Vauxhall Workshop Service and Repair Manuals

Fuel Tank, Remove and Install

Model F08, F08 & W5L, F68

Note:   Fuel escapes – observe safety measures and national legislation.

  Remove

5.   Unclip parking brake cable at right connecting piece (1) and disengage from guide (2) at rear axle. Note:   Only for vehicles with rear drum brake

6.   Release tension on parking brake cable – to do this, unclip folding cover for parking brake lever (1) from centre console and push up. Detach protective cap (3) and turn back adjustment nut (2) completely. Note:   Only for vehicles with rear disc brake 7.   Detach parking brake cable (6) from actuation lever (4) at both brake callipers of the rear axle. Note:   Only for vehicles with rear disc brake 8.   Detach retaining clamps (5) and remove parking brake cable from counterholds on brake callipers and brackets on rear axle. Note:   Only for vehicles with rear disc brake

9.   Remove air guide plate on underbody Note:   For "ECO" model version 10.   Remove parking brake cable from brackets at fuel tank (1). Note:   For "ECO" model version 11.   Detach rubber attachments (arrows) for rear silencer and lay exhaust system on rear axle. Note:   For "ECO" model version 12.   Release and disconnect wiring harness plug (2) for fuel tank sensor and electric fuel pump (petrol engines) at vehicle floor. Note:   Illustration shows vehicle with Z 10 XE.

13.   Disconnect fuel line from quick-release fitting (1) with KM-796 and seal with Closure Plug KM-807 (petrol engine) or KM-6015 (diesel engine) 14.   Disconnect degassing line (petrol engine) or fuel return line (diesel engine) at quick-release fitting (4) with KM-796 and seal with KM-807 . 15.   Remove fastening bolt for lower fuel filler pipe (3) and release ventilation and degassing hoses from brackets (arrows). 16.   Remove fuel filler hose (2) from fuel tank. Note:   Illustration shows "petrol engines" version.

17.   Support fuel tank with hydraulic jack and remove both retaining bands (1) (arrows). 18.   Lower fuel tank carefully – move to the right and free from exhaust system. Note:   Do not exert tension on hoses, do not kink plastic hoses and lines.

19.   Remove degassing hose from rear degassing line at quick-release fitting (2) with KM-796 and seal both with KM-807 20.   Release degassing hose (3) and rear degassing hose (1) from brackets (arrows) at fuel tank.

21.   Carefully Lower fuel tank further. 22.   Detach gas venting hose (2) and rear gas venting hose (1) from fuel tank connection. Note:   Fuel can escape from hoses/lines. 23.   Lower fuel tank with hydraulic jack and remove.

  Install

25.   Lift fuel tank with hydraulic jack 26.   Install ventilation hose (2) with new clamp and rear degassing hose (1) to pipe at fuel tank.

27.   Lift fuel tank further with hydraulic jack 28.   Clip degassing hose (3) and rear degassing hose (1) to brackets (arrows) at fuel tank. 29.   Remove KM-807 from degassing hose and rear degassing line. Connect degassing hose and rear degassing line with quick-release fitting (2) Note:   Quick-release fitting must audibly engage

30.   Lift fuel tank further carefully – move to the left and position beneath exhaust system. 31.   Install retaining bands (1) (arrows) – tightening torque 20 Nm 32.   Remove hydraulic jack

33.   Lay ventilation and degassing hoses at fuel filler pipe and attach with brackets (arrows). Install fastening bolt (2) of lower fuel filler pipe. 34.   Install fuel filler hose (1) at fuel tank – tightening torque of the hose clamp 2.5 Nm

35.   Remove KM-807 from degassing line and rear degassing line (petrol engines) or from fuel return line and rear fuel return line (diesel engines). Connect degassing line and rear degassing line (petrol engines) or fuel return line and rear fuel return line (diesel engines) with quick-release fitting (1). 36.   Remove KM-807 (petrol engines) or KM-6015 (diesel engines) from fuel line and rear fuel line. Connect fuel line and rear fuel line with quick-release fitting (2). Note:   Quick release fittings must engage perceptibly. "Petrol Engines" version "Diesel engines" version

37.   Connect and secure wiring harness plug (2) for fuel tank sensor and electric fuel pump (petrol engines) at vehicle floor. 38.   Attach rubber attachments for rear silencer (arrows). 39.   Install parking brake cable to brackets at fuel tank (1). Note:   For "ECO" model variant: Install underbody air guide plate Note:   Illustration shows vehicle with Z 10 XE.

40.   Engage right parking brake cable in guide (2) at rear axle and install with new connecting piece (1). Note:   Only for vehicles with drum brake. 41.   Install right rear wheel – tightening torque 110 Nm

42.   Attach parking brake cable (1) on both sides to bracket (2) on rear axle. Note:   Only for vehicles with rear disc brake. Note:   Illustration shows left side

43.   Attach parking brake cable (5) to both brake callipers of rear axle in counterhold (2) and actuation lever (4). Install retaining clamps (3). 44.   Adjust parking brake