Opel Frontera UBS. Manual - part 263

6C–8

ENGINE FUEL

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.

141RW020

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

6C–10

ENGINE FUEL

Reuse of Quick–Connector

(Delivery 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

(Return Pipe)

D

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

D

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

D

After cleaning the pipe, insert it straight into the
connector until it clicks. After it clicks, try pulling it out
to make sure that it is not drawn and is securely
locked.

141RW017

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.

6C–11

ENGINE FUEL

Fuel Gauge Unit

Fuel Gauge Unit and Associated Parts

140RS004

Legend

(1) Wiring Connector
(2) Fuel Gauge Unit

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. Wiring connector

D

Disconnect wiring connector(1) from the unit.

5. Fuel gauge unit

D

Remove the fixing screws, then the fuel gauge
unit(2).

NOTE: After removing fuel gauge unit, cover fuel tank to
prevent any dust entering

Installation

1. Fuel gauge unit(2).
2. Wiring connector(1).

D

Connect the wiring connector to the fuel gauge unit.

D

Fill the tank with fuel and tighten fuel filler cap.

D

Connect battery ground cable.