Vauxhall Workshop Service and Repair Manuals

  Remove

Remove panelling from luggage compartment floor, remove assembly aperture cover from floor panel.

Disconnect fuel tank wiring harness plug. Mark fuel hoses.

Close off fuel hoses with spring clamps.

Detach fuel feed and return lines.

Remove fuel tank cover union nut with KM-673 (1).

Raise fuel tank cover and detach wiring harness plugs (1) and (2).

Detach fuel supply line (3) and fuel return line (4) from fuel tank cover.

Release fuel sensor.

Press hook (1) outwards and remove fuel sensor upwards out of storage pot – keep suitable collecting basin at the ready and deposit fuel sensor in it.

Caution

When replacing the fuel sensor, note the type code (2) and the final digit (1).

Each type of fuel sensor is only compatible with certain speedometers/tachometers with the appropriate scales (I and II)

  Install

Fuel sensor must engage audibly in guides (1) of storage pot.

New rubber seal ring on fuel tank cover. Connect wiring harness plug and fasten fuel feed and return lines. Install fuel tank cover union nut with KM-673 – 50 Nm / 37 lbf. ft.

Attach fuel feed and return lines to fuel tank cover – note installation position. Remove spring clamps.

Note:   For Y 25 DT: Hose clamp for supply hose has a green marking, hose clamp for return hose has a black marking.

Connect fuel pump wiring harness plug.

Attach assembly aperture cover to floor panel. Install panelling in luggage compartment floor.

Refill with drained fuel. Observe safety rules and national regulations!