Contents: Removal ⬇ Installation ⬇
Removal
Open the hood.
Disconnect the battery.
Disconnect the ground clamp from the ground terminal.
Disconnect the fuel tank filler pipe. To do this, open the fuel tank filler flap (3)
Remove the fuel tank filler cap.
Remove the rubber casing.
Loosen the bolt.
Attach the fuel tank filler cap.
Remove the right rear wheel.
Raise the car halfway.
Remove the right rear wheel.
Remove the inner wheel arch lining by unscrewing 2 bolts and two nuts.
Raise the car halfway.
Loosen the rear muffler mounting clamp by unscrewing the mounting nut.
Remove the rear muffler from the bracket in 2 places.
Disconnect the rear muffler from the center muffler.
(Material copied from this portal: www.opelbook.ru)
Disconnect the oxygen sensor wiring harness (catalytic converter control).
Disconnect the wiring harness connector and unscrew the 4 clamps.
Disconnect the front exhaust pipe with the front muffler from the catalytic converter by unscrewing the 3 mounting nuts.
Remove the front exhaust pipe with the front muffler.
Remove from bracket in 4 places.
Disconnect the in-tank module wiring harness connector.
Disconnect 2 fuel lines.
Disconnect the 2 quick release couplings.
Close the ends of the fuel lines using special plugs.
Remove the parking brake cable from the bracket in 3 places.
Disconnect the fuel tank filler neck tube. To do this, remove the clamp and unscrew the mounting bolt.
Disconnect the fuel water separator from the fuel tank filler neck tube by unscrewing the mounting bolt.
Remove the jack.
Remove 2 fuel tank mounting clamps, unscrew 4 bolts.
Remove the fuel tank with the fuel tank filler tube.
Note: The fuel tank filler tube must be routed over the rear axle.
Caution: Make sure that the fuel tank fittings are not damaged when disconnecting the hoses.
Leakage from damaged fittings may cause a fire.
Disconnect the water separator from the fuel tank filler tube.
Disconnect 3 cable ties.
Disconnect 2 ventilation hoses (4) and (5)
Note: Cut along the dotted line with a sharp knife.
Remove the 2 ventilation hoses from the bracket and disconnect them from the filler pipe in 4 places.
Disconnect the fuel supply hose from the fuel tank filler tube.
Loosen the mounting clamp.
Installation
Connect the fuel supply hose to the fuel tank filler tube.
Tighten the clamp to a torque of 3.5 Nm.
Connect the vent tube to the fuel tank filler tube.
Connect the ventilation tube.
Attach the fuel water separator.
Connect 2 ventilation hoses.
Remove the 2 ventilation hoses from the bracket.
Fix to the filler pipe in 4 places.
Install 3 cable ties.
Install the fuel tank with the fuel tank filler tube.
Attach the 2 fuel tank mounting clamps.
Tighten the 4 mounting bolts to 20 Nm.
Raise the jack.
Attach the fuel water separator to the fuel tank filler tube and tighten the mounting bolt.
Attach the fuel tank filler tube, tighten the bolt and secure with a clamp.
Install the parking brake cable into the bracket.
Connect 2 fuel lines.
Connect 2 quick release couplings.
Connect the module wiring harness connector in the tank.
Install the front exhaust pipe with the front muffler.
Connect the front exhaust pipe with the front muffler to the catalytic converter, tighten to 20 N·m.
Install a new gasket.
Tighten the 3 new mounting nuts to 20 Nm.
Connect the oxygen sensor wiring harness connector (catalytic converter control).
Install the rear muffler.
Attach the rear muffler to the front muffler.
Secure the rear muffler and tighten the clamp to 18 Nm.
Lower the car halfway.
Install the rear right wheel arch inner lining.
Install the right rear wheel.
Lower the car halfway.
Tighten the right rear wheel.
Connect the fuel tank filler tube.
Remove the fuel tank filler cap.
Install the rubber shell.
Attach the fuel tank filler cap.
Close the fuel filler cap.
Connect the battery.
Connect the ground clamp to the ground terminal.
Program volatile memory.
Close the hood.
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