Removal and installation the fuel tank (Opel Corsa C)

1. Fuel tanks (see accompanying illustration) the different models described in this Manual may have different fuel and ventilation line routings due to the specific layout of the units and systems. The general procedure for removing/installing the fuel tank is described below.

10.1a. Fuel tank of Corsa C models: 1. EVAP system tube; 2. Fitting for the rear hose of the EVAP system; 3. EVAP hose fitting; 4. Fuel pump assembly cover; 5. Return fuel line; 6. Rear section of the fuel supply line; 7. Fuel filter (petrol models only); 8. Heat shield; 9. Wiring harness

10.1b. Fuel tank for Meriva models: 1. Wiring harness; 2, 3, 6. EVAP system lines; 4. Fuel pump assembly cover; 5. Rear section of the fuel supply line; 7. Return fuel line; 8. Fuel filter (petrol models only)

2. Disconnect the negative battery cable (see Chapter 5). Release residual pressure in the fuel system (petrol models) (see Section 2).

3. Before removing the fuel tank, it is necessary to remove all fuel from it. Since the manufacturers do not provide a drain plug, pump out the fuel with a special pump - be careful, there will still be some fuel left in the tank.

4. On models with rear drum brakes, remove the rear right wheel, mark the position of the wheel hub. Release the parking brake cable from the connecting element (see accompanying illustration) and remove it from the guide on the rear suspension beam.



5. On models with rear drum brakes, it is necessary to loosen the tension of the parking brake cable (see Chapter 9).

6. If necessary (depending on the model) disconnect the parking brake cable ends from the drive levers of both rear brake mechanisms and release the ends from the holders (see Chapter 9).

7. On Corsa-Eco models, remove the spoiler from the underbody of the car.

8. Release the parking brake cables from the holders on the fuel tank and move them to the side.

Note: Depending on the model and type of rear brake mechanisms, the cable routing routes differ from each other.

9. Release the rear section of the exhaust system from the damper holders (see accompanying illustration) and place it on the rear suspension beam.

Note: On some models (for example, Meriva) it may be necessary to completely remove the exhaust system (see Part D).

10. Disconnect the fuel pump wiring connector (see illustration 10.9).

11. Place a suitable container to collect the fuel, disconnect the fuel line connectors and close them with suitable plugs. A special device KM-796 is used to disconnect the quick-release connections.

12. If necessary (depending on the model) release the EVAP system line from the holders. Loosen the fastening (if necessary, unscrew the mounting bolt) and disconnect the fuel filler neck connecting hose from the fuel tank.

13. Support the tank with a trolley jack (see accompanying illustration), first, to distribute the load, place a piece of board on the head of the last one, unscrew the fastening bolts and remove the 2 mounting strips.





14. Gently lower the fuel tank, using an assistant to move it out of the way so as not to damage the exhaust system. Disconnect all supply lines from the tank. If necessary, remove the fuel pump assembly from the tank (see Section 8).

15. Installation is carried out in the reverse order. If the tank is being replaced, reinstall all removable parts from the old to the new one. Before the first trip, pour a small amount of fuel into the tank and check it for signs of developing leaks.