|
Remove and install fuel pump closure cap
Note: Fuel escapes
– observe safety measures and national legislation.
 Remove
| 1. |
Disconnect earth lead from battery.
|
| 2. |
Reduce fuel pressure with pressure tester KM-J-34730-91 via test connection
Note: For petrol
engines
| • |
Collect escaping fuel in a suitable container.
Note: To do this - if
necessary - detach upper engine cover and reattach subsequently
|
|
| 3. |
Empty fuel tank with fuel transfer unit
| • |
Store drained fuel in suitable, lockable container.
Note: see catalogue
"Opel/Vauxhall Workshop Equipment"
|
|
| 4. |
Remove rear seat
Note: For F08, F68, F08
& W5L
|
| 5. |
Return rear seat to upright position
Note: For F06
|
| 6. |
Remove fuel tank
Note: For F 25
|
| 7. |
Fold up acoustic insulation (2) and remove cap (1) of
installation opening with a suitable lever.
Note: For Tigra-B
(model R97): Remove luggage compartment floor covering at the front
.
|
|
|
| 8. |
Detach wiring harness plug (1) from fuel pump closure cap
|
| 9. |
Mark fuel lines (2) and remove using KM-796 . Seal fuel lines with Closure Plug (3) KM-807 (petrol engine) or KM-807 and KM-6015 (diesel
engine)
Note: In-tank module
closure cap can only be opened with difficulty – therefore
ensure that the tool KM-797 is fully
inserted into the bores provided.
|
| 10. |
Detach fuel pump closure cap locking ring (5) with KM-797 (4)
Note: Turn
anti-clockwise to unlock.
|
| 11. |
Lever fuel pump closure cap off fuel tank
Note: Lift carefully
and note the position in which the wiring and hose connections are
laid.
|
|
|
| 12. |
Disengage fuel tank sensor wiring harness plug (4) and pull off
fuel pump closure cap
Note: Illustration
shows "petrol engine" version.
|
| 13. |
Disengage fuel pump wiring harness plug (3) and pull off fuel
pump closure cap.
Note: For petrol
engines
|
| 14. |
Disconnect wiring harness plug for earth from pressure
regulator
Note: For model F06,
F25 (petrol engine).
|
| 15. |
Detach fuel supply hose (2) from fuel pump closure cap
|
| 16. |
Detach fuel return hose (5) from fuel pressure regulator
(petrol engines) or fuel pump closure cap (diesel engines) and
remove fuel pump closure cap
Note: Observe
arrangement and laying of the fuel hoses.
|
| 17. |
Remove seal ring (1).
|
|
|
Install
| 18. |
Attach fuel supply hose (4) to fuel pump closure cap with new
hose clamp
- "Petrol Engines" version
- "Diesel engines" version
|
| 19. |
Install fuel return hose (3) with new hose clamp on fuel
pressure regulator (petrol engines) or on fuel pump closure cap
(diesel engines).
|
| 20. |
Attach fuel tank sensor wiring harness plug (2) to fuel pump
closure cap
|
| 21. |
Attach fuel pump wiring harness plug (1) to fuel pump closure
cap
Note: For petrol
engines
|
| 22. |
Connect wiring harness plug, earth, to pressure regulator.
Note: For Combo (petrol
engines)
|
|
|
| 23. |
Insert fuel pump closure cap in fuel tank with new gasket
Note: Insert carefully,
note arrangement and laying of the wiring harnesses and fuel
hoses.
|
| 24. |
Using KM-797 , attach fuel pump
closure cap locking ring
Note: Turn clockwise to
lock.
| • |
Ensure that it is fully engaged
|
| • |
Note installation position of fuel pump closure cap
|
| • |
Connections for fuel lines point directly backwards
|
|
| 25. |
Remove Closure Plug KM-807 (petrol
engines) or KM-807 and KM-6015 (diesel engines) from fuel lines and push
fuel lines on to connections in accordance with markings
Note: Quick release
fittings must engage perceptibly.
|
|
|
| 26. |
Attach wiring harness plug to fuel pump closure cap.
|
| 27. |
Close assembly aperture with cover and cover with sound
insulation.
|
| 28. |
Install rear seat
Note: For F08, F68, F08
& W5L
|
| 29. |
Fold down rear seat
Note: For F06
|
| 30. |
Install fuel tank
Note: For F25
|
| 31. |
Install floor covering, front of luggage compartment
Note: For Tigra-B
(model R97) .
|
| 32. |
Fill fuel tank with fuel
Note: Comply with
nationally specific safety regulations.
|
| 33. |
Connect earth cable to battery.
|
| 34. |
Program volatile memories
|
|
