Replacing the fuel tank and its filler pipe Opel Astra H

If a fuel leak is detected from the tank, replace the tank, since on an Opel Astra it is molded from special plastic and cannot be repaired.

If the fuel filter mesh is often clogged, remove and flush the tank.

Useful advice

It is more convenient to remove an empty tank while working on a lift, overpass or inspection ditch. For removal of the remains of fuel remove the fuel module (Removal, repair and installation of the fuel pump see) and pump out fuel through the opened opening in a tank.

You will need: a “7” key, a “13” socket head, side cutters, a flat-blade screwdriver.

1. Reduce the pressure in the supply system (see Reducing the pressure in the supply system).

2. Disconnect a wire from the minus plug of the storage battery.

3. Remove the additional muffler (Replacement of the additional muffler see).

4. Disconnect the rear parking brake cables from the equalizer (see Replacing the rear parking brake cables)...

5. ...and away from the two holders on the fuel tank, move the cables to the side.

6. Squeeze the clamps of the fuel module wiring harness block ...

7. ... and disconnect the block.

8. Snip the air outlet tube clamp with side cutters ...

Note

Clamp disposable.

9. ... and disconnect the tube from the fitting of the filler pipe of the fuel tank.

10. Snip the three clamps that secure the air outlet tube to the filler pipe with side cutters.

Note

Disposable clamps.

11. Loosen the clamp that secures the connecting hose of the filler pipe to the fuel tank pipe ...

12. ... and disconnect the hose from the nozzle, at the same time removing the clamp from the hose so as not to lose it.

13. Use a screwdriver to wring out the retainer of the pressure pipe tip ...

14. ... and disconnect the pipeline from the fuel supply line.

15. Disconnect the drain pipe in the same way.

16. Place a secure support under the tank.

17. Turn out bolts of fastening of two collars of a suspension bracket of a fuel tank, remove collars, remove a support and remove a fuel tank.

18. Install the fuel tank in the reverse order of removal.

19. After connecting the pipelines and the fuel pump wiring harness, fill the tank with gasoline, start the engine and check the tightness of all pipeline connections.

If you need to remove the fuel tank filler pipe , do the following.

1. Remove the right rear wheel and place the vehicle on a secure stand.

2. Remove the right back fender liner (see Removal and installation of fender liner).

3. Disconnect the air outlet pipe from the filler pipe fitting and the pipe connecting hose from the fuel tank nozzle (see paragraphs 8-12 above in this subsection).

4. Screw in a bolt of fastening of a bulk pipe of a fuel tank to the right back side member.

5. Open the hatch cover of the filler pipe of the fuel tank and remove the filler seal by removing it from the hatch flanging.

6. Turn out a bolt of fastening of a bulk pipe to an arm on a body sidewall...

7. ... and remove the fill pipe.

8. Install the parts in the reverse order of removal.

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  Source http://www.automnl.com/model/opel_astra_h2/291/