Fuel Tank Replacement — Opel Agila B (2008-2011)

Fuel Tank Replacement Opel Agila B

1. Drain fuel tank - see "Opel / Vauxhall Workshop Equipment" catalogue
2. Relieve fuel pressure • Open fuel tank filler flap • Remove fuel filler cap to release fuel vapour pressure from fuel tank
3. Disconnect battery negative lead • Release nut
4. Raise vehicle
5. Release rear muffler with tail pipe (1) from centre exhaust pipe with muffler (3) • Remove 2x nut • Remove gasket (2)
6. Remove centre exhaust pipe with muffler (3) from front exhaust pipe • Remove 2x bolt, 2x spring • Release centre exhaust pipe from 2x rubber mount (4)
7. Remove gasket (5) from front exhaust pipe

8. Disconnect ventilation hose (2) from fuel tank • Release clip • Install 2x new blanking plug
9. Disconnect filler hose (1) from fuel tank • Release clip • Install 2x new blanking plug
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
11. Disconnect fuel tank ventilation pipe (4) from fuel tank ventilation pipe • Release integral clip – Use Remover KM-796-A • Install 2x new blanking plug • Remove collecting container

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

13. Transfer fuel tank to work bench
14. Remove rear fuel feed pipe from fuel tank • Disconnect fuel pipe from fuel pump/sensor unit (2) – Release lock (1) • Release fuel pipe from fuel tank – Release from 2x clip • Install 2x new blanking plug

15. Remove 2x retaining strap from fuel tank • Release from 2x clip
16. Remove heat shield from fuel tank • Remove 2x nut
17. 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.

18. Install fuel pump/sensor unit to fuel tank • Install new seal (2) • Install new securing ring – Use Remover/Installer (1) CH-48378 – Align arrow mark on securing ring with 3x match mark on fuel tank

19. Install heat shield to fuel tank • Install 2x nut
20. Install 2x retaining strap to fuel tank • Secure to 2x clip
21. 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 to fuel pump/sensor unit (2) – Secure lock (1)

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

22. Transfer fuel tank to vehicle
23. Install fuel tank (1) 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

24. Connect rear fuel feed pipe to centre fuel feed pipe (3) • Place collecting container below • Remove 2x blanking plug • Secure integral clip
25. Connect fuel tank ventilation pipe (4) to fuel tank ventilation pipe • Remove 2x blanking plug • Secure integral clip • Remove collecting container
26. Connect filler hose (1) to fuel tank • Remove 2x blanking plug • Secure clip 1.5 Nm
27. Connect ventilation hose (2) to fuel tank • Remove 2x blanking plug • Secure clip

28. Clean mating surfaces of front exhaust pipe and centre exhaust pipe with muffler
29. Install new gasket (5) to front exhaust pipe • Push on
30. Install centre exhaust pipe with muffler (3) to front exhaust pipe • Secure centre exhaust pipe with muffler to 2x rubber mount (4) • Install 2x spring, 2x bolt 43 Nm
31. Clean mating surfaces of centre exhaust pipe with muffler and rear muffler with tail pipe
32. Secure rear muffler with tail pipe (1) to centre exhaust pipe with muffler (3) • Install new gasket (2) • Install 2x new nut 60 Nm

Fuel Tank Replacement Opel Agila B