From Corsa forum , maybe a later model from your car ,
25-06-2009, 04:10 PM #3
taurus
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Thanked 625 Times in 538 Posts Siphon out the petrol from the old tank and store carefully.
Disconnect the battery and work in a place where there is no source of ignition. Beware of using tools that might cause sparks. If possible have a fire extinguisher or blanket handy.
Jack up the back end of the car - make sure the car is left in gear and the front wheels are chocked. Place axle stands under the rear end before going under the car. (Never rely on a jack alone - they do collapse and people get killed.)
You will need to move the exhaust to one side - usually just disconnect the rubbers at the back end gives you enough clearance.
You also need to slacken off the handbrake cable and move that out of the way.
Take the fuel hoses off the tank - rear end.
You will need to remove the fuel filter. Note that there will still be some pressure in the system so some fuel will spill. (You can depressurise the system in advance by removing the fuel relay and running the engine until it cuts out - but so long as you are careful, and perhaps leave it stationary overnight, the pressure will have dropped anyway.)
Then - inside the car - fold up the rear seat to get at the top of the tank. Take off the plastic cover and disconnect the wiring and fuel hoses from the top of the pump. Again, be prepared for some spillage. Make sure you mark everything so you know how to put it all back together again.
Use a plastic or copper drift to remove the locking ring and withdraw the fuel pump and gauge sender unit. Make sure you keep the gasket safe.
Back under the car - support the weight of the tank with a jack or blocks, then undo the nuts that hold the straps at the rear end of the tank. (The front ends of the straps are hinged so you don't need to undo anything there.)
Lower the tank slowly - there are hoses clipped to it which you can't get at until it is partially lowered. Remove these carefully.
Then lower the tank and slide it out.
Posted Nov 4, 2010 (14 years ago)