Astra J
Fuel Injection Pump ReplacementSpecial ToolsEN-6015 Closure PlugsFor equivalent regional tools, refer to Special Tools . Removal Procedure
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| Warning: Refer to
Gasoline/Gasoline Vapors Warning
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| Warning: Refer to
Safety Goggles and Fuel Warning
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| 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. | Remove the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement . |
| 5. | Remove the fuel injection fuel feed pipe. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Rail to Fuel Injector . |
| 6. | Remove fuel return hose. Refer to Fuel Return Hose Replacement - Diesel Fuel Separator to Injection Pump . |
| 7. | Disconnect the fuel feed pipe (2) from the fuel injection fuel pump connector (3). Refer to Plastic Collar Quick Connect Fitting Service . |
| 8. | Close all connections with EN-6015 plugs . |
| 9. | Disconnect the wiring harness plug from the fuel injection pump. |
| 10. | Remove the 3 fuel injection pump bolts (3). |
Note: Do not tilt the fuel injection pump actuator (1) at timing gear groove (4). |
| 11. | Remove the fuel injection pump (2) |
| 12. | Remove and DISCARD the fuel injection pump seal. |
Installation Procedure
| 1. | Install a NEW fuel injection pump seal. |
Note: Do not tilt the fuel injection pump actuator (1) at timing gear groove (4). |
| 2. | Install the fuel injection pump (2) |
Caution: Refer to Fastener Caution |
| 3. | Install the 3 fuel injection pump bolts (3) and tighten to 15 N·m (11 lb ft) . |
| 4. | Connect the wiring harness plug to the fuel injection pump. |
| 5. | Connect the fuel feed pipe (2) to the fuel injection fuel pump connector (3). Refer to Plastic Collar Quick Connect Fitting Service . |
| 6. | Install the fuel return hose. Refer to Fuel Return Hose Replacement - Diesel Fuel Separator to Injection Pump . |
| 7. | Install the fuel Injection fuel feed pipe. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Rail to Fuel Injector . |
| 8. | Install the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement . |
| 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. |
