Vauxhall Workshop Service and Repair Manuals

Fuel Tank, Remove and Install  

  Remove, Disconnect   

Empty fuel tank with fuel transfer unit, see "Opel/Vauxhall Workshop Equipment" catalogue. Store drained fuel in suitable locking container.   Remove moulded rubber. Remove fuel filler neck fastening bolt (1).   Remove right rear wheel well protective panelling. Mark positions of the bleeder lines (2) and detach from fuel filler pipe.

  Remove, Disconnect   

Disconnect fuel hose clamps from fuel filler neck (arrows).   Remove fuel filler neck fastening bolts (1). Remove fuel filler neck.   Remove front muffler with centre exhaust pipe and rear muffler.   Mark fuel lines (3) and (4).   Detach fuel lines and vent line (2) at quick fittings with KM-769 and seal off with KM-807.

  Remove, Disconnect   

Petrol engine: Detach fuel filter (3) at retaining strap.   Disconnect wiring harness plug (4).   Position hydraulic jack under fuel tank and support fuel tank.   Remove fastening bolts (arrows) for retaining straps. Remove retaining straps (1) and (2).   Slightly lower hydraulic jack and remove fuel tank forwards.

  Remove, Disconnect   

Remove all hose connections and retaining clips from fuel tank.   I:   Petrol engine   1   Fuel filter   2   Vent line   3   Fuel return line   4   Fuel supply line     Notice:  For Y 16 XE, Z 16 XE, X 18 XE1, Z 18 XE, Z 18 XEL and Z 22 SE the fuel return line is discontinued.   II:   Diesel engine   5   Vent line   6   Fuel return line   7   Fuel supply line

  Remove, Disconnect   

Disconnect fuel lines (1) and wiring harness plug (2) from fuel tank.   Remove fuel gauge - see operation "Fuel Gauge, Remove and Install".   Remove fuel pump - see operation "Fuel Pump, Remove and Install (Petrol Engine)".

  Install, Connect   

Install fuel pump - see operation "Fuel Pump, Remove and Install (Petrol Engine)". Install fuel gauge - see operation "Fuel Gauge, Remove and Install".  

Attach retaining clips, hose connections and wiring harness plug to fuel tank. Insert fuel tank and lift with hydraulic jack.  

Fasten fuel tank to chassis with retaining straps. Lower hydraulic jack.  

Connect fuel gauge or fuel pump wiring harness plug (to underside of vehicle).  

Attach fuel filter (petrol engine) to retaining strap. Remove KM-807 from fuel lines and ventilation line.  

Connect fuel lines (note identification) and ventilation line with quick fittings. Install front muffler with centre exhaust pipe and rear muffler.  

  Install, Connect   

Install fuel filler pipe and fasten to rear frame using fastening bolt. Attach vent lines to fuel filler pipe - note identification code. Install right rear protective panelling for wheel well.  

Fasten fuel filler neck to rear quarter panel with fastening bolt. Install moulded rubber.  

Top up fuel tank with fuel transfer unit, see "Opel/Vauxhall Workshop Equipment" catalogue.  

  Tighten (Torque)   

Fuel tank with retaining straps to chassis - 20 Nm / 15 lbf. ft.  

Fuel filler pipe to rear frame - 12.5 Nm / 9 lbf. ft.