Replacing the fuel level sensor — removal and installation (Opel Corsa C)

Removal

Open the hood.

Disconnect the battery.

Disconnect the ground clamp from the ground terminal.

Place a drain container underneath.

Relieve fuel pressure using special tool KM-J-34730-91 through the test channel.

Note: Collect any leaking fuel in a suitable container – observe safety regulations and national legislation.

Open both rear doors

Remove the bench seat.



Pull out the 2 release clips.

Remove from bracket in direction of arrows in 2 places.

Remove the bench seat from the vehicle.

Remove the cover.

Bend the sound insulation and open the lid.

Disconnect the wiring harness connector.



Mark the fuel lines and remove using the special tool KM-796-A.



Close the fuel lines with plugs from the special tool KM 807 and KM 6015.

Note: Make sure that the special tool KM 797 is properly and securely installed.

Loosen the cover locking ring using the special tool KM 797.

Note: Rotate counterclockwise.

Carefully lift the module cover upwards.

Note: Be careful not to damage the wires and hoses.

Disconnect the 2 wire harness connectors from the cover.

Note: Special tool KM-6391-1 must be installed so that the sensor in the tank moves vertically. Install special tool 4 KM-6391-1 and remove the module.

Remove the module using the special tool KM 6391.



Install special tool 4 KM 6391 on the module as shown in the figure.

Release the module by pressing the special tool and remove it.

Remove the module from the fuel tank.



Remove the fuel level sensor and release the holders.

Note: Do not pull the fuel level sensor shaft.

Gently pull out from the guide in the direction of the arrow.

Installation

Install the fuel level sensor.

Install into the guide.

Install the module.

Install in 4 latches 1.

Note: The latches should click into contact.

Connect the 2 wire harness connectors with the cover.

Close the module cover with the locking disc.

Install the cover with a new gasket using the special tool KM 797.

Rotate clockwise.

Connect the fuel lines and connect the quick release coupling.



Connect the wiring harness connector.

Close the lid.

Bend the sound insulation to the side.

Install the rear bench seat.

Fasten 2 clamps.

Press down and lock in place.

Close both rear doors.

Connect the battery.

Connect the ground clamp to the ground terminal.

Program volatile memory.

Close the hood.