Opel Corsa B 1993–2000 Service and Repair Manual: Fuel tank - removal and refitting

Note: Refer to the warning note in Section 1 before proceeding.

Removal

1. Disconnect the battery negative lead cap.

Remove the fuel tank filler cap.

2. A drain plug is not provided and it will therefore be necessary to syphon or hand pump all the fuel from the tank before removal.

3. Having emptied the tank, jack up the rear of the car and support it on axle stands.

Hatchback and Saloon models

4. Remove the exhaust system.

5. Measure and record the length of exposed thread protruding through the handbrake cable adjusting locknut at the compensating yoke on the rear axle.

6. Hold the cable with pliers or a spanner, unscrew the adjusting nut and remove the cable end from the yoke.

7. Remove the retainer and detach the cable from the connecting link located just to the rear of the handbrake lever rod.

8. Detach the cable from its retainers on the fuel tank and underbody and move it clear of the tank.

9. Disconnect the two electrical leads from the fuel gauge sender unit.

10. Remove the single bolt which secures the fuel filler pipe to the underbody.

11. Slacken the hose clips and disconnect the filler pipe from the tank neck (see illustration). Unclip the vent hose.

Fuel tank filler pipe-to-neck junction

12. Support the tank with a jack and suitable blocks of wood, or have an assistant hold it up, then undo the two retaining strap nuts (see illustration).

One of the fuel tank retaining strap nuts (arrowed)

13. Pivot the straps out of the way of the tank 14 Lower the tank slightly and, when sufficient clearance exists, disconnect the overflow and vent hoses from the top of the tank 15 Lower the tank fully and slide it out from under the car.

16. If the tank is contaminated with sediment or water, remove the sender unit and swill out the tank with clean fuel. If the tank is damaged, or leaks, it should be repaired by a competent specialist or renewed. Do not attempt to solder or weld a fuel tank yourself.

Estate and Van

17. The procedure is similar to that just described, but note the following points:

1. The fuel filler pipe must be unscrewed from the rear quarter panel (see illustration).
2. There is no need to disconnect the handbrake cable or to remove the exhaust system.

Fuel filler pipe retaining screws - Estate model

Refitting

18. Refit in the reverse order to removal.

Renew hoses, clips etc as necessary, and adjust the handbrake on completion.