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Fuel Tank Replacement > < Fuel Tank Fuel Pump Module Replacement

Astra J

Fuel Tank Fuel Pump Module Wiring Harness Replacement

Special Tools

EN-6015   Closure Plugs

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning:  Refer to Gasoline/Gasoline Vapors Warning .

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Fuel tank draining. Refer to Fuel Tank Draining .
3. Remove the rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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5. Unclip the fuel tank fuel pump module wiring harness (1) from the body.

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6. Disconnect the fuel return pipe (3) from the fuel return pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service .
7. Close all connections with EN-6015   plugs .

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8. Disconnect the fuel feed pipe (3) from the fuel feed pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service .
9. Close all connections with EN-6015   plugs .

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10. Disconnect the fuel tank fill EVAP emission pipe quick connect fitting (5) from the fuel tank vent pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
11. Close all connections with EN-6015   plugs .
12. Loosen the fuel filler pipe clamp (3).
13. Remove the fuel filler hose (4) from the fuel filler pipe (2).
14. Place a suitable adjustable jack under the fuel tank.

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15. Remove the 2 fuel tank strap bolts (2).
16. Remove the 2 fuel tank straps (1).

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17. Lower the fuel tank (2) slowly and carefully to a height where the fuel pump wiring harness (1) is accessible.
  Unclip the fuel tank fuel pump module wiring harness from the 2 bracket clips (3).

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18. Disconnect the fuel pump wiring harness plug (1) from the fuel tank fuel pump module (2).
19. Disconnect the fuel filter wiring harness plug (3) from the fuel filter (4).

Installation Procedure


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1. Connect the fuel pump wiring harness plug (1) to the fuel tank fuel pump module (2).
2. Connect the fuel filter wiring harness plug (3) to the fuel filter (4).

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3. Clip in the fuel tank fuel pump module wiring harness (1) to the 2 bracket clips (3).

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4. Install the 2 fuel tank straps (1).

Caution: Refer to Fastener Caution .
5. Install the 2 fuel tank strap bolts (2) and tighten to 23 N·m (17 lb ft) .

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6. Install the fuel filler hose (4) to the fuel filler pipe (2).
7. Install the fuel filler pipe clamp (3).
8. Remove the EN-6015   plugs from all connections.
9. Connect the fuel tank fill EVAP emission pipe quick connect fitting (5) to the fuel tank vent pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .

           2028100


10. Remove the EN-6015   plugs from all connections.
11. Connect the fuel feed pipe (3) to the fuel feed pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service .

           2028094


12. Remove the EN-6015   plugs from all connections.
13. Connect the fuel return pipe (3) to the fuel return pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service .

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14. Clip the fuel tank fuel pump module wiring harness (1) to the body.
15. Install the rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement .
16. Lower the vehicle.
17. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Fuel Tank Replacement > < Fuel Tank Fuel Pump Module Replacement