Vauxhall Workshop Service and Repair Manuals > Astra J > Engine | Engine control and fuel system - 1.3L Diesel | Repair Instructions

Diesel Fuel Separator Replacement

EN-6015 Closure Plugs

For equivalent regional tools, refer to Special Tools .

Warning: Refer to Gasoline/Gasoline Vapors Warning .

Warning: Refer to Safety Goggles and Fuel Warning .

1.	Open the hood.

2.	Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

3.	Remove the engine sight shield. Refer to Engine Sight Shield Replacement .

4.	Disconnect the fuel return front pipe from the diesel fuel separator. Refer to Plastic Collar Quick Connect Fitting Service .

5.	Close the fuel return front pipe, use EN-6015 plugs .

6.	Unclip the 4 fuel injection fuel return hose retaining clips (6) in direction of arrow.

7.	Remove the 4 fuel return hose connectors (1) from the 4 fuel injectors.

8.	Remove the diesel fuel separator bolt (4).

9.	Remove the fuel return hose clamp (5).

10.	Remove the fuel return hose (2) from the fuel injection pump.

11.	Remove the diesel fuel separator (3).

1.	Install the diesel fuel separator (3).

2.	Install the fuel return hose (2) to the fuel injection pump.

3.	Install the fuel return hose clamp (5).

Caution: Refer to Fastener Caution .

4.	Install the diesel fuel separator bolt (4) and tighten to 9 N·m (80 lb in) .

5.	Clip in the 4 fuel injection fuel return hose retaining clips (6).

Note: The fuel return hose connectors must engage in 4 fuel injection fuel return hose retaining clips (6) audibly.

6.	Install the 4 fuel return hose connectors (1) to 4 fuel injectors.

7.	Remove the EN-6015 plugs .

8.	Connect the fuel return front pipe to the diesel fuel separator. Refer to Plastic Collar Quick Connect Fitting Service .

9.	Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

10.	Install the engine sight shield. Refer to Engine Sight Shield Replacement .

11.	Close the hood.