See the warning at the beginning of the section Relieving pressure in the power supply system of gasoline engines.
1. On petrol models, relieve residual pressure in the fuel system (see Relieving pressure in the power supply system of gasoline engines). Disconnect the negative cable from the battery.
2. Before removing the fuel tank, all fuel must be removed from it. Since the manufacturers do not provide a drain plug, you will have to remove the tank with a minimum amount of fuel, having previously removed its main supply using the siphon method.
3. Remove exhaust system components and heat shields (see System of release of the fulfilled gases - the general information, removal and installation).
4. Support the front wheels with wheel chocks and loosen the parking brake adjusting nut (see chapter Brake system).
5. On models equipped with rear wheel drum brakes, disconnect the parking brake cable from the hook located in front of the brake drum. On models with disc brakes, release the parking brake lever and disconnect the end of the drive cable from it, then release the latch and release the cable from the support bracket on the caliper (see chapter Brake system).
6. Release the parking brake cable of the intermediate brackets and clamps and take it away from the tank.
7. On Astra models disconnect the wiring harness from the fuel pump/fuel flow sensor unit (see Removal and installation of the fuel pump - petrol models and Removal and installation of the gauge of a stock of fuel), - on Zafira models, the electrical wiring is disconnected from under the car.
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8. Open the filler cap and remove the rubber o-ring. Turn out a bolt of fastening of a mouth to a body.
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9. Remove the right back wheel, give fixing screws and nuts and remove a locker of protection of a wheel arch.
10. Mark and disconnect two small hoses from the neck, after loosening the clamps of their fastening.
11. Release the clamps and disconnect the fuel lines leading to the base of the filler neck. Turn out the bottom bolt of fastening of a jellied mouth and take last from under the car.
12. Walk along the fuel lines from the tank to their nearest attachment point. Mark and disconnect both hoses after loosening their clamps.
If quick connectors are used to secure the hoses, follow the instructions (see Check of a condition and replacement of fuel lines and their union connections).
10. On petrol models separate the fuel filter from the fuel tank mounting strip.
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11. Support the tank with a cart jack, after laying a piece of board on the head of the latter.
12. Turn out fixing bolts and remove mounting strips.
13. Slowly lower the tank, disconnecting all hoses along the way. Remove the tank from under the car.
14. If water has accumulated in the tank, remove the fuel pump/fuel flow sensor cover (see Removal and installation of the fuel pump - petrol models) and remove any remaining fuel from the tank. If there are traces of moisture in the tank, flush it with clean fuel. The tank is made of plastic and must be replaced in case of serious damage. Minor defects can be eliminated in a specialized workshop.
15. Installation is carried out in the reverse order to the dismantling of the components. Pay attention to the following points:
- Make sure that when installing the tank, the hoses laid above it are not pinched.
- Track the reliability of tightening the fasteners of the mounting strips.
- Make sure that all hose and electrical connections are properly connected and secure.
- Don't forget to adjust the parking brake (see chapter Brake system).
- Before the first trip, fill the tank with a small amount of fuel and check it for signs of leaks.
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