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Fuel Injection Pump Driven Sprocket Replacement > < Engine Control Module Replacement

Astra J

Fuel Injection Pump Replacement

Special Tools

•  DT-328-B  Pin Remover
•  EN-956-1  Extension
•  EN-6347  Holder
•  EN-46786  Remover
•  EN-46790  Remover

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the timing belt front cover. Refer to Timing Belt Front Cover Replacement .
2. Remove the fuel feed hose protector. Refer to Fuel Feed Hose Protector Removal .
3. Remove the fuel injection fuel feed pipe. Refer to Fuel Injection Fuel Feed Pipe Removal .
4. Remove the diesel fuel separator. Refer to Diesel Fuel Separator Removal .

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5. Remove the fuel feed pipe clamp (1) and the fuel feed pipe (2).
6. Disconnect the electrical connection (3).
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
8. Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
9. Lower the vehicle.

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Note:  When affixing the pulley, use two hex socket head bolts M6 X 40 (30 mm unthread and 10 mm thread). The bolt must be tightened the whole length of the thread. This way the pulley is prevented from moving out of position.

Note:  Rotate the engine only on crankshaft sprocket bolt and clockwise.
10. Fix the fuel injection pump driven sprocket.
  •  Rotate the engine until it is possible to install the 2 bolts (1).
  •  Install the 2 bolts (1).
11. Remove the fuel injection pump driven sprocket nut (2) use EN-6347  holder in conjunction with EN-956-1  extension to hold up.

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12. Remove the 3 fuel injection pump nuts (1).

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13. Remove the fuel injection pump.
  •  Pressing out the fuel injection pump shaft from the pump driven sprocket, use EN-46790  remover (1) and counter hold with a wrench (2).
  •  Remove the fuel injection pump.

Installation Procedure


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1. Position the fuel injection pump shaft (1) in order that the key on it fits to the groove (see arrow in picture) in the fuel injection pump driven sprocket (2).
2. Install the fuel injection pump to the fuel injection pump bracket and the fuel injection pump driven sprocket (2).

Caution: Refer to Fastener Caution .

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3. Install the 3 nuts (1) and tighten to 25 N·m (18 lb ft) .

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4. Install the fuel injection pump driven sprocket nut (2) and tighten to 50 N·m (37 lb ft) , use EN-6347  holder in conjunction with EN-956-1  extension to hold up.
5. Remove the 2 bolts (1).

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6. Connect the electrical connection (3).
7. Install the fuel feed pipe (2) in conjunction with the fuel feed pipe clamp (1).
8. Install the fuel injection fuel feed pipe. Refer to Fuel Injection Fuel Feed Pipe Installation .
9. Install the diesel fuel separator. Refer to Diesel Fuel Separator Installation .
10. Install the fuel feed hose protector. Refer to Fuel Feed Hose Protector Installation .
11. Install the timing belt front cover. Refer to Timing Belt Front Cover Replacement .
12. Raise the vehicle.
13. Install the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
14. To deflate the fuel system, use the diagnostic tool to activate the low pressure pump for 60 seconds.
15. Lower the vehicle.

Fuel Injection Pump Driven Sprocket Replacement > < Engine Control Module Replacement