vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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"Anti-Runout" Valve, Check Function > < Fuel Tank Sensor, Replace

Astra

FUEL SYSTEM

 

Fuel Tank, Remove and Install

Remove (Saloon up to Model Year 1986)

Disconnect ground cable from battery.

Remove fuel filler cap.

Drain fuel tank.

Close off textile hoses for fuel feed and return lines with spring clamps.

Loosen hose clamps and pull off textile hoses from fuel lines.

Object Number: 2375666 Size: DEFAULT

 

 

Lengthen both textile hoses and put into clean container.

Open spring clamps and allow fuel to flow into container.

 

NOTE:

On vehicles with 18 E engine, connection for feed line to fuel pump is located at fuel tank sensor.

 

 

On all engines except 12 SC and 12 ST, unbolt front muffler with pipe from front exhaust pipe at flexible joint flange.

Object Number: 2375679 Size: DEFAULT

 

 

Detach front and rear mufflers from vehicle underbody and swing exhaust system towards left side of vehicle.

 

On 20 XE and 20 XEJ engines, rear muffler is secured to underbody with rubber dampers and rings.

Object Number: 2375667 Size: DEFAULT

 

 

Disconnect electric cable from fuel tank sensor.

Illustration C 7674 shows version on petrol fuel injection engines.

Object Number: 2378946 Size: DEFAULT

 

 

On 12 SC and 12 ST, unbolt front exhaust pipe from exhaust manifold.

 

Illus. C 0474 shows flange on 12 SC, similar on 12 ST.

Object Number: 2375668 Size: DEFAULT

 

 

Measure free thread length and remove parking brake cable.

Unscrew nut.

Detach parking brake cable from brackets on underbody and tank and hang out of way to rear.

Object Number: 2375669 Size: DEFAULT

 

 

Unscrew fuel filler pipe from panel.

Object Number: 2375670 Size: DEFAULT

 

 

Loosen hose clamps.

Pull off fuel filler pipe with overflow line from fuel filler neck and overflow line.

Remove long vent hose from brackets on fuel filler neck and tank.

Support fuel tank with hydraulic jack and unscrew both retaining straps.

Object Number: 2375671 Size: DEFAULT

 

 

Lower fuel tank slightly.

Loosen hose clamps and remove short vent hose and fuel overflow hose from tank.

 

When replacing tank, adapt textile hoses, retaining clamps, fuel tank sensor, rubber dampers and bracket for parking brake cable to fit new tank.

 

Install (Saloon up to Model Year 1986)

Install in reverse order.

Object Number: 2375672 Size: DEFAULT

 

 

Remove (Saloon as of Model Year 1986)

 

As of Model Year 1986 a fuel tank with a volume of 52 litres is installed in the saloon.

This does not result in any changes for removal and installation.

Object Number: 2376091 Size: DEFAULT

 

 

NOTE:

The two tanks are not interchangeable with one another due to the modified floor assembly and mounting points.

 

 

Remove (Estate)

 

Remove fuel filler cap and unscrew fuel filler pipe from right rear quarter panel.

 

Close off textile hoses for fuel feed and return lines with spring clamps, loosen hose clamps and pull off fuel lines from textile hoses.

 

Disconnect electric cable from fuel tank sensor.

Object Number: 2375694 Size: DEFAULT

 

 

Support tank with hydraulic jack, unscrew retaining straps and lower tank.

 

NOTE:

When replacing tank, drain fuel before removing tank (see removal on Saloon).

Adapt fuel filler pipe, hoses, retaining clamps and fuel tank sensor from old tank to fit new one.

 

Install (Estate)

Install in reverse order.

Object Number: 2375695 Size: DEFAULT

 

 

"Anti-Runout" Valve, Check Function > < Fuel Tank Sensor, Replace