SECTION 6C - ENGINE FUEL
General Description
Service Precaution
Fuel Metering
Fuel Filter
Fuel Filter and Associated Parts
Removal
Inspection
Installation
Inspection
In-Tank Fuel Filter
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 Gage Unit
Removal and Installation
General Description
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
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.
Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application.Holden will 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.
Fuel Metering
Engine Control Module (ECM) 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 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 ECM.
With receipt of the signals sent from the MAP sensor, Intake
Air Temperature sensor and others, the ECM 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
ECM 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
(2.2L & 2.0L Models)
(2.4L Model)
Legend
1 Fuel Hose
2 Fuel Filter
3 Fixing bolt
Legend
1 Fuel Hose
2 Quick Connector
3 Fuel Filter
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connections or leakage. For the fuel system
diagnosis, see Section "Driveability and Emissions".
(2.2L & 2.0L)
1. Disconnect battery ground cable.
2. Remove fuel filler cap.
3. Loosen the fixing bolt and disconnect fuel hoses (1).
4. Remove fuel filter (2).
(2.4L)
1. Disconnect battery ground cable.
2. Disconnect the quick connector from the fuel filter.
3. Pull off fuel filter from the holder to side member side.
4. Remove the fuel filter.
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 and if it is clogged with dust, clean it out
with air.
Installation
(2.2L & 2.0L)
1. Install the fuel filter in the proper direction.
2. Install fuel filter holder fixing bolt.
3. Connect fuel hoses on engine side and fuel tank side.
4. Install fuel filler cap
5. Connect the battery ground cable.
(2.4L)
1. Install the fuel filter.
2. Install the quick connectors.
3. 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 the 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 stop. In such a
case, the tank must be cleaned throughly.
Fuel Pump
Fuel Pump and Associated Parts
Legend
1 Fuel Feed Port
2 Fuel Return Port
3 Fuel Emission Port
4 Fuel Pump and Sender Assembly
5 Connector ; Fuel Feed Pump & Sender
6 Fuel Tube / Quick Connector
7 Retainer (Fuel Pump Lock)
8 Seal ; Fuel Pump
9 Fuel Tank Assembly
(2.4L Model)
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 “Driceability and Emission”.
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.
3. Support underneath of the fuel tank assembly (2) with a
lifter.
4. Remove fuel tank assembly (2). Refer to “Fuel Tank
Removal” in this section.
5. Remove fuel pump and sender (FPAS) assembly (1) fixing
snapring and remove the FPAS assembly.
NOTE:
• After removing pump assembly (1), cover fuel tank to
prevent any dust entering.
• Remove the fuel pump lock.
Installation
1. Install FPAS assembly (1).
2. Install fuel tank assembly (2). Refer to “Fuel Tank
Installation”.
3. Fill the tank with fuel and tighten fuel filler cap.
4. Connect battery ground cable.
Fuel Tube/Quick-Connector Fittings
Precautions
•Do not light a match or create a flame.
•Keep flames away from your work area to prevent
flammable materials from catching fire.
•Disconnect battery ground cable to prevent electrical shorts.
•Pre-treat piping system or associated parts from thermal
damage or from spattering when welding or similar heat-
generating work.
Legend
(1) O-ring
(2) Port
(3) Connector
(4) Plastic Tube
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
electrolyte.
Piping that has been splattered with battery electrolyte or
battery electrolyte soaked cloth that was wiped on the piping
cannot be used.
Removal
1. Open the fuel cap to relieve the fuel pressure in the tank.
Use compressed air to remove any dirt on the fuel quick
connect fittings prior to disconnecting the fittings.
When disconnecting the fuel pipe, cover the area with a
cloth to prevent fuel from splashing as the fuel pipe may still
have some pressure in it.
2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connector with the
other hand while pressing the square relieve button of the
connector, as illustrated.
NOTE: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light oil)
and/or push and pull the connector until the pipe is
disconnected.
Cover the connectors that was removed with a plastic bag,
to prevent dust or rain water from entering.
Reuse of Quick-Connector
•Replace the port and connector if scratch, dent or crack is
found.
•Remove any dirt build up on the port when installing the
connector. Replace the connector, if there is any forms of
rust, dent, scratch.
•After cleaning the port, insert it straight into the connector
until it clicks. After it clicks, try pulling at 49N (5kgf) it out to
make sure that it is not drawn and is securely locked.
Assembling Advice
By applying engine oil light oil to the pipe, port makes pipe
assembly easier. The pipe assembly should take place
immediately after applying oil (to prevent dust from sticking to
the pipe surface-which may decrease sealing ability).
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Turn the ignition key to the “ON” position and listen for
pump start-up sound. Inspect for leaks, the fuel pressure
will increase as the fuel pump is actuated.
3. Perform leak inspection (step 2) several times.
4. Start the engine and observe the engine idle speed. The
presence of dirt in the fuel system may 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
Legend
1 Roll Over&Float Valve (If applicable)
2 Hose; Evaporative Fuel (If applicable)
3 Hose; Air Breather
4 Hose; Fuel Filter
5 Fuel Pump and Sender Assembly
6 Fuel Tank Assembly
7 Hose; Fuel Delivery
8 Hose; Fuel Return
(2.4L Model)
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.Support underneath of the fuel tank protector with a lifter.
4.Disconnect evaporative fuel hose at the canister.
5.Disconnect fuel delivery hose and fuel return hose near the
fuel filter.
NOTE: Plug both ends of the fuel hoses to prevent fuel
leakage.
6.Disconnect air breather hose (3) and fuel filler hose (4) at
the fuel filler neck.
NOTE: Cover fuel hose to prevent any dust entering.
7.Remove the four fuel tank assembly fixing bolts at four
corners of the tank.
8.Let down the tank and disconnect the wiring connectors
and the emission hose at the emission port on the fuel
pump and sending assembly (5).
9.Remove fuel tank assembly along with protectors.
10.Remove roll over&float valve (1) along with the evaporative
fuel hose and pipe (2).
11.Remove fuel pump and sender assembly (5) by removing
the snap ring along with the fuel hoses (7, 8).
12.Remove tank protector by removing the fixing bolts.
Installation
1. Install protectors and tighten the fixing bolts to the
specified torque.
Torque; 68 N⋅
⋅⋅
⋅m (6.9 kgf⋅
⋅⋅
⋅m)
2. Install fuel pump and sender assembly by fitting in the snap
ring.
3. Install roll over&float valve (1).
4. Lift up fuel tank assembly and connect the emission hose
to the emission port and the wiring connectors on the fuel
pump and sending assembly (5).
5. Install fuel tank assembly along with protectors and tighten
the four fixing bolts to the specified torque.
Torque: 68 N⋅
⋅⋅
⋅m (6.9 kgf⋅
⋅⋅
⋅m)
6. Connect fuel filler hose (4) and air breather hose (3), and
clip them firmly.
7. Connect fuel delivery hose (7) and fuel return hose (8), and
clip them firmly.
8. Connect evaporative fuel hose (2).
9. Tighten fuel filler cap.
10. Connect battery ground cable.
Fuel Gage Unit
Removal and Installation
As for removal and installation of the Fuel Gauge Unit, refer to
"Fuel Tank" of this section 6C as the fuel gauge unit is
combined with the fuel pump and sender assembly.
(2.4L Model)
Legend
1 Vacuum Valve
2 Pressure Valve
3 Seal Ring
Fuel Filler Cap
General Description
Fuel filler cap includes vacuum valve.
In case any high vacuum happen in tank, the valve works to
adjust the pressure to prevent the tank from being damaged.
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 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.
Fuel Filter
Removal and Installation
Removal
1. Inlet and outlet fuel hose
2. Fuel filter
Installation
2. Fuel filter
1. Inlet and outlet fuel hose
Important Operations - Removal
1. Inlet and Outlet Fuel Hose
Use a rag to prevent the fuel from flowing from the fuel hoses.
NOTE:
Immediately plug the fuel hoses.
Do not work in close proximity to sparks or an open flame.
Important Operations - Installation
1. Fuel Filter
1) Install the fuel filter to the fuel pump in the direction
indicated by the arrow stamped on the side of the fuel filter.
2) Start the engine.
Check for fuel leakage from the fuel hose joints.
(2.4L Model)
Main Data and Specification
Torque Specification
N⋅m (kgf⋅m)
Installation
To install, follow the removal steps in the reverse order.
Removal
1.Fuel hose (Delivery)
2.Fuel hose(Return)
3.Evapo fuel hose
4.Breather hose
5.Fuel filler hose
6.Fuel Pump
7.Fuel tank
8.Roll over valve
Fuel Tank
Removal and Installation
Removal
Preparation
•Disconnect battery ground cable.
•Loosen fuel filler cap.
•Drain fuel.
Tighten drain plug to the specified torque after drain fuel.
N⋅m (kgf⋅m)
20 (2.0)
NOTE:
Cover fuel hose with waste to prevent any dust entering.
Installation
7. Fuel Tank
•Tighten fuel tank bolt.
N⋅m (kgf⋅m)
26.5 (2.7)