Fuel tank — removal and installation (Opel Vectra B)

Warning: When working on the fuel tank, do not use open flames or tools that may create sparks.

When removing the fuel tank, the fuel level in it should be at a minimum.

Removal

1. Relieve the pressure in the fuel system and remove the ground cable from the battery.

2. Remove the exhaust system and heat shields.

3. Move the rear seat cushion forward and lift the carpet over the fuel pump.

4. Using a thin screwdriver blade as a lever, remove the plastic cover to expose the fuel pump.

5. Disconnect the electrical connector from the fuel pump and tape it to the body to prevent it from falling behind the fuel tank.



6. Open the fuel filler flap and remove the rubber cover from the filler neck.



7. Unscrew the bolt securing the fuel filler neck to the body (indicated by the arrow).



8. Remove the right rear wheel, unscrew the screws, remove the mounting brackets and wheel arch protection.

9. Place identification marks on the small hoses secured to the top of the fuel filler neck. Loosen the clamps and remove both hoses.

10. Loosen the clamps and disconnect the main hoses from the base of the fuel filler neck. Unscrew the lower bolt securing the fuel filler neck and remove it.



11. Trace the fuel supply and return hoses to the fuel tank to their connections in front of the fuel tank (indicated by arrows). Apply identification marks, loosen clamps and disconnect hoses.



12. Remove the belt securing the fuel filter to the fuel tank

(Source is on this resource: www.opelbook.ru)



13. Support the fuel tank from below and remove the bolts (the bolt is indicated by the arrow), securing two fuel tank mounting straps.



14. Slowly lower the fuel tank, disconnect the remaining pipes from it and remove the tank from under the car.

15. Visually inspect the condition of the fuel tank from the outside. Unscrew the ring and remove the fuel pump cover and inspect the fuel tank from the inside. If there is dirt or sediment in the tank, wash it with clean water or gasoline.

Installation

Installation is carried out in the reverse order of removal, taking into account the following points:

• when installing the fuel tank into the vehicle, make sure that none of the hoses are pinched;
• check that all pipes and hoses are properly connected and securely fastened with clamps;
• add a small amount of fuel to the fuel tank and check the fuel system for leaks.