Fuel Supply Component Description. Pontiac Bonneville 2000

For 1990-2009 cars only

Makes 🢒 Pontiac 🢒 2000 🢒 Bonneville 🢒 Engine 🢒 Engine Controls - 3.8L 🢒 Fuel Supply Component Description

Caution: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to the Cautions in the On-Vehicle Service and the SIR Component and Wiring Location view in the Supplemental Inflatable (SIR) System before any performing service on or around SIR components or wiring. Failure to follow the Cautions could result in possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs.

Notice: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application.

The applicable service procedure will identify, where necessary, those fasteners that must be replaced after removal; or those fasteners that require the use of thread locking compound 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.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Fuel Supply Components (VIN K)


(1)	In-Line Fuel Filter
(2)	Fuel Feed Pipe
(3)	In-Tank Fuel Pump
(4)	Fuel Return Pipe
(5)	Fuel Pressure Gauge
(6)	Fuel Rail Assembly
(7)	Fuel Pressure Regulator
(8)	Fuel Pipe Shut-Off Adapters

Fuel Supply Components (VIN 1)


(1)	In-Line Fuel Filter
(2)	Fuel Feed Pipe
(3)	In-Tank Fuel Pump
(4)	Fuel Return Pipe
(5)	Fuel Rail Assembly
(6)	Fuel Pressure Regulator
(7)	Fuel Pressure Gauge
(8)	Fuel Pipe Shut-Off Adapters

General Description

The fuel supply is stored in the fuel tank. An electric fuel pump (3), attached to the fuel sender inside the fuel tank pumps fuel through an in-line filter (1) to the fuel injection system. The fuel pump is designed to provide fuel at a pressure above the regulated pressure needed by the fuel injectors. A fuel pressure regulator keeps fuel available to the fuel injectors at a regulated pressure. Unused fuel is returned to the fuel tank by a separate pipe (4). For further information on the fuel injection system, refer to Fuel Metering System Component Description .

Unleaded fuel must be used with all gasoline engines for proper emission control system operation. Using unleaded fuel also decreases spark plug fouling and extends the life of the engine oil. The use of leaded fuel can damage the emission control system, and can result in cancellation of the emission warranty coverage.

All vehicles with gasoline engines are equipped with an evaporative emission system that minimizes the escape of fuel vapors into the atmosphere. For information regarding this system, refer to: Evaporative Emission Control System Diagnosis

On-Board Refueling Vapor Recovery System (ORVR)

The on-board refueling vapor recovery (ORVR) system is used to recover fuel vapors during the vehicle re-fueling operation. The flow of liquid fuel down to the fuel tank filler neck provides a liquid seal. The purpose of the ORVR system is to prevent re-fueling vapors from exiting the fuel tank filler neck.

The ORVR components include:

The fuel tank which contains the modular fuel sender, the fuel limiter vent valve, and 3 rollover valves.
The fuel filler pipe, which carries fuel from the fuel nozzle to the fuel tank.
The EVAP canister receives refueling vapor from the fuel system, stores the vapor, and releases the vapor to the engine upon demand.
The vapor lines transport fuel vapor from the tank assembly to the EVAP canister.
The check valve limits fuel "spit-back" from the fuel tank during the refueling operation by allowing the fuel to flow only into the fuel tank. This check valve is located at the bottom of the fuel filler pipe.
The modular fuel sender assembly pumps fuel to the engine from the fuel tank.
The fill limiter vent valve acts as a shut-off valve located in the fuel tank and has the following functions:

•	Controls the fuel tank fill level by closing the primary vent from the fuel tank.

•	Prevents fuel from exiting the fuel tank via the vapor line to the canister.

•	Provides fuel-spillage protection in the event of a vehicle rollover by closing the vapor path from the tank to the EVAP canister.

The pressure/vacuum relief valve provides venting of excessive fuel tank pressure and vacuum. The valve is located in the fuel filler neck on a plastic fuel tank.
The vapor recirculation line is used to transport vapor from the fuel tank to the top of the fill pipe during the refueling in order to reduce vapor loading of the enhanced EVAP canister.
The variable orifice valve regulates the amount of vapor allowed to enter the vapor recirculation line.

Fuel Tank

The fuel tank is used to store fuel for the vehicle. The tank is located in the rear of the vehicle and is held in place by 2 straps that are attached to the underbody. The fuel tank is made of plastic and is coated internally with a special corrosion inhibitor. Due to the internal coating of the fuel tank, the fuel tank is not repairable. The fuel tank shape includes a reservoir in order to maintain a constant supply of fuel around the fuel pump strainer during low fuel conditions and aggressive vehicle maneuvers.

The tank also contains a fuel vapor vent valve with roll-over protection. The vent valve also features a 2-phase vent calibration which increases fuel vapor flow to the canister when operating temperatures increase the tank pressure beyond an established threshold.

The fuel tank contains 3 rollover valves that prevents fuel from entering the fuel pipes in the event of a vehicle rollover. The rollover valves are not repairable.

Fuel Tank Filler Pipe


(1)	Fuel Tank Filler Pipe
(2)	Fuel Tank Filler Pipe Clamp
(3)	Fuel Tank

The fuel tank filler pipe carries dispensed fuel from the fuel nozzle to the fuel tank.

In order to prevent refueling with leaded fuel, the fuel tank filler pipe has a built-in restrictor and deflector.

A fuel tank filler pipe check-valve is attached to the fuel tank filler pipe and extends from the fuel tank inlet to the reservoir. The fuel tank filler pipe check-valve is located inside the fuel tank filler pipe check-valve tube and prevents fuel from splashing back out of the fuel tank filler pipe during re-fueling.

Fuel Tank Filler Pipe Cap

Notice: If a fuel tank filler pipe cap requires replacement, use only a fuel tank filler pipe cap with the same features. Failure to use the correct fuel tank filler pipe cap can result in a malfunction of the fuel system. A loose or incorrect fuel tank filler pipe cap can set a DTC.

The fuel tank filler pipe is equipped with a screw-type fuel tank filler pipe cap. A built-in ratchet-type torque limiting device prevents overtightening. In order to install the cap, the cap must be turned clock-wise until a clicking noise is heard. This signals that the correct torque has been reached and the cap is fully seated. A fuel filler cap that is not fully seated can cause a malfunction in the emission system.

The fuel tank filler pipe cap has a pressure relief and vacuum relief. The fuel tank filler pipe cap has a tether connected to the fuel tank filler pipe.

Modular Fuel Sender Assembly


(1)	Fuel Tank Pressure Sensor
(2)	Fuel Pipes
(3)	Fuel Pump
(4)	External Fuel Sender Strainer
(5)	Fuel Level Sensor Assembly
(6)	Fuel Sender Cover

The modular fuel sender assembly is attached to the top of the fuel tank, and extends from the top of the fuel tank to the bottom.

The modular fuel sender assembly consists of the following major components:

•	The fuel sender cover assembly

•	The fuel pipes above the cover

•	The fuel pump

•	The fuel pump strainer

•	The fuel pump reservoir

•	The external fuel sender strainer

•	The fuel level sensor assembly

•	The fuel tank pressure sensor

The fuel level sensor assembly consists of the float, the wire float arm, and the rheostat. The fuel level is determined by the position of the float and the float arm, which operate the rheostat. As the float position changes, the amount of current passing through the rheostat varies, thus changing the gauge reading on the instrument panel.

The modular fuel sender assembly mounts to the opening of the plastic fuel tank. The design provides:

•	Optimum fuel level in the integral fuel reservoir during all fuel tank levels and driving conditions.

•	Improved accuracy of the tank fuel level measuring.

•	Improved coarse straining and added pump inlet filtering.

•	More extensive internal fuel pump isolation for noiseless operation.

Fuel Sender Fuel Flow


(1)	Fuel Feed
(2)	Fuel Return
(3)	Convoluted Fuel Tube (Flex Pipe)
(4)	Secondary Umbrella Valve
(5)	External Fuel Pump Strainer
(6)	Fuel Flow from External Strainer
(7)	Fuel Pump Strainer
(8)	Fuel Pump

The modular fuel sender assembly maintains an optimum fuel level in the reservoir. Fuel entering the reservoir is drawn through the external strainer or the umbrella valve, or through the return fuel pipe whenever the level of fuel is below the top of the reservoir.

The fuel pump used in this system is part of the fuel sender assembly. The lower connector assembly of the fuel pump prevents the transmission of vibrations generated by the pump to the fuel tank.

Fuel enters the secondary umbrella valve located inside of lower inlet port of the fuel pump after being filtered by the external fuel strainer and the fuel pump strainer. The initial function of the pump is to fill the reservoir.

The second stage separates the vapor from the fuel in the pump. This vapor separation maximizes hot fuel handling and permits the vapor to return to the fuel tank at lower pressure and temperature. By creating positive fuel pressure, the pump then discharges the liquid fuel into the third stage of the pump. The pump outlet allows the fuel volume to flow through a check valve into the fuel pump flex pipe. The check valve seat is molded inside the connector body. The check valve body and retainer are assembled into the connector body. The check valve restricts fuel back flow.

After the fuel pump flex pipe, the fuel exits the assembly through the fuel feed output fitting on the molded cover. The cover also contains a fuel return provision which connects to one of 3 hollow support pipes.

Quick-connect pipe end fittings are molded onto the cover of the modular unit for ease of unit removal from the fuel tank. These quick-connect end fittings allow fuel feed and fuel return.

The electrical power to the fuel pump enters the unit by way of a connector which is attached to the cover. An internal wire harness and connector assembly connects to the fuel pump and the fuel level sensor. The modular design adds additional functions that improve accuracy and ensure a constant, steady fuel supply under all conditions. All components and subassemblies of the modular sender attach to a common cover and enter the fuel tank through a single opening. The modular fuel sender assembly is spring loaded to the bottom of the fuel tank. This bottom referencing permits continuous fuel pickup and accurate fuel level sensing. The reservoir assembly is the lower section of the modular unit which encases the fuel pump. A retainer attaches to the top of the reservoir. The fuel is captured and maintained in the reservoir at a level sufficient to submerge the fuel pump.

Fuel Tank Vapor Pressure Sensor

The fuel tank pressure sensor is used to detect small leaks in the evaporative emission system. The fuel tank pressure sensor is a 3-wire strain gauge sensor much like that of the common MAP sensor. However, this sensor has very different electrical characteristics due to a pressure differential design. The sensor measures the difference between the air pressure or vacuum in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel tank. A 3-wire electrical harness connects the sensor to the powertrain control module (PCM). The PCM supplies a 5 volt reference voltage and a ground to the sensor. The sensor returns a voltage between 0.1 and 4.9 volts. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel fill cap is removed, the output voltage of the sensor is 1.3 to 1.7 volts. Refer to Evaporative Emission Control System Diagnosis for further information and diagnosis of the enhanced EVAP system.

Enhanced Evaporative Emission (EVAP) Service Port

The enhanced EVAP service port is located in the evaporative purge hose located between the purge solenoid and the EVAP charcoal canister. The service port is identified by a green colored cap. The port contains a Schrader valve and fittings to allow the connection of the J 41413 evaporative pressure/purge diagnostic system. Refer to Evaporative Emission Control System Diagnosis for further information and diagnosis of the enhanced EVAP system.

External Fuel Sender Strainer


(1)	External Fuel Sender Strainer

The function of the fuel sender strainer is filter contaminants and to wick fuel.

The life of the fuel sender strainer is generally considered to be that of the fuel sender. The fuel sender strainer is self-cleaning, and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water, in which case the tank should be thoroughly cleaned. Refer to Fuel System Cleaning . If the fuel sender strainer is plugged, replace the strainer.

Fuel Level Sensor Assembly

The fuel sender assembly consists of the float, the wire float arm, and the ceramic resistor card. The fuel level sensor is mounted on the modular fuel sender assembly, and is located in series with the voltage supply circuit from the PCM. As the position of the float varies with the fuel level, the ceramic resistor card produces variable resistance between the PCM and ground. The PCM uses the variable resistance in order to calculate the expected vapor pressures within the fuel system. The vapor pressure is critical in determining if the EVAP system is operating properly. The PCM also uses the variable resistance in order to indicate the actual fuel level to the fuel level gauge. The fuel level gauge is controlled by the instrument panel cluster (IPC). The IPC receives fuel level information from the PCM through the Class 2 communication circuit.

In-Line Fuel Filter


(1)	Fuel Filter Housing
(2)	Fuel Filter Element

A fuel filter is used in the fuel feed pipe ahead of the fuel injection system. The fuel filter is mounted on the right side of the underbody. The fuel filter housing is constructed of steel with a quick-connect fitting at the inlet of the fuel filter and a threaded fitting at the outlet of the fuel filter. The filter element is made of paper and is designed to trap particles suspended in the fuel that may damage the injection system.

There is no service interval for in-line fuel filter replacement. Only replace the in-line fuel filter if the filter is restricted.

Nylon Fuel Pipes

Caution: In order to reduce the risk of fire and personal injury observe the following items:

•	Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes

•	Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak.

•	Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period.

•

Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.)

Nylon fuel pipes are designed to perform in the same manner as the steel or flexible fuel pipes or hoses. Nylon fuel pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are 2 sizes used: 3/8 inch ID for the fuel feed pipe, and 5/16 inch ID for the fuel return pipe.

The fuel feed and fuel return pipes are assembled as a harness. Retaining clips hold the fuel pipes together and provide a means for attaching the fuel pipes to the vehicle. Sections of the fuel pipes that are exposed to chafing, high temperature, or vibration are protected with heat resistant rubber hose and/or corrugated plastic conduit.

Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, the pipes are if forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon fuel pipes may become stiffer and are more likely to kink if bent too far. Special care should be taken when working on a vehicle with nylon fuel pipes.

Quick-Connect Fittings

Caution: In order to reduce the risk of fire and personal injury observe the following items:

•	Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes

•	Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak.

•	Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period.

•

Quick-connect type fittings provide a simplified means of installing and connecting fuel system components. Depending on the vehicle model, 2 types of quick-connect fittings are used at different locations in the fuel system. Each type of quick-connect fitting consists of a unique female connector and a compatible male fuel pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs hold the quick-connect fittings together.

Fuel Feed and Fuel Return Pipes

The fuel feed and fuel return pipes carry fuel from the fuel sender assembly to the fuel injection system and back to the fuel sender assembly.

Roll-Over Valve

The roll-over valve is pressed into the EVAP pipe of the fuel sender and is not serviced separately. The roll-over valve prevents fuel from entering the engine compartment if the vehicle rolls over by closing the EVAP pipe to the evaporative emission canister.

Fuel Pump

The fuel pump is mounted in the modular fuel sender, inside the fuel tank. The fuel is pumped to the engine at a specified flow and pressure through the fuel pump. Excess fuel is returned to the fuel tank by a return pipe.

The fuel pump delivers a constant flow of fuel to the engine even during low fuel conditions and aggressive vehicle maneuvers. The electric fuel pump operation is controlled by the powertrain control module (PCM) through a fuel pump relay. The fuel pump is not serviceable. Refer to Fuel Metering System Component Description and for further description and a wiring diagram of the fuel pump relay.

A fuel pump strainer is attached to the lower end of the fuel pump in the fuel tank. The fuel pump strainer is designed to filter contaminants and to wick fuel.

The life of the fuel pump strainer is generally considered to be the same as that of the fuel pump. The fuel pump strainer is self-cleaning. The fuel pump strainer cannot be replaced. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water, in which case the tank should be thoroughly cleaned, refer to Fuel System Cleaning .

Fuel Pump Relay VIN K

When the ignition switch is turned on, and before engaging the starter, the PCM energizes the fuel pump relay for 2 seconds, causing the fuel pump to pressurize the system. If the PCM does not receive ignition reference pulses within 2 seconds the fuel pump relay is shut off, causing the fuel pump to stop. Refer to Fuel Pump Electrical Circuit Diagnosis .

Fuel Pump Relay VIN 1

When the ignition switch is first turned on, and before engaging the starter, the PCM energizes the fuel pump relay which applies power to the fuel pump control module (VIN 1). The PCM sends a signal based on the engine fuel demand to the fuel pump control module in order to change the control module's voltage output. The fuel pump will then pressurize the fuel system. The fuel pump relay remains on as long as the engine is running or cranking and the PCM is receiving reference pulses. If reference pulses are not present, the PCM de-energizes the fuel pump relay within 2 seconds of the ignition turning on. During high engine load situations the PCM commands the fuel pump to run at high speed. Refer to Fuel Pump Electrical Circuit Diagnosis for further description and diagnosis of the fuel pump electrical circuit.

Fuel Pump Control Module (VIN 1 only)

The L67 supercharged engine utilizes a 2-speed fuel pump control module. The fuel pump control module is located on the wheel house flange in the trunk. The fuel pump control module controls the fuel pump output depending on the MAP sensor input received by the PCM.

EVAP Pipes

The EVAP pipes are made of nylon and carry vapors from the fuel sender assembly, the fuel tank, and the EVAP components to the EVAP canister.