Vauxhall Workshop Service and Repair Manuals

Fuel Tank, Remove and Install  

  Remove, Disconnect   

Empty fuel tank. Guide siphoning hose through fuel filler connection into fuel tank and empty with external pump. Unscrew and remove fuel hoses from tank (arrows, see illus. I).     Important!    Observe safety precautions and national regulations.     Remove, Disconnect    Remove complete exhaust system.   Remove heat shield in front of parking brake cable. Remove plastic locking plugs and detach parking brake cable from connection piece (see illus. II). Pull parking brake cable out of bracket on underbody and suspend towards rear.   Close off feed and return lines on fuel pump with commercially available spring clamps. Unscrew feed and return lines from fuel pump.

  Remove, Disconnect   

Support fuel tank with hydraulic jack and suitable adapter. Unscrew both fuel tank retaining straps from underbody.

Lower fuel tank slightly. Remove wiring harness plugs (1) for fuel pump and fuel tank sensor.   Remove all fuel lines (2) and lines to activated carbon canister from fuel tank. Lower fuel tank carefully and remove from hydraulic jack.

  Install, Connect   

Bring fuel tank into installation position using a hydraulic jack (see illus. I). Attach and connect fuel lines and line to activated carbon canister to fuel tank. Connect wiring harness plug for fuel sensor and fuel pump.   Connect and tighten fuel filler pipe line with new clamps. Screw on retaining straps - 20 Nm / 15 lbf. ft.     Important!    Ensure that hoses and cables are correctly routed.     Install, Connect    Attach parking brake cable in bracket and secure with locking plugs. Bolt on heat shield for centre muffler (arrows, see illus. II). Install complete exhaust system.

  Install, Connect   

Connect fuel lines with quick release fittings.   Connect fuel filler pipe fuel hoses with fuel tank and tighten with new hose clamps.   Fill up tank with drained fuel.     Important!    Check complete fuel system for leaks.