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Fuel Tank, Remove and Install (Estate)
Caution
Observe safety precautions and national regulations.
Use draining equipment to drain the fuel tank. Draining
equipment – refer to Opel/Vauxhall Workshop Equipment
Catalogue. Store drained fuel in a suitable sealable container.
Open bonnet, disconnect battery
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 Remove
Remove panelling from luggage compartment floor, remove assembly
aperture cover from floor panel.
Detach fuel pump wiring harness plug (1).
Remove fuel tank closure cap and rubber seal ring (2).
Remove rear right wheel, protective panelling from rear right
wheel housing.
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Loosen hose clamp (1) and detach vent hose (2) from fuel
tank.
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Loosen hose clamp (1) and detach vent hose (2) from T-piece.
Vent hose (2) remains on vehicle.
Remove vent hose (3) from bracket (4).
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Loosen hose clamp (1) and detach vent hose (2) from vent line
connection (3).
Release quick fittings from fuel filter using KM-796-A.
Close off fuel lines using closure plugs KM-807 or KM-6015 and
KM-6320.
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Support fuel tank with hydraulic jack and suitable holder.
Detach both tensioning bands from underbody, note reinforcement
plate (1).
Lower fuel tank carefully and remove from hydraulic jack.
When replacing fuel tank: install new storage pot. Transfer heat
shield, hoses, fuel pump, fuel sensor and rubber dampers.
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Install
Install fuel tank with reinforcement plate – note vent
hoses and wiring harness plug. Fasten tension straps – the
filler pipe must be located exactly in the middle of the rear
quarter panel filler opening. Attach tension straps to underbody
– tightening torque 30 Nm / 22 lbf. ft.
Remove closure plug KM-807 or plugs KM-6015 and KM-6320. Attach
fuel lines to metal pipe and fuel filter until quick fittings can
be felt and seen to engage. Fit venting hoses and attach using hose
clamps.
Install protective panelling in rear right wheel housing and
install rear right wheel.
Install rubber seal ring.
Connect wiring harness plug for fuel sensor and fuel pump.
Attach assembly aperture cover to floor panel. Install panelling
in luggage compartment floor.
Refill with drained fuel. Observe safety rules and national
regulations!
Install fuel tank closure cap.
Connect battery and program volatile memories - see operation
"Volatile Memories, Program"
Close bonnet
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