Technical Fuel system confusion

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Technical Fuel system confusion

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Hi all.
I'm currently stripping a 2004 mk2b 1.2 8v for a donor project and I'm a little confused as to the layout of the fuel system.

The Haynes manual describes the system as "returnless" yet there are quite clearly two lines running from the tank to the fuel rail.

The second thing is if the fuel pump, filter and regulator are in the tank and the rail acts as the resevior then what is the black box in the drivers side arch for?

Can anybody explain?
 
So you're doing "projects" (engine swaps etc.) without BASIC automotive knowledge? :rolleyes: And Fiat basics (eLearn + ePER)?
Those Fiats (with FIRE engines) had two systems: with or without return line (then it's a higher chance that filter is embedded into pump).
Black magic box (in the wheel arches or under the hood) is an EVAP system charcoal canister. Nothing new (Punto Mk1 had it).

Fuel injection system (first hose): https://aftersales.fiat.com/elearnsections/main.aspx?nodeID=3123018&languageID=2&markID=1&modelID=2000003&valID=2000307&prodID=2003009&modelName=Fiat - 188 - Punto Classic&langDesc=English&sectionName=Descrizioni&validityName=1.2 16v&isExaminer=
2028225_2.jpg



EVAP (second "mystery" hose): https://aftersales.fiat.com/elearnsections/main.aspx?nodeID=3118672&languageID=2&markID=1&modelID=2000003&valID=2000307&prodID=2003009&modelName=Fiat - 188 - Punto Classic&langDesc=English&sectionName=Descrizioni&validityName=1.2 16v&isExaminer=
2042410_2.jpg


Feel free to ask more questions. What else is "confusing" in such simple car? :confused: Don't bother "Googling" things, we'll provide links for you.
Also, don't use "AI", it is not better than us (actually the answers are based on the existing content, including...forums).
Ask_AI_next_time.jpg
 
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