Fuel Supply Pump; Fuel Tank; Insert Removal Tools Down Through Slots On Side Of In-Tank Module; Push The Tools Down Into The Slots - Opel Zafira B MPV 2006 Owners Workshop Manual

6.9a Carefully insert the removal tools
down through the slots on the side of the
in-tank module •••
6.10 With the tabs in the mounting bracket
released, lift the in-tank module up and out
of the fuel tank
retaining tabs in the tank mounting bracket
(see illustrations). Move the float arm on the
sender unit slightly when inserting the toot
adjacent to the sender unit.
10 Once the tabs in the tank mounting
bracket are released, carefully lift the in-tank
module up and out of the fuel tank (see
illustration).
11 With the assembly on the bench, release
the two retaining tabs and lift the fuel gauge
sender unit up and out of the in-tank module
(see illustrations).
Refitting
12 Refit the gauge sender unit to the in-tank
module ensuring that the retaining tabs
positively engage.
13 Manoeuvre the in-tank module carefully
in through the tank aperture and push it down
onto the retaining tabs of the tank mounting
bracket. Ensure that the retaining tabs audibly
engage with the module.
14 Locate the fuel pump or fuel filter into the
in-tank module and engage the retaining tabs.
15 Reconnect the wiring connector(s) to the
fuel pump cover, and place a new sealing
ring in position on the tank. Locate the cover
on the tank and align the marks, or direction
arrow in the position noted during removal.
16 Refit the locking ring and tighten it with
the special tool until it locks in place.
17 Reconnect the fuel hose to the pump
cover, using the marks made on removal, then
reconnect the wiring connector.
18 Refit the fuel tank as described in Sec-
tion 8.
Fuel and exhaust systems - petrol engines 4A•5
6.9b ••• push the tools down into the
slots •••
6.11 a Release the two retaining tabs •••
1 The fuel pump is located in the in-tank
module in the fuel tank. The removal and
refitting procedures are the same as for the
fuel gauge sender unit described in Section 6.
The pump is integral with the in-tank module
and cannot be renewed separately.
Note 1: Refer to the information contained in
Section 1 before proceeding.
Note 2: The fuel tank should be as empty as
possible when carrying out this procedure.
Removal
1 Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter), then depressurise the
fuel system as described in Section 5.
2 Before removing the fuel tank, all fuel
must be drained from the tank. Since a fuel
tank drain plug is not provided, it is therefore
preferable to carry out the removal operation
when the tank is nearly empty. The remaining
fuel can then be syphoned or hand-pumped
from the tank.
3 Chock the front wheels then jack up
the rear of the car and securely support it
6.9c ••• until they release the four retaining
tabs (arrowed) in the tank mounting bracket
(shown with in-tank module removed)
6.11 b ••. and lift the fuel gauge sender
unit up and out of the in-tank module
on axle stands (see Jacking and vehicle
support).
4 Disconnect the wiring for the gauge sender
unit and fuel pump at the underbody connector
adjacent to the fuel tank (see illustration).
Unclip the wiring harness from the retaining
clips.
5 Disconnect the fuel and vapour lines at the
underbody quick-release connectors on the
left-hand side of the tank (see illustration).
Be prepared for some loss of fuel. A Vauxhall/
Opel special tool is available to release the
fuel line connectors, but provided care is
taken, the connectors can be released using
a pair of long-nosed pliers, or a similar tool, to
depress the retaining tangs. Suitably plug the
disconnected fuel and vent hoses to prevent
entry of dust and dirt.
6 Unclip the handbrake cables from the
8.4 Disconnect the wiring for the
gauge sender unit and fuel pump at the
underbody connector (arrowed)