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Fuel Tank Replacement Opel Agila B

Engine Control and Fuel System - D13A ~857 words

Remove

  1. 1. Remove fuel filler cap to release fuel vapour pressure from fuel tank
  2. 2. Disconnect battery negative lead • Release nut
  3. 3. Drain fuel tank - see "Opel / Vauxhall Workshop Equipment" catalogue
  4. 4. Raise vehicle
  5. 5. Release rear muffler with tail pipe (3) from centre exhaust pipe • Remove 2x nut • Remove gasket (2)
  6. 6. Remove centre exhaust pipe (4) from diesel particulate filter (1) • Remove 2x nut • Release centre exhaust pipe from rubber mount
  7. 7. Remove gasket (5) from diesel particulate filter
  1. 8. Disconnect ventilation hose (2) from fuel tank • Release clip • Install 2x new blanking plug
  2. 9. Disconnect filler hose (1) from fuel tank • Release clip • Install 2x new blanking plug
  3. 10. Disconnect rear fuel feed pipe from centre fuel feed pipe (3) • Place collecting container below • Release integral clip – Use Remover KM-796-A • Install 2x new blanking plug
  4. 11. Disconnect rear fuel return pipe (4) from centre fuel return pipe • Release integral clip – Use Remover KM-796-A • Install 2x new blanking plug • Remove collecting container
  1. 12. Remove fuel tank (1) from vehicle • Support fuel tank from underneath – Use hydraulic jack (2) (commercially available) • Remove 4x bolt • Lower fuel tank to suitable working height • Release harness from fuel tank – Release from 2x clip • Disconnect harness connector (3) from fuel pump/sensor unit
  1. 13. Transfer fuel tank to work bench
  2. 14. Remove rear fuel feed pipe from fuel tank • Disconnect fuel pipe (1) from fuel pump/sensor unit – Release lock • Release fuel pipe from fuel tank – Release from 2x clip • Install 2x new blanking plug
  3. 15. Remove rear fuel return pipe from fuel tank • Disconnect fuel pipe (2) from fuel pump/sensor unit – Release lock • Release fuel pipe from fuel tank – Release from 2x clip • Install 2x new blanking plug
  1. 16. Remove 2x retaining strap from fuel tank • Release from 2x clip
  2. 17. Remove heat shield from fuel tank • Remove 2x nut
  3. 18. Remove fuel pump/sensor unit from fuel tank • Remove securing ring – Use Remover/Installer (1) CH-48378 • Remove seal (2)

Important. Do not reuse seal or securing ring. Always install new seal and new securing ring.

Install

  1. 19. Install new fuel pump/sensor unit to fuel tank • Install new seal • Install new securing ring (2) • Use Remover/Installer (1) CH-48378 – Align arrow mark on securing ring with 3x match mark on fuel tank (3)
  1. 20. Install heat shield to fuel tank • Install 2x nut
  2. 21. Install 2x retaining strap to fuel tank • Secure to 2x clip
  3. 22. Install rear fuel feed pipe to fuel tank • Remove 2x blanking plug • Secure fuel pipe to fuel tank – Secure to 2x clip • Connect fuel pipe (1) to fuel pump/sensor unit – Secure lock
  4. 23. Install rear fuel return pipe to fuel tank • Remove 2x blanking plug • Secure fuel pipe to fuel tank – Secure to 2x clip • Connect fuel pipe (2) to fuel pump/sensor unit – Secure lock
  1. 24. Transfer fuel tank (1) to vehicle

Important. Do not reuse fuel tank bolts. Always install new bolts.

  1. 25. Install fuel tank to vehicle • Support fuel tank from underneath – Use hydraulic jack (2) (commercially available) • Raise fuel tank • Connect harness connector (3) to fuel pump/sensor unit • Secure harness to fuel tank – Secure to 2x clip • Install 4x new bolt 45 Nm
  1. 26. Connect rear fuel feed pipe to centre fuel feed pipe (3) • Place collecting container below • Remove 2x blanking plug • Secure integral clip
  2. 27. Connect rear fuel return pipe (4) to centre fuel return pipe • Remove 2x blanking plug • Secure integral clip • Remove collecting container
  3. 28. Connect filler hose (1) to fuel tank • Remove 2x blanking plug • Secure clip 1.5 Nm
  4. 29. Connect ventilation hose (2) to fuel tank • Remove 2x blanking plug • Secure clip
  1. 30. Clean mating surfaces of diesel particulate filter and centre exhaust pipe
  2. 31. Install new gasket (5) to diesel particulate filter (1) • Push on
  3. 32. Install centre exhaust pipe (4) to diesel particulate filter • Secure centre exhaust pipe to rubber mount • Install 2x new nut 60 Nm
  4. 33. Clean mating surfaces of centre exhaust pipe and rear muffler with tail pipe
  5. 34. Secure rear muffler with tail pipe (3) to centre exhaust pipe (4) • Install new gasket (2) • Install 2x new nut 60 Nm
  1. 35. Lower vehicle
  2. 36. Replenish fuel tank - see "Opel / Vauxhall Workshop Equipment" catalogue
  3. 37. Install fuel filler closure cap
  4. 38. Close fuel tank filler flap
  5. 39. Connect battery negative lead • Secure nut 11 Nm
  6. 40. Program all volatile memories – see operation “Program Volatile Memories”

Important. Air bleeding must be carried out when fuel system has been disassembled or when vehicle ran out of fuel.

  1. 41. Bleed fuel system • Turn ignition on for 5 seconds, then switch off • Repeat this 6 times then check engine starts

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