Vauxhall Workshop Service and Repair Manuals

Fuel System Repair Instructions

Warning:   When the fuel system is open, fuel can escape - observe safety regulations and country-specific regulations.

1. Petrol engines:

Note:   The fuel system on vehicles with petrol engines, except A 16 LEL, A 16 LER, Z 16 LEL and Z 16 LER, is designed as a non-return fuel system. Only a short fuel return line to the fuel tank is fitted.

Fuel pressure dissapates slowly after the ignition is switched off. Before opening this pressurised section of the fuel system, always relieve fuel pressure using pressure tester KM-J-34730-91 at the testing port. Collect escaping fuel in a suitable container.

2. Diesel engines:

Note:   The high pressure pump of the diesel engines is self-bleeding and is supplied by an additional electric pre-pressurising pump (in the fuel tank) on A 13 DTC, A 13 DTE, A 13 DTR, Z 13 DTJ and Z 13 DTH engines.

3. Drain fuel tank

Note:   The fuel tank is drained using a suitable conventional fuel removal unit and suction hose - observe safety regulations and country-specific regulations.

4. Fuel lines, quick-release fittings

Note:   The following procedure should be observed when connecting lines using quick release couplings:

Pull of clip (2) from connector (1) Insert clip into housing (3) Allow clip to engage on both sides Insert connector into housing Engage connector by applying considerable pressure Check that quick release coupling is properly engaged Perform tensile test