.
• When welding or conducting other heat-generating
work on other parts, be sure to provide pretreatment
to protect the piping system from thermal damage or
spattering.
CAUTIONS DURING WORK
Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spilt
battery electorolyte.
The piping wet with battery electrolyte cannot be used.
Be careful not to give a bending or twisting force to the
piping during the work. If deformed, replace with a new
piping.
REMOVAL
1. Open the fuel cap to reliev e the fuel press ure in the
tank.
If the fuel quick-connect fittings are dusty, clean with
an air blower, etc. and then remove it.
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As some pressure may remain in the piping, cover
the connector with a cloth, etc. to prevent the
splashing of fuel in the first disconnection of the
piping.
2. For rem oval of the deliv ery pipe (feeding fuel to the
engine), and return pipe (returning fuel to the tank)
hold the connector in one hand, and hold the
retainer tab with the other hand and pull out the
connector, as illustrated. The pipe can be removed
with the retainer attached.
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This work should be done by hands. Do not use any
tools. Should the pipe can hardly be removed from the
connector, use a lubricant (light oil) and/or push and pull
the connector longitudinally until the pipe is removed.
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When reusing the delivery and return pipe retainer,
reuse without removing the retainer from the pipe. If
the retainer is damaged or deformed, however,
replace with a new retainer.
Cover the connectors removed with a plastic bag,
etc. to prevent the entry of dust or rain water.
141R100006
REUSE OF QUICK–CONNECTOR
(Delivery Pipe and Return Pipe)
• Replace the pipe and connector if scratch, dent or
crack is found.
• Remove mud and dust from the pipe and make sure
that the end including spool is free of defects, such as
scratch, rust, and dent, which may cause poor
sealability. If defective, replace with a new pipe.
• If the retainer removed according to the removal step
above is attached to the pipe, clean and insert it
straight into the quick-connector till it clicks. After it
clicks, try pulling it out to make sure that it is not
drawn and is securely locked.
The retainer, once removed from the pipe, cannot be
reused. Just replace with a new retainer. Insert the new
retainer into the connector side until it clicks, and
connect the pipe as inserting it into the retainer until it
clicks.
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ASSEMBLING ADVICE
Application of engine oil or light oil to the pipe facilitates
connecting work. The work should be started
immediately after lubrication, since dust may stick to the
pipe surface to cause poor sealability if a long time
passes after lubrication.
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Turn the ignition key to the “ON" position and check
pump startup sound. As the pump is actuated to
raise fuel pressure, check and see fuel leak from the
piping system.
3. Make sure of no fuel leakage by conducting the
above fuel leak check a few times.
4. Start the engine and make sure of stable idling
speed and normal vehicle run.The entry of dust
during the work may sometimes affect the fuel
injection system.
FUEL PUMP RELAY
GENERAL DESCRIPTION
In order to control the FPAS operation, the FPAS relay
is provided. When the starter switch is turned to “ON"
position, the FPAS relay operates the FPAS for 2
seconds.
When it is turned to “START" position, the Engine
Control Module receives the reference pulse from the
Ignition Control Module and it operates the relay, again
causing the FPAS to feed fuel.
FUEL TANK
FUEL TANK AND ASSOCIATED PARTS
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REMOVAL
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section 6C1 “Driveability and
Emission".
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.
3. Support underneath of the fuel tank protector (15)
with a lifter.
4. Disconnect evaporative fuel hose (3) at the canister.
5. Discon nect fuel feed hos e (17) and fuel retur n hose
(18) near the fuel filter.
NOTE: Plug both ends of the fuel h os es to pr ev en t f uel
leakage.
6. Discon nect air b reather hos e (4) and fuel filler hose
(5) at the fuel filler neck.
NOTE: Cover fuel hose to prevent any dust entering.
7. Remove the four fuel tank assembly fixing bolts (14)
at four corners of the tank.
8. Let down the tank and disconnect the wiring
connectors (8,9).
Legend
(1) Roll Over&Float Valve
(2) Retaining Cover
(3) Hose; Evaporative Fuel
(4) Hose; Air Breather
(5) Hose; Fuel Filler
(6) Bolt; Fuel Tank Protector Fixing
(7) Snap Ring
(8) Connector; Fuel Level Sensor
(9) Connector; Fuel Feed Pump
(10) Fuel Pump and Sender Assembly
(11) Fuel Feed Port
(12) Fuel Tube/Quick Connector
(13) Fuel Return Po rt
(14) Bolt; Fuel Tank Asm. Fixing
(15) Protector; Fuel Tank
(16) Fuel Tank Assembly
(17) Hose; Fuel Feed
(18) Hose; Fuel Return
(19) Protect or; Heat
Techline
9. Remove fuel tank assembly along with protectors
(15,19) .
10. Remove retaining cover (2) and roll over & float
valve (1) along with the evaporative fuel hose and
pipe (3).
11. Remove Fuel Tube/Quick Connector (12).
NOTE: Handling of the fuel tube sure to refer “Fuel
Tube/Quick Connector Fittings" in this section.
12. Remove fuel pump and sender assembly (10) by
removing the snap ring (7) along with the fuel hoses
(17,18).
13. Remove protectors (15,19) by removing the six
fixing bolts (6).
INSTALLATION
1. Install protectors (15,19) and tighten the six fixing
bolts to the specified torque.
Torque: 69 N·m
2. Install fuel pump and sender assembly by fitting in of
the snap ring (7).
3. Install Fuel Tube/Quick connector (12).
NOTE: Handling of the fuel tube sure to refer “Fuel
Tube/Quick Connector Fittings" in this section.
4. Install roll over & float valve (1) by fitting in of the
retaining cover (2).
5. Lift up fuel tank assembly and connect the wiring
connectors (8,9).
6. Install fuel tank assembly along with protectors and
tighten the four fixing bolts to the specified torque.
Torque: 69 N·m
7. Connect fuel filler hose (5) and air breather hose
(4), and clip them firmly.
8. Connect fuel feed hose (17) and fuel return hose
(18), and clip them firmly.
9. Connect evaporative fuel hose (3).
10. Tighten fuel filler cap.
11. Connect battery ground cable.
FUEL GAUGE UNIT
REMOVAL AND INSTALLATION
As for removal and installation of the Fuel Gauge Unit,
refer to “Fuel Tank" of this section 8A as the fuel gauge
unit is combined with the fuel pump and sender
assembly.
FUEL FILLER CAP
GENERAL DESCRIPTION
Fuel filler cap includes vacuum valve and pressure
valve.
In case any high vacuum and any high pressure happen
in tank, each valve works to adjust the pressure to
prevent the tank from being damaged.
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INSPECTION
Check the seal ring in the filler cap for presence of any
abnormality and for seal condition.
Replace the filler cap, if abnormal.
CAUTION:
The fuel filler cap valve has characteristics.
A defective valve, no valve at al l or a valve with th e
wrong characteristics will do a lot of harm to engine
operating characteristics; be sure to use the same
fuel filler cap as installed in this vehicle.
Legend
(1) Vacuum Valve
(2) Pressure Valve
(3) Seal Ring
MAIN DATA AND SPECIFICATIONS
Torque Specification
N·m (kg·m/lbft)
140RY00018