Fuel Injection System; Fuel Gauge Sender Unit; Fuel Pressure Connection Valve On Fuel Rail; Fuel Pressure Connection Valve On High-Pressure Fuel Pump - Opel Zafira B MPV 2006 Owners Workshop Manual

4A•4 Fuel and exhaust systems - petrol engines
5.3a Fuel pressure connection valve
(arrowed) on the fuel rail -
1.8
litre engines
Warning: Refer to the warning
note in Section 1 before pro-
ceeding. The following procedure
will merely relieve the pressure in the
fuel system - remember that fuel will still
be present in the system components,
and take precautions accordingly before
disconnecting any of them.
1 The fuel system referred to in this Section
is defined as the tank-mounted fuel pump,
the fuel injectors, the high-pressure fuel pump
(2.2 litre engines) and the metal pipes and
flexible hoses of the fuel lines between these
components. All these contain fuel which will
be under pressure while the engine is running,
6.5 Lift the fuel pump cover away from
tank and remove the cover sealing ring
6.6 Disconnect the wiring connector(s)
from the underside of the fuel pump cover
5.3b Fuel pressure connection valve
(arrowed) on the high-pressure fuel pump -
2.2 litre engines
and/or while the ignition is switched on. The
pressure will remain for some time after the
ignition has been switched off, and it must be
relieved in a controlled fashion when any of
these components are disturbed for servicing
work.
2
Where fitted, remove the plastic cover over
the top of the engine.
3 Locate the fuel pressure connection valve
which is fitted to the fuel rail. On 1.6 litre
engines, the valve is located at the top
right-hand end of the fuel rail. On 1.8 litre
engines it can be found on the top left-hand
end of the fuel rail, and on 2.2 litre engines the
valve is located on the fuel inlet pipe
connection on the high-pressure fuel pump
(see illustrations).
4 Unscrew the cap from the valve and position
a container beneath the valve. Hold a wad of
rag over the valve and relieve the pressure in
the fuel system by depressing the valve core
with a suitable screwdriver. Be prepared for
the squirt of fuel as the valve core is depressed
and catch it with the rag. Hold the valve core
down until no more fuel is expelled from the
valve.
5 Once all pressure is relieved, securely refit
the valve cap.
6 Fuel
gauge
sender unit ..
removal ~ refitting
Note 1: Vauxha/1/0pel special tool KM-797 (or
suitable alternative) will be required to remove
6.7 Depress the retaining tabs and lift the
fuel pump out of the in-tank module
and refit the fuel pump cover locking ring, and
special tool KM-6391 (or suitable alternative)
will be required to remove the in-tank module
from the fuel tank.
Note 2:
A new fuel pump cover sealing ring
will be required on refitting.
Removal
1 Remove the fuel tank as described in
Section 8.
2 Compress the clips located on each side of
the fuel hose end fitting and ease the fitting
off of its union. Plug the hose end to minimise
fuel loss.
3 Using the Vauxhall/Opel special tool,
unscrew the locking ring and remove it from
the tank.
4 Make identification marks on the fuel pump
cover and the body to ensure that the cover is
refitted in its original position. There may be
an arrow stamped on the cover; if so note its
direction.
5 Carefully lift the fuel pump cover away from
tank and remove the cover sealing ring (see
illustration).
6 Disconnect the wiring connector(s) from
the underside of the fuel pump cover (see
illustration).
7 Depress the retaining tabs and lift the
fuel pump out of the in-tank module ~see
illustration). Place the assembly to one side.
8 To remove the in-tank module (containing
the gauge sender unit) from the fuel tank,
Vauxhall/Opel special tool KM-6391, or a
suitable alternative will be required. The
special tool consists of four metal strips that
are inserted down the sides of the in-tank
module, to release the module from the four
tabs of the mounting bracket, which remains
in the tank. In the absence of the special tool
a suitable alternative can be easily made (see
Tool Tip).
g Carefully insert the four tools down through
the slots on the side of the in-tank module
until they engage and release the four