Opel Frontera UBS. Manual - part 1238

6E–318

ENGINE DRIVEABILITY AND EMISSIONS

2. Remove the fuel pump relay from the underhood

relay box.  Refer to 

Fuel Pump Relay.

TS23976R

3. Start the engine and allow it to stall.
4. Crank the engine for 30 seconds.
5. Disconnect the negative battery cable.

Fuel Pump Assembly

Removal Procedure

1. Disconnect the negative battery cable.
2. Drain all the fuel from the tank.
3. Install and tighten the drain plug.

Tighten

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Tighten the drain plug to 20 N·m (14 lb ft.).

4. Remove the fuel tank. Refer to 

Fuel Tank.

5. Remove the retaining screws from the fuel tank.
6. Remove the fuel pump assembly from the fuel tank.

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Cover the fuel pump opening in order to prevent
dust, dirt, or debris from entering the fuel tank.

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Inspection Procedure

1. Inspect the fuel pump gasket for tears, cracks,

stretching, or rotting. If any of these conditions are
found, replace the fuel pump gasket.

2. Inspect the in-tank fuel filter for tears or evidence of

dirt, debris, or water in the fuel. If any of these
conditions are found, replace the in-tank fuel filter.

Installation Procedure

1. Install the fuel pump assembly.
2. Install the fuel pump assembly retaining screws.
3. Install the fuel tank assembly. Refer to 

Fuel Tank.

4. Fill the tank with fuel.
5. Tighten the fuel filler cap.
6. Connect the negative battery cable.

TS23795

6E–319

ENGINE DRIVEABILITY AND EMISSIONS

Fuel Pump Relay

Removal Procedure

1. Remove the fuse and relay box cover from under the

hood.

2. Consult the diagram on the cover to determine which

is the correct relay.

3. Insert a small screwdriver into the catch slot on the

forward side of the fuel pump relay.

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The screwdriver blade will release the catch inside.

T321092

4. Pull the relay straight up and out of the fuse and relay

box.

TS23976R

Installation Procedure

1. Insert the relay into the correct place in the fuse and

relay box with the catch slot facing forward.

2. Press down until the catch engages.

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An audible “click” will be heard.

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3. Install the fuse and relay box cover.

Fuel Rail Assembly

Removal Procedure

NOTE:

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Do not attempt to remove the fuel inlet fitting on the
fuel rail.  It is staked in place.  Removing the fuel inlet
fitting will result in damage to the fuel rail or the
internal O-ring seal.

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Use care when removing the fuel rail assembly in
order to prevent damage to the injector electrical
connector terminals and the injector spray tips.

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Fittings should be capped and holes plugged during
servicing to prevent dirt and other contaminants from
entering open lines and passages.

6E–320

ENGINE DRIVEABILITY AND EMISSIONS

IMPORTANT:

An eight-digit identification number is

stamped on the side of the fuel rail.  Refer to this number
when you service the fuel rail or when a replacement part
is required.

TS24022

Before removal, the fuel rail assembly may be cleaned
with a spray type engine cleaner.  Follow the spray
package instructions.  Do not immerse the fuel rails in
liquid cleaning solvent.
1. Depressurize the fuel system. Refer to Fuel Pressure

Relief Procedure in this Section.

2. Disconnect the negative battery cable.
3. Remove the engine cover.
4. Disconnect the accelerator pedal cable from throttle

body and cable bracket.

5. Disconnect the connectors from manifold absolute

pressure sensor, solenoid valve, electric vacuum
sensing valve.

6. Disconnect the vacuum hose on canister VSV and

positive crankcase ventilation hose.

7. Remove the common chamber. Refer to the common

chamber in Engine Mechanical.
1. Lift up carefully on the fuel injectors. Do not

separate the fuel injectors from the fuel rail.

2. If an injector becomes separated from the fuel

rail, the infector O-ring seals and the retainer clip
must be replaced.

3. Drain residual fuel into an approved container.

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8. If removal of the fuel pressure regulator is necessary,

refer to 

 Fuel Pressure Regulator.

9. If removal of the fuel injectors is necessary, refer to

Fuel Injectors.

Installation Procedure

1. If the fuel injectors were removed, install them.  Refer

to 

Fuel Injectors.

2. If the fuel pressure regulator was removed, install it.

Refer to 

Fuel Pressure Regulator.

3. Install the common chamber. Refer to common

chamber in engine Mechanical.

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6E–321

ENGINE DRIVEABILITY AND EMISSIONS

4. Connect the vacuum hose on Canister VSV and

positive crankcase ventilation hose.

5. Connect the connectors to manifold absolute

pressure sensor, solenoid valve, electric vacuum
sensing valve.

6. Connect the accelerator pedal cable to throttle body

and cable bracket.

7. Install the engine cover.
8. Connect the negative battery cable.
9. Crank the engine until it starts.  Cranking the engine

may take longer than usual due to trapped air in the
fuel rail and in the injectors.

Fuel Tank

Removal Procedure

1. Disconnect the negative battery cable.
2. Loosen the fuel filler cap.
3. Drain the fuel from the tank into an approved

container.

4. Install and tighten the drain plug.

Tighten

D

Tighten the drain plug to 20 N·m (14 lb ft.).

5. Disconnect the fuel filler hose at the fuel tank.
6. Disconnect the air breather hose at the fuel tank.

TS23796

7. Remove the undercover retaining bolts.
8. Remove the undercover.

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9. Disconnect the wiring connector to the fuel pump.
10. Disconnect the wiring connector to the fuel gauge

unit.

11. Remove the fuel gauge unit connector from the

bracket.

12. Disconnect the EVAP vapor hose.
13. Disconnect the fuel supply hose.
14. Disconnect the fuel return hose.

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Plug the hoses to prevent dust from entering the
hoses.

TS23769