Removal and installation the fuel pump/fuel level sensor (Opel Vectra C)

General information

1. On petrol models and on models equipped with a 1.9-litre diesel engine, fuel is pumped into the system by an electric fuel pump. The electric pump, together with the fuel level sensor, is installed in the housing of the assembly, which is immersed in the fuel tank. On other diesel models, only the fuel level sensor is installed in the tank. Fuel is supplied to the system by the high-pressure fuel pump.

2. The reserve sensor consists of a float and a potentiometer. When the fuel level drops, the sensor float drops, and 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 should not be filled more than 2/3 of its capacity. Before removing the fuel pump assembly, empty the fuel tank to the required level by using fuel while driving the car, or by pumping out the fuel using a special pump through the filler neck of the tank. Work should be carried out in a well-ventilated room, preferably equipped with a special exhaust system.

Removal

4. Disconnect the negative cable from the battery.

5. To gain access to the floor panel access hatch, 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 carpet area above the hatch is already cut, but on newer vehicles there may still be connecting straps, carefully cut these with a sharp knife

7. Pry up and remove the service hatch cover (see accompanying illustration) access to the fuel pump assembly.



8.7 Service cover (1) of the access hatch to the fuel pump assembly

8. Disconnect the electrical wiring connector (see accompanying illustration) secure the harness by taping it to the floor panel. Clearly mark the supply and return fuel lines to avoid confusion during installation, and disconnect them from the fittings on the pump assembly cover. To prevent fuel spills, immediately plug the fuel lines with suitable plugs and move them to the side. Remove any traces of fuel leaks.

Note: If the fuel lines are equipped with quick-release couplings, a special tool, such as Hazet 4501-1, will be required to disconnect them. In a similar manner, disconnect the fuel line of the heating/ventilation system of the car's interior while it is parked.

9. Install the special device KM-797 (see accompanying illustration) into the grooves of the retaining ring, unscrew and remove the ring. If there is no device, install a plastic wedge or a suitable wooden block into the groove of the retaining ring and unscrew the ring with light blows of a plastic or wooden hammer.

Caution: Never use metal objects for this purpose - there is a risk of sparks when striking!

10. Carefully pull the cover upwards - it is connected to the assembly body by cable connectors and hose connections (see accompanying illustration). After removing the cover, disconnect the two supply lines and the sealing ring from its inner side; if necessary, remember or write down the order in which the lines are connected.

Note: On petrol models (except for models equipped with Z22YH engine) the fuel pump cover has a built-in safety valve to release excess pressure in the fuel tank. If necessary, the valve is replaced only as a set with the 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.







12. Press down on three clamps at the same time (see accompanying illustration) fuel pump assemblies and, holding them in this position, remove the pump from the fuel tank.



13. Remove the pump from the housing and place it in a specially prepared container. Remove traces of spilled fuel.

Installation

Install the pump in its regular place, carefully insert the pump assembly body into the tank and securely fasten it in the clamps.

Note: If replacing a pump, re-route the wiring from the old to the new one.

The source is on the online website www.opelbook.ru

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 system for leaks.