Fuel Supply Component Description. Geo Metro 1997

For 1990-2009 cars

### Fuel Tank

(1) | Fuel Tank Pressure (FTP) Sensor, if equipped
(2) | Fuel Level Sensor
(3) | Fuel Pump Assembly
(4) | Fuel Breather Hose
(5) | Fuel Filler Cap
(6) | Filler Neck Protector
(7) | Fuel Return Line
(8) | Fuel Feed Line
(9) | Fuel Filter
(10) | Fuel Vapor Lines
(11) | Fuel Tank Protector
(12) | Fuel Cut Valve
(13) | Fuel Tank
(14) | Fuel Vapor Separator
(15) | Fuel Return Volume

The fuel tank is used to store fuel for the vehicle. The fuel tank has a 40 liter (10.6 gallon) fuel capacity. The tank is molded from steel and is located in front of the rear wheels below the rear seat. The tank is held in place with five bolts. The tank's shape allows for a constant supply of fuel around the fuel pump strainer during low fuel conditions and also during aggressive vehicle maneuvers.

### Fuel Tank Filler Neck

In order to prevent refueling with leaded fuel, the fuel filler neck has a built-in restrictor and deflector. The opening of the restrictor only admits the smaller unleaded fuel nozzle. The nozzle must be fully inserted to bypass the deflector. Any attempt at refueling with leaded fuel will result in fuel splashing out of the filler neck.

### Fuel Filler Cap

(1) | Vacuum Relief Valve
(2) | Pressure Relief Valve
(3) | Gasket

Important: Replace the fuel filler cap with a cap that meets OEM specifications. Failure to use the correct fuel filler cap can result in the incorrect operation of the fuel delivery system.

The fuel filler cap is a pressure-vacuum type. A built-in torque-limiting device prevents over tightening and also eliminates the escape of fuel vapors. To install, turn the cap clockwise until a clicking noise is heard. This indicates that the cap is fully seated.

A vacuum relief valve is incorporated into the fuel filler cap. If the pressure in the fuel tank becomes negative (vacuum), the relief valve opens in order to relieve the pressure created within the fuel tank. Only when vacuum becomes excessive within the tank does this occur. Vacuum pressure is also vented through the tank pressure control valve which is located next to the EVAP canister.

A pressure relief valve is also located in the fuel filler cap. If the pressure of the fuel vapor within the tank should exceed that for which the fuel system is designed, the pressure relief valve opens. When the pressure relief valve opens excess pressure is vented to the atmosphere.

### Fuel Level Sensor

The fuel level sensor on Enhanced EVAP vehicles is the same as that of non-enhanced vehicles. The fuel level sensor on the Enhanced EVAP vehicle sends a signal to the PCM as well as the I/P cluster assembly. If the fuel level is higher than a specified amount, the PCM turns OFF the EVAP tank pressure control solenoid vacuum valve. This prevents liquid fuel from flowing into the EVAP canister from the fuel tank.

### Fuel Filter

(1) | Fuel Feed Outlet Hose
(2) | Fuel Filter
(3) | Parking Brake Cable
(4) | Fuel Return Hose
(5) | Fuel Tank
(6) | Fuel Feed Inlet Hose
(7) | Fuel Vapor Hose

A steel in-line fuel filter is used in the fuel feed pipe ahead of the fuel injector. The filter housing is constructed to withstand the maximum fuel system pressure, exposure to fuel additives and changes in temperature. The filter element is made of paper and is designed to trap particles in the fuel that may damage the fuel injection system. The fuel filter is located at the left front side of the fuel tank.

### Fuel Pump

(1) | Fuel Outlet Port
(2) | Check Valve
(3) | Magnet
(4) | Impeller
(5) | Pump Cover
(6) | Fuel Inlet Port
(7) | Bearing
(8) | Housing
(9) | Armature
(10) | Choke Coil

The fuel pump is located in the fuel tank. The fuel pump is an electric pump that is controlled by the powertrain control module through the fuel pump relay. When the PCM commands the fuel pump to operate an impeller is driven by an electric motor in the pump assembly. The pump impeller causes the fuel in the tank to be drawn into the fuel pump inlet port. The fuel is then pumped out under pressure through the fuel feed pipe and hoses to the fuel injector. The fuel pressure is maintained by a fuel pressure regulator located within the throttle body assembly. Excess fuel is returned to the fuel tank by the fuel return pipe and hoses.

### Fuel Pump Strainer

The fuel pump strainer attaches to the lower end of the fuel pump assembly at the inlet port of the fuel pump. The fuel pump strainer is made of woven plastic. The function of the fuel pump strainer is to filter contaminants and to wick fuel. The fuel pump strainer is self-cleaning and normally requires no maintenance.

### Fuel Filter

The fuel filter is located in the fuel tank and is part of the fuel sender assembly. The filter element is made of paper and is designed to trap particles in the fuel that may damage the fuel injection system. The fuel sender assembly has to be removed for inspection or replacement of the fuel filter.

### Fuel Feed and Fuel Return Pipes and Hoses

The fuel feed and return pipes and hoses carry the fuel from the fuel tank to the throttle body and back to the fuel tank. These pipes and hoses are attached to the underbody of the vehicle and should be inspected periodically for kinks or dents that could restrict the fuel flow.

### Fuel Vapor Pipe and Hoses

The fuel vapor pipe and hoses carry the fuel vapors from the fuel tank to the evaporative emission canister located in the engine compartment. The fuel vapors are stored in the canister when the engine is not running. When the engine is running at the normal operating temperature and the accelerator pedal is depressed, the powertrain control module will command the evaporative emission canister purge valve to open and allow the stored fuel vapors to be purged into the intake manifold where they will be burned in the combustion process. For a more detailed explanation of the evaporative emission control system refer to the EVAP Control System section.

### Accelerator Controls

(1) | Cable Free Travel (End Play)
(2) | Throttle Lever
(3) | Accelerator Cable
(4) | Adjusting Nut
(5) | Locknut

The accelerator control system is cable-operated. When the accelerator pedal is depressed, the cable pulls the throttle lever open (increasing the throttle plate opening). When the accelerator pedal is released, the throttle lever spring pressure returns the throttle lever to the idle position (decreasing the throttle plate opening).

#### Accelerator Pedal

(1) | Accelerator Cable
(2) | Accelerator Pedal Assembly
(3) | C-Clip
(4) | Pedal Mounting Bracket

The accelerator cable must move smoothly and freely throughout the full range of the throttle opening. Proper adjustment of the accelerator cable is critical to safe vehicle operation.