Opel Frontera UE. Manual - part 1436

6C–8

ENGINE FUEL (6VD1 3.2L)

When reusing the delivery and return pipe retainer,
reuse without removing the retainer from the pipe. If
the retainer is damaged or deformed, however,
replace with a new retainer.
Cover the connectors removed with a plastic bag, etc.
to prevent the entry of dust or rain water.

141R100006

Reuse of Quick–Connector

(Delivery Pipe and Return Pipe)

D

Replace the pipe and connector if scratch, dent or
crack is found.

D

Remove mud and dust from the pipe and make sure
that the end including spool is free of defects, such as
scratch, rust, and dent, which may cause poor
sealability. If defective, replace with a new pipe.

D

If the retainer removed according to the removal step
above is attached to the pipe, clean and insert it
straight into the quick-connector till it clicks. After it
clicks, try pulling it out to make sure that it is not drawn
and is securely locked.

NOTE: The retainer, once removed from the pipe, cannot
be reused. Just replace with a new retainer. Insert the
new retainer into the connector side until it clicks, and
connect the pipe as inserting it into the retainer until it
clicks.

141RW018

Assembling Advice

Application of engine oil or light oil to the pipe facilitates
connecting work. The work should be started immediately
after lubrication, since dust may stick to the pipe surface
to cause poor sealability if a long time passes after
lubrication.
Test/Inspection After Assembling

1. Reconnect the battery negative cable.
2. Turn the ignition key to the “ON” position and check

pump startup sound. As the pump is actuated to raise
fuel pressure, check and see fuel leak from the piping
system.

3. Make sure of no fuel leakage by conducting the above

fuel leak check a few times.

4. Start the engine and make sure of stable idling speed

and normal vehicle run.The entry of dust during the
work may sometimes affect the fuel injection system.

Fuel Pump Relay

General Description

In order to control the FPAS operation, the FPAS relay is
provided. When the starter switch is turned to “ON”
position, the FPAS relay operates the FPAS for 2
seconds.
When it is turned to “START” position, the Engine Control
Module receives the reference pulse from the Ignition
Control Module and it operates the relay, again causing
the FPAS to feed fuel.

SECTION

6C–9

ENGINE FUEL (6VD1 3.2L)

Fuel Tank

Fuel Tank and Associated Parts

140RX005

Legend

(1) Roll Over&Float Valve
(2) Retaining Cover
(3) Hose; Evaporative Fuel
(4) Hose; Air Breather
(5) Hose; Fuel Filler
(6) Bolt; Fuel Tank Protector Fixing
(7) Snap Ring
(8) Connector; Fuel Level Sensor
(9) Connector; Fuel Feed Pump

(10) Fuel Pump and Sender Assembly

(11) Fuel Feed Port

(12) Fuel Tube/Quick Connector
(13) Fuel Return Port
(14) Bolt; Fuel Tank Asm. Fixing
(15) Protector; Fuel Tank
(16) Fuel Tank Assembly
(17) Hose; Fuel Feed
(18) Hose; Fuel Return
(19) Protector; Heat

Removal

CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission”.

1. Disconnect battery ground cable.
2. Loosen fuel filler cap.
3. Support underneath of the fuel tank protector (15)

with a lifter.

4. Disconnect evaporative fuel hose (3) at the canister.
5. Disconnect fuel feed hose (17) and fuel return hose

(18) near the fuel filter.

NOTE: Plug both ends of the fuel hoses to prevent fuel
leakage.

6. Disconnect air breather hose (4) and fuel filler hose

(5) at the fuel filler neck.

NOTE: Cover fuel hose to prevent any dust entering.

7. Remove the four fuel tank assembly fixing bolts (14)

at four corners of the tank.

8. Let down the tank and disconnect the wiring

connectors (8,9).

9. Remove fuel tank assembly along with protectors

(15,19) .

10. Remove retaining cover (2) and roll over & float valve

(1) along with the evaporative fuel hose and pipe (3).

SECTION

6C–10

ENGINE FUEL (6VD1 3.2L)

11. Remove Fuel Tube/Quick Connector (12).

NOTE: Handling of the fuel tube sure to refer “Fuel
Tube/Quick Connector Fittings” in this section.

12. Remove fuel pump and sender assembly (10) by

removing the snap ring (7) along with the fuel hoses
(17,18).

13. Remove protectors (15,19) by removing the six fixing

bolts (6).

Installation

1. Install protectors (15,19) and tighten the six fixing

bolts to the specified torque.

Torque: 69 N·m (7.0 kg·m/51 lb ft)

2. Install fuel pump and sender assembly by fitting in of

the snap ring (7).

3. Install Fuel Tube/Quick connector (12).

NOTE: Handling of the fuel tube sure to refer “Fuel
Tube/Quick Connector Fittings” in this section.

4. Install roll over & float valve (1) by fitting in of the

retaining cover (2).

5. Lift up fuel tank assembly and connect the wiring

connectors (8,9).

6. Install fuel tank assembly along with protectors and

tighten the four fixing bolts to the specified torque.

Torque: 69 N·m (7.0 kg·m/51 lb ft)

7. Connect fuel filler hose (5) and air breather hose (4),

and clip them firmly.

8. Connect fuel feed hose (17) and fuel return hose (18),

and clip them firmly.

9. Connect evaporative fuel hose (3).

10. Tighten fuel filler cap.

11. Connect battery ground cable.

Fuel Gauge Unit

Removal and Installation

As for removal and installation of the Fuel Gauge Unit,
refer to  “Fuel Tank” of this section 6C as the fuel gauge
unit is combined with the fuel pump and sender assembly.

Fuel Filler Cap

General Description

Fuel filler cap includes vacuum valve and pressure valve.
In case any high vacuum and any high pressure happen in
tank, each valve works to adjust the pressure to prevent
the tank from being damaged.

140R100051

Legend

(1) Vacuum Valve
(2) Pressure Valve
(3) Seal Ring

Inspection

Check the seal ring in the filler cap for presence of any
abnormality and for seal condition.
Replace the filler cap, if abnormal.

CAUTION:
The fuel filler cap valve has characteristics.
A defective valve, no valve at all or a valve with the
wrong characteristics will do a lot of harm to engine
operating characteristics; be sure to use the same
fuel filler cap as installed in this vehicle.

SECTION

6C–11

ENGINE FUEL (6VD1 3.2L)

Main Data and Specifications

Torque Specification

N·m (kg·m/lb ft)

140RY00018

SECTION