See warning at beginning of section Relieving pressure in the fuel system of gasoline engines.
1. On petrol models, relieve residual pressure in the fuel system (see Relieving pressure in the fuel system of gasoline engines). Disconnect the negative cable from the battery.
2. Before removing the fuel tank, it is necessary to drain all the fuel from it. Since the manufacturers do not provide a drain plug, you will have to remove the tank with a minimum amount of fuel remaining, having previously removed the main supply using the siphon method.
3. Remove the exhaust system components and heat shields (see Exhaust system - general information, removal and installation).
4. Support the front wheels with wheel chocks and loosen the parking brake adjusting nut (see Chapter Brake system).
5. On models equipped with rear drum brakes, disconnect the parking brake cable from the hook located in front of the brake drum. On models equipped with disc brakes, release the parking brake lever and disconnect the end of the cable from it, then release the lock and release the cable from the support bracket on the caliper (see Chapter Brake system).
6. Release the parking brake drive cable from the intermediate brackets and clamps and move it away from the tank.
7. On astra models disconnect the electrical wiring from the fuel pump/fuel flow sensor unit (see Removal and installation the fuel pump - petrol models and Removal and installation the fuel level sensor), - on zafira models, the electrical wiring is disconnected from under the vehicle.
8. Open the filler cap and remove the rubber sealing ring. Unscrew the bolt securing the filler cap to the body.
9. Remove the right rear wheel, loosen the mounting screws and nuts and remove the wheel arch protection liner.
10. Mark and disconnect the two small hoses from the neck, having first loosened the clamps that secure them.
11. Loosen the clamps and disconnect the fuel lines connected to the base of the filler neck. Unscrew the lower bolt securing the filler neck and remove the latter from under the car.
12. Follow the fuel lines from the tank to their nearest attachment point. Label and disconnect both hoses, first loosening the clamps holding them in place.
If quick-connect connectors are used to attach the hoses, follow the instructions (see Checking the condition and replacing fuel lines and their fittings).
10. On petrol models separate the fuel filter from the fuel tank mounting strip.
11. Support the tank with a trolley jack, having first placed a piece of board on the head of the latter.
12. Unscrew the mounting bolts and remove the mounting strips.
13. Gently lower the tank, disconnecting all hoses along the way. Remove the tank from under the car.
14. If water has accumulated in the tank, remove the fuel pump/fuel flow sensor cover (see Removal and installation the fuel pump - petrol models) and remove any remaining fuel from the tank. If there are traces of moisture in the tank, rinse it with clean fuel. The tank is made of plastic and must be replaced if seriously damaged. Minor defects can be repaired in a specialized workshop.
15. Installation is carried out in the reverse order of dismantling the components. Please note the following points:
- Make sure that when installing the tank, the hoses laid above it are not pinched.
- Make sure that the mounting strip fasteners are tightened securely.
- Make sure all hose and electrical connections are connected correctly and securely.
- Do not forget to adjust the parking brake (see Chapter Brake system).
- Before your first ride, add a small amount of fuel to the tank and check for signs of developing leaks.
Visitor comments