General information
1. On petrol models and on models equipped with a 1.9L diesel engine, fuel is pumped into the system by an electric fuel pump. The electric pump, together with the fuel reserve sensor, is installed in the assembly body, which is immersed in the fuel tank. On other diesel models, only the fuel reserve sensor is installed in the tank. The fuel supply to the system is carried out at the expense of the injection pump.
2. The reserve sensor consists of a float and a potentiometer. When the fuel level drops, the sensor float drops, while the potentiometer connected to the float increases the electrical resistance of the sensor, and the corresponding signal is sent to the meter built into the instrument cluster.
3. When performing work, the fuel tank must not be filled with more than 2/3 of its capacity. Before removing the fuel pump assembly, empty the fuel tank to the required level by consuming fuel while the vehicle is moving, or by pumping fuel with a special pump through the tank filler neck. Work should be carried out in a well-ventilated room, preferably equipped with a special exhaust hood.
Removing
4. Disconnect the negative cable from the battery.
5. To gain access to the hatch in the floor panel, lift and remove the rear seat cushion.
Note: If necessary, remove the rear seat back as well.
6. Fold back the carpet over the service hatch cover.
Note: The area of the carpet above the hatch has already been cut, but on newer vehicles there may be connecting bridges cut carefully with a sharp knife
7. Pry and remove the service hatch cover (see resist. illustration) access to fuel assembly oncoca.
8.7 Service cover (1) fuel pump assembly access hatch
8. Disconnect the wiring connector (see resist. illustration) secure the harness by taping it to the floor panel. Clearly mark so as not to confuse during installation the fuel lines of the supply and return lines, disconnect them from the fittings on the cover of the pump assembly. Plug the fuel lines immediately with suitable plugs to prevent fuel spillage and lay them aside. Remove traces of fuel leaks.
8.8 Supply lines for the cover of the fuel pump assembly: 1. Wiring connector; 2. Fuel return line; 3. Fuel line heating system in the parking lot; 4. Fuel supply line; 5. Retaining ring
Note: When equipping the fuel lines with quick couplings, a special tool is required to disconnect them, e.g. Hazet 4501-1. In the same manner, disconnect the fuel line from the vehicle's interior heating/ventilation system while parked.
9. Install special tool KM-797 (see resist. illustration) into the grooves of the retaining ring, unscrew and remove the ring. If no tool is available, place a plastic wedge or suitable wooden block in the groove of the retaining ring and unscrew the ring with light blows from a plastic or wooden hammer.
8.9 Special device KM-797 (A) for removing the retaining ring of the pump assembly cover (the illustration shows the fuel pump of another Opel model)
Attention: Never use metal objects for this - there is a risk of sparks during impacts!
10. Gently pull the cover up - it is connected to the body of the assembly by cable connectors and hose connections (see resist. illustration). After removing the cover, disconnect the two supply lines and the sealing ring from its inside, if necessary, remember or write down the order of connecting the lines.
8.10 Laying electrical lines: 1. Fuel return line hose; 2. Fuel line heating system in the parking lot; 3. Cable connector «masses»; 4. Wiring connector; 5. Connector for the electrical wiring of the fuel reserve sensor; 6. Fuel supply hose; 7. O-ring
Note: On petrol models (except models equipped with Z22YH engine) The safety valve for releasing excess pressure in the fuel tank is built into the fuel pump cover. if necessary, the valve is replaced only complete with a cover.
11. Press the latch (see illustration 8.11a) in the direction indicated by the arrow (see illustration 3.11b) pull the sensor out of the assembly housing upwards.
8.11a Retainer (1) fuel gauge (sensor in the removed position)
8.11b Removing the sensor (1) fuel reserve: 1. Fixing nuts
12. Press simultaneously on three latches (see resist. illustration) assembly of the fuel pump and, holding them in this position, remove the pump from the fuel tank.
8.12 Fasteners (indicated by arrows) fuel pump assembly
13. Remove the pump from the housing and place it in a specially prepared container. Clean up any spilled fuel.
Installation
Install the pump in its original place, carefully fill the pump assembly housing into the tank and securely fasten it in the latches.
Note: If the pump is being replaced, change the wiring lines from the old one to the new one.
15. Further installation is carried out in the reverse order of removal. The sealing ring of the fuel pump assembly cover must be replaced without fail. After completing the work, check the system for leaks.
Note: The service cover and rear seat are installed after checking the tightness of the system.
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