SECTION 6C1 - ENGINE FUEL

Service Precaution

General Description

Fuel Metering

Fuel Filter

Fuel Filter and Associated Parts

Removal

Inspection

Installation

Inspection

In–Tank Fuel Filter

Fuel Pump Flow Test

Fuel Pump

Fuel Pump and Associated Parts

Removal

Installation

Fuel Pump Relay

General Description

Fuel Tank

Fuel Tank and Associated Parts

Removal

Installation

Fuel Tube / Quick – Connect Fittings

Precautions

Cautions During Work

Removal

Reuse of Quick–Connector

Assembling Advice

Fuel Gauge Unit

Fuel Gauge Unit and Associated Parts

Removal

Installation

Fuel Filler Cap

General Description

Inspection

Main Data and Specifications

Service Precaution

WARNING: IF SO EQUIPPED WITH 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.

HOLDENwill call out those fasteners that require 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 fasteners

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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When working on the fuel system, there are several

things to keep in mind:

• 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 gasoline engines are designed to use only unleaded

Legend

(1) Fuel Filler Cap

(2) Fuel Tank

(3) Rollover Valve

(4) Fuel Pump

(5) Fuel Filter

(6) Fuel Rail Right

(7) Right Bank

(8) Fuel Rail Left

(9) Left Bank

(10) Fuel Pressure Control Valve

(11) Common Chamber

(12) Duty Solenoid Valve

(13) Throttle Valve

(14) Canister

gasoline. Unleaded gasoline must be used for proper

emission control system operation.

Its use will also minimize spark plug fouling and extend

engine oil life. Using leaded gasoline 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 this fuel delivery system during normal driving

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 Mass Air Flow (MAF) sensor measures the quantity

and density of the air entering the engine, which will

vary with both engine load and vehicle speed. This

sensor generates a frequency signalcorresponding to

the flow of the air into the engine.The frequency signal

is then transmitted to the PCM.

With receipt of the signals sent from the MAF sensor,

ECT sensor etc., 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 correct amount of fuel is metered depending on

driving conditions.

Two interchangeable “O” rings are used on the injector

that must be replaced when the injectors are removed.

The fuel rail is attached to the top of the intake manifold

and supplies fuel to all the injectors.

Fuel is recirculated through the rail continually while the

engine is running. This removes air and vapors from the

fuel as well as keeping the fuel cool during hot weather

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 “Driveability and Emission” for more

information and diagnosis.

Fuel Filter

Fuel Filter 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“Driveability and Emission”.

1. Disconnect battery ground cable.

2. Remove Fuel filler cap(1).

3. Disconnect fuel hoses(2) from fuel filter on both

engine side and fuel tank side.

4. Fuel filter fixing bolt(3).

• Remove the fuel filter fixing bolt(3) on fuel filter

holder.

5. Remove fuel filter(4).

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.

Legend

(1) Fuel Filler Cap

(2) Fuel Hose

(3) Fuel Filter Fixing Bolt

(4) Fuel Filter

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.

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 self cleaning 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.

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CAUTION: Never generate sparks when connecting

a jumper wire.

If the measure value is out of standard, conduct the

pressure test.

Pressure test

For the pressure test to the fuel system, see Section

6E“Fuel Control System”.

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“Driveability and Emission”.

1.Disconnect battery ground cable.

2.Loosen fuel filler cap.

3.Drain fuel.

Tighten drain plug to the specified torque after

draining fuel.

Torque: 20 N·m (2.0 Kg·m/14 lb ft) — M8

4.Remove fuel tank assembly(1). Refer to “Fuel Tank

Removal” in this section.

5.Remove fuel pump (FP) assembly(2) fixing screws

and remove the FP assembly.

NOTE: After removing FP, cover fuel tank to prevent

any dust entering.

Installation

1.Install FP assembly(2).

2.Install fuel tank assembly(1). Refer to “Fuel Tank

Installation”.

3. Fill the tank with fuel and tighten fuel filler cap.

4. Connect battery ground cable.

Fuel Pump Relay

General Description

In order to control the FP operation, the FP relay is

provided. When the starter switch is turned to “ON”

position, the FP relay operates the FP for 2 seconds.

When it is turned to “START” position, the Power Train

Control Module (PCM) receives the reference pulse

from the Crankshaft Sensor and it operates the

relay, again causing the FP 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“Driveability and Emission”.

1. Disconnect battery ground cable.

2. Loosen fuel filler cap.

3. Drain fuel.

Tighten drain plug to the specified torque after

draining fuel.

Torque: 20 N·m (2.0 Kg·m/14 lb ft) — M8

4. Remove fender liner (1) of wheel well on rear right

side.

5. Fuel filler hose, air breather hose and evapo hose

(2).

6. Remove undercover fixing bolts on both sides and

remove under cover(3).

7. Disconnect two fuel tank wiring connectors(4) on

Legend

(1) Fender Liner

(2) Fuel Filler Hose and Air Breather Hose and

Evapo Hose

(3) Undercover

(4) Fuel Tank Wiring Connector

(5) Evapo Fuel Hose

(6) Fuel Feed Tube and Fuel Return Tube/Quick–

Connect Fittings

(7) Fuel Tank

front right side of tank.

8.Disconnect evapo fuel hose(5).

9.Disconnect fuel feed tube and fuel return tube(6).

NOTE: Handling of the fuel tube, be sure to refer “Fuel

Tube/Quick–Connect Fittings” in this section.

10. Remove fuel tank fixing bolts on both sides and

remove fuel tank(7).

Installation

1. Install fuel tank(7).

• Place a flange on right side of tank on the

bracket.

• Install a flange on left side on the bracket from the

bottom, and tighten bolts to the specified torque.

Torque: 36 N·m (3.7 Kg·m/27 lb ft)

2. Connect fuel feed tube and fuel return tube(6).

3. Connect evapo fuel hose(5).

4. Connect fuel tank wiring connector(4).

5. Install undercover(3).

6. Connect fuel filler hose, air breather hose and

evapo hose(2).

7. Install fender liner(1).

• Mount fender liner to the wheel well.

• Fill the tank with fuel and tighten fuel filler cap.

• Connect battery ground cable.

Fuel Tube / Quick – Connect 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 relieve the fuel pressure 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 removal of the delivery pipe (feeding fuel to the

engine), 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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3. For removal of the return pipe (returning fuel to the

tank), hold the pipe in one hand, and pull out the

connentor with the other hand while pressing the

square relieve button of the retainer, as illustrated.

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NOTE: 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 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.

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Reuse of Quick–Connector

(Delivery 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.

NOTE: 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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(Return Pipe)

• Replace the pipe and connector if scratch, dent or

crack is found.

• Remove mud or dust from the pipe and make sure

that the end including spool is free from defects, such

as scratch, rust, and dent, which may cause poor

sealability. If defective, replace with a new pipe.

• After cleaning the pipe, insert it straight into the

connector until it clicks. After it clicks, try pulling it out

to make sure that it is not drawn and is securely

locked.

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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 Gauge Unit

Fuel Gauge Unit 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“Driveability and Emission”.

1. Disconnect battery ground cable.

2. Loosen fuel filler cap.

3. Drain fuel.

Tighten drain plug to the specified torque after

draining fuel.

Torque: 20 N·m (2.0 Kg·m/14 lb ft) — M8

4. Wiring connector

• Disconnect wiring connector(1) from the unit.

5. Fuel gauge unit

• Remove the fixing screws, then the fuel gauge

unit(2).

NOTE: After removing fuel gauge unit, cover fuel tank

to prevent any dust entering

Installation

1. Fuel gauge unit(2).

2. Wiring connector(1).

• Connect the wiring connector to the fuel gauge

unit.

• Fill the tank with fuel and tighten fuel filler cap.

• Connect battery ground cable.

Legend

(1) Wiring Connector

(2) Fuel Gauge Unit

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 valves have

characteristics.

A defective valve, no valve at all or a valve with the

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

Main Data and Specifications

Torque Specification N·m (Kg·m/lbft)

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