d)Disconnect the fuel pump hose and wiring
as described in Section 12.
e)When releasing the tank mounting straps,
note that the fuel filter must either be
moved aside or removed completely,
whichever is most convenient
f)One of the fuel hoses connects to a pipe
in the side of the tank.
DOHC models
2Disconnect the battery negative lead.
3Siphon out any remaining fuel in the tank
through the filler pipe. Siphon the fuel into a
clean metal container that can be sealed.
4Chock the front wheels, then jack up the
rear of the vehicle, and support on axle stands
placed under the body side members (see
“Jacking and Vehicle Support”).
5Open the fuel filler flap, then pull back the
rubber seal to expose the fuel filler pipe
securing screw (see illustration). Remove the
screw.
6Release the fuel tank vent hoses from the
clips on the underbody.
7Support the weight of the fuel tank on a
jack, with an interposed block of wood.
8Unscrew the securing bolts from the tank
mounting straps. Then remove the straps and
lower the tank sufficiently to enable the fuel
hoses, vent hoses and fuel tank sender unit
wiring to be disconnected (see illustration).
9Disconnect the vent hoses and the fuel tank
sender unit wiring. Note the positions of the
vent hoses as an aid to refitting.
10Disconnect the fuel hoses from the tank and
the fuel tank sender unit, making a note of the
hose positions for use when refitting. Be
prepared for fuel spillage, and take adequate fire
precautions. Plug the open ends of the hoses, to
prevent dirt ingress and further fuel loss.
11Lower the fuel tank, and withdraw it from
under the vehicle.
12If the tank contains sediment or water, it
may be cleaned out using two or three rinses
with clean fuel. Shake vigorously using
several changes of fuel, but before doing so,
remove the fuel tank sender unit, as described
in Section 17. This procedure should be
carried out in a well-ventilated area, and it is
vital to take adequate fire precautions - refer
to the “Safety first!” Section at the beginning
of this manual for further details.
Refitting
13Any repairs to the fuel tank should be
carried out by a professional.
14Refitting is a reversal of removal, ensuring
that all hoses are reconnected to their correct
locations as noted during removal.
15On completion, fill the fuel tank, then run
the engine and check for leaks. If leakage is
evident, stop the engine immediately, and
rectify the problem without delay.
17Fuel tank sender unit -
removal and refitting
3
Note:Refer to Section 2 before proceeding
Removal
SOHC models
1Remove the fuel tank, (refer to Section 16),
if necessary. Note that there is only one hose
connected to the sender unit. This must also
be disconnected from the union on the inside
of the unit before it can be withdrawn
completely from the tank (see illustration).
DOHC models
2Remove the fuel tank, as described in
Section 16.
3Make alignment marks on the sender unit
and the fuel tank so that the sender unit can
be refitted in its original position.
4To remove the sender unit, an improvised
tool must be used which engages with thecut-outs in the sender unit retaining ring. The
Vauxhall special tool KM-673 for this purpose
is shown (see illustration).
5Withdraw the unit carefully, to avoid
bending the float arm.
6Recover the sealing ring.
Refitting
7Refitting is a reversal of removal,
remembering the following points.
8Renew the sealing ring.
9Ensure that the marks made on sender unit
and fuel tank before removal are aligned.
10Refit the fuel tank, (Section 16).
18Fuel flow damper - removal
and refitting
3
Note:Refer to Section 2 before proceeding
Removal
1The fuel flow damper is located on the fuel
pump bracket under the rear of the vehicle, on
the right-hand side of the spare wheel well or
in front of the fuel tank, depending on model
(see illustration). The damper is positioned in
the fuel feed line between the fuel pump and
the fuel filter, and its purpose is to reduce
pressure fluctuations in the fuel return line,
thus reducing noise levels.
2Disconnect the battery negative lead.
3Have a container to hand, to catch the fuel
that will be released as the damper is
removed.
4B•8Fuel and exhaust systems - fuel injection models
16.5 Fuel filler pipe securing screw
(arrowed) - models with semi-trailing arm
rear axles17.1 Fuel level sender unit - models with
semi-independent rear axles
18.1 Fuel flow damper - models with semi-
trailing arm rear axles17.4 Vauxhall special tool KM-673 for
removing fuel level sender units
16.8 Fuel tank mounting - models with
semi-trailing arm rear axles
1 Strap securing bolt 2 Vent hose securing
The jack supplied with the vehicle tool kit
should only be used for changing roadwheels.
When carrying out any other kind of work,
raise the vehicle using a hydraulic jack, and
always supplement the jack with axle stands
positioned under the vehicle jacking points.
When jacking up the vehicle with a trolleyjack, position the jack head under one of the
relevant jacking points (note that the jacking
points for use with a hydraulic jack are
different to those for use with the vehicle
jack). Do not jack the vehicle under the sump
or any of the steering or suspension
components. Supplement the jack using axlestands. The jacking points and axle stand
positions are shown in the accompanying
illustrations. Never work under, around, or
near a raised vehicle, unless it is adequately
supported in at least two places.
The radio/cassette unit fitted as standard
equipment by Vauxhall is equipped with a
built-in security code, to deter thieves. If the
power source to the unit is cut, the anti-theft
system will activate. Even if the power source
is immediately reconnected, the
radio/cassette unit will not function until the
correct security code has been entered.Therefore, if you do not know the correct
security code for the radio/cassette unit, do
not disconnect the battery negative terminal
of the battery, or remove the radio/cassette
unit from the vehicle.
Refer to the Audio handbook supplied in
the owners handbook pack, for further details
of how to use the code.If you should loose or forget the code, seek
the advice of your Vauxhall dealer. On
presentation of proof of ownership, a Vauxhall
dealer will be able to unlock the unit and
provide you with a new security code.
Jacking and Vehicle Support REF•5
Rear jacking point for hydraulic jack or
axle standsWhen raising the front of the vehicle,
locate the jack underneath the centre of
the subframe. Note the use of the block of
wood placed on the jack headFront jacking point for hydraulic jack or
axle stands
Location of jacking points
1 Jacking points for use with vehicle jack 2 Jacking points for use with hydraulic jack or axle stands
REF
Radio/cassette unit Anti-theft System
