Opel Frontera UE. Manual - part 771

ENGINE FUEL (X22SE 2.2L)

6C–5

Inspection

After installation, start engine and check for fuel leak 
age.

In–Tank Fuel Filter

The filter is located on the lower end of the fuel pickup 
tube in the fuel tank. It prevents dirt from entering the 
fuel pipe and also stops water unless the filter is 
completely submerged in the water. It is a self cleaning 
type, not requiring scheduled maintenance. Excess 
water and sediment in the tank restricts fuel supply to 
the engine, resulting in engine stop. In such a case, the 
tank must be cleaned throughly.

Fuel Pump Flow Test

If reduction of fuel supply is suspected, perform the 
following checks.

1. Make sure that there is fuel in the tank.

2. With the engine running, check the fuel feed pipe 

and hose from fuel tank to injector for evidence of 
leakage. Retighten, if pipe or hose connection is 
loose. Also, check pipes and hoses for squashing or 
clogging.

3. Insert the hose from fuel feed pipe into a clean 

container, and check for fuel pump flow rate.

4. Connect the pump relay terminals with a jumper 

wire(1) as shown and start the fuel pump to 
measure delivery.

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CAUTION:  Never generate sparks when connecting 
a jumper wire.

If the measure value is out of standard, conduct the 
pressure test.

Pressure test

For the pressure test to the fuel system, see Section 6E 
“Fuel Control System".

Delivery

Delivery

15 seconds

0.38 liters minimum

6C–6

ENGINE FUEL (X22SE 2.2L)

Fuel Pump

Fuel Pump and Associated Parts

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Legend

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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 assembly (13) 

with a lifter.

4. Remove fuel tank assembly (13). Refer to “Fuel 

Tank Removal" in this section.

5. Remove Fuel Tube/Quick Connector (2).

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

(1) Fuel Feed Port
(2) Fuel Tube/Quick Connector
(3) Fuel Return Port
(4) Fuel Pump and Sender Assembly
(5) Connector; Fuel Feed Pump
(6) Connector; Fuel Level Sensor
(7) Fuel pump lock

(8) Hose; Evaporative Fuel
(9) Hose; Air Breather

(10) Hose; Fuel Filler
(11) Fuel Return Hose
(12) Fuel Feed Hose
(13) Fuel Tank Assembly

ENGINE FUEL (X22SE 2.2L)

6C–7

6. Remove fuel pump and sender (FPAS) assembly(4) 

using 5–8840–2602–0.

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NOTE:

• After removing pump assembly (4), cover fuel tank to 

prevent any dust entering.

Installation

1. Install FPAS assembly(4) using 5–8840–2602–0.

2. Install Fuel Tube/Quick Connector (2).

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

3. Install fuel tank assembly(11). Refer to “Fuel Tank 

Installation".

4. Fill the tank with fuel and tighten fuel filler cap.

5. Connect battery ground cable.

6C–8

ENGINE FUEL (X22SE 2.2L)

Fuel Tube / Quick – Connector Fittings

Precautions

• Lighting of Fires Prohibited.

• Keep flames away from your work area to prevent the 

inflammable from catching fire.

• Disconnect the battery negative cable to prevent 

shorting during work.

• When welding or conducting other heat-generating 

work on other parts, be sure to provide pretreatment 
to protect the piping system from thermal damage or 
spattering.

Cautions During Work

Do not expose the assembly to battery electrolyte or do 
not wipe the assembly with a cloth used to wipe off spilt 
battery electorolyte.
The piping wet with battery electrolyte cannot be used.
Be careful not to give a bending or twisting force to the 
piping during the work. If deformed, replace with a new 
piping.

Removal

1. Open the fuel cap to relieve the fuel pressure in the 

tank.
If the fuel quick-connect fittings are dusty, clean with 
an air blower, etc. and then remove it.

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As some pressure may remain in the piping, cover 
the connector with a cloth, etc. to prevent the 
splashing of fuel in the first disconnection of the 
piping.

2. For removal of the delivery pipe (feeding fuel to the 

engine), hold the connector in one hand, and hold 
the retainer tab with the other hand and pull out the 
connector, as illustrated. The pipe can be removed 
with the retainer attached.

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3. For removal of the return pipe (returnig fuel to the 

tank), hold the pipe in one hand, and pull out the 
connentor with the other hand while pressing the 
square relieve button of the retainer, as illustrated.

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