Vauxhall Workshop Service and Repair Manuals

Fuel Tank, Remove and Install (Saloon)  

  Important!   

Empty fuel tank and fuel system. Fuel pump - refer Catalogue "Opel/Vauxhall Workshop equipment". Run drained fuel into a suitable sealable container. Follow safety instructions and country specific regulations.     Remove, Disconnect    Remove fuel filler pipe with anti-leak device - see operation "Fuel Filler Pipe with Anti-leak Device, Remove and Install (Saloon)".   Detach wiring harness plug (1) from fuel tank sensor and, if present, detach wiring harness plug (2) from fuel pump.   Removing fuel filter - refer works instruction "Fuel filter removal and fitting (Injection motor)". Clamp with hose clamps and remove activated carbon canister (3) hose and return lines (4).   Remove parking brake cable - see operation "Parking Brake Cable, Remove and Install" in group "H".

  Remove, Disconnect   

Separate middle muffler from front exhaust pipe and from rear muffler.   Support fuel tank with hydraulic jack and suitable pad.   Remove fastening bolts (arrows) for both tension straps from underbody. Suspend retaining straps downwards out of the way and carefully lower fuel tank.   Detach fuel ventilation hoses from fuel tank - remove fuel tank.   When replacing fuel tank, transfer attaching parts.     Install, Connect    Carefully lift fuel tank, Remove fuel ventilation hose from fuel tank. Fasten fuel tank to underbody with fastening straps - Tightening torque 20 Nm. Be careful of rubber cushions and associated hoses and cable runs. Attach middle muffler to front exhaust pipe and rear muffler. Fit hand break cable - refer works instruction "Hand break cable removal and fitting" in Construction group "H". Attach hoses to fuel tank, fuel sensor and if present to fuel pump with new hose clamps. Plug wiring harness plug into fuel sensor and if present into fuel pump. Fit anti-leak device to fuel filler pipe - refer works instruction "Fuel filler pipe with anti-leak device - removal and fitting (Saloon)".