Fuel level sensor unit — removal and installation (Opel Vectra A)

Note: Before you begin, see. Chapter 2.

Removal

1. Disconnect the negative cable from the battery.

2. Pump out all remaining fuel from the tank through the filler pipe.

3. Block the front wheels, then jack up the rear of the vehicle and support it on axle stands placed under the sides of the body frame.

4. The sensor is located on the right side of the fuel tank.

5. Make alignment marks on the sensor and fuel tank so that the sensor can be installed in its original position.

6. Disconnect the fuel supply hoses from the sensor unit. Plug the open ends of the hoses to prevent dirt from entering and further fuel loss.

7. Disconnect the electrical wiring from the fuel level sensor.

8. To remove the sensor, insert a metal strip between the two slots in the sensor frame and turn it clockwise.

9. Carefully remove the block, do not bend the float lever.

10. Remove the O-ring.

Installation

11. Perform installation in reverse order, paying attention to the following.

12. Check the condition of the O-ring, replace if necessary.

13. Align the marks made on the sensor and the fuel tank before removal.

14. Check that the hoses are properly connected as noted before removal.

15. Finally, fill the fuel tank, then start the engine and check the system for leaks. Also check that the fuel gauge is working properly. If there is a leak, turn off the engine immediately and fix the problem without delay.