Opel Frontera UBS. Manual - part 2231

6C–6

ENGINE FUEL

Fuel Pump

Fuel Pump and Associated Parts

035R200009

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. Drain fuel.

Tighten drain plug to the specified torque after
draining fuel.

Torque: 20 N·m (2.0 Kg·m/14 lb ft) — M8

4. Remove fuel tank assembly(1). Refer to “Fuel Tank

Removal” in this section.

5. Remove fuel pump (FP) assembly(2) fixing screws

and remove the FP assembly.

NOTE: After removing FP, cover fuel tank to prevent any
dust entering.

Installation

1. Install FP assembly(2).
2. Install fuel tank assembly(1). Refer to “Fuel Tank

Installation”.

3. Fill the tank with fuel and tighten fuel filler cap.
4. Connect battery ground cable.

6C–7

ENGINE FUEL

Fuel Pump Relay

General Description

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

Fuel Tank

Fuel Tank and Associated Parts

035R200010

Legend

(1) Fender Liner
(2) Fuel Filler Hose and Air Breather Hose
(3) Undercover
(4) Fuel Tank Wiring Connector

(5) Evapo Fuel Hose
(6) Fuel Feed Tube and Fuel Return

Tube/Quick–Connect Fittings

(7) Fuel Tank

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. Drain fuel.

Tighten drain plug to the specified torque after
draining fuel.

Torque: 20 N·m (2.0 Kg·m/14 lb ft) — M8

4. Remove fender liner (1) of wheel well on rear right

side.

5. Fuel filler hose, air breather hose and evapo hose (2).

6C–8

ENGINE FUEL

6. Remove undercover fixing bolts on both sides and

remove under cover(3).

7. Disconnect two fuel tank wiring connectors(4) on

front right side of tank.

8. Disconnect evapo fuel hose(5).
9. Disconnect fuel feed tube and fuel return tube(6).

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

10. Remove fuel tank fixing bolts on both sides and

remove fuel tank(7).

Installation

1. Install fuel tank(7).

D

Place a flange on right side of tank on the bracket.

D

Install a flange on left side on the bracket from the
bottom, and tighten bolts to the specified torque.

Torque: 36 N·m (3.7 Kg·m/27 lb ft)

2. Connect fuel feed tube and fuel return tube(6).
3. Connect evapo fuel hose(5).
4. Connect fuel tank wiring connector(4).
5. Install undercover(3).
6. Connect fuel filler hose, air breather hose and evapo

hose(2).

7. Install fender liner(1).

D

Mount fender liner to the wheel well.

D

Fill the tank with fuel and tighten fuel filler cap.

D

Connect battery ground cable.

Fuel Tube / Quick – Connect Fittings

Precautions

D

Lighting of Fires Prohibited.

D

Keep flames away from your work area to prevent the
inflammable from catching fire.

D

Disconnect the battery negative cable to prevent
shorting during work.

D

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.

141RW016

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.

6C–9

ENGINE FUEL

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 (returning 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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NOTE: This work should be done by hands. Do not use
any tools. Should the pipe can hardly be removed from
the connector, use a lubricant (light oil) and/or push and
pull the connector longitudinally until the pipe is removed.

141RW021

When reusing the delivery 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.

141RW022