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Evaporative Emission Canister Replacement > < Fuel Pressure Relief

Astra J

Fuel Feed Pipe Replacement (1.4L LDD)

Special Tools

•  CH-807   Closure Plugs
•  CH-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. Relief the fuel pressure. Refer to Fuel Pressure Relief .

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3. Unclip the fuel feed pipe (2) from the retainer clip (1)
4. Remove the fuel feed pipe (2) from fuel injector rail.
5. Close the fuel feed pipe connector with CH-807   plug .

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6. Open the upper bulk head clip (1).
7. Remove the fuel feed pipe (2) from the upper bulkhead clip.
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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9. Remove and DISCARD the exhaust front hanger bracket bolt (3).
10. Remove and DISCARD the frame reinforcement bolt (2).
11. Loosen the drive train and front suspension frame bolt (1).

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12. Rotate the right frame reinforcement (1) to a position shown to get access to the fuel pipes.

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13. Open the 4 fuel pipe clips (2).
14. Remove the lower bulk head clip.

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15. Disconnect the fuel tank feed pipe connector (1) from fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
16. Close the fuel feed pipe and fuel tank feed pipe with CH-6015   plugs .
17. Open the fuel pipe clip (2) and remove the fuel feed pipe.

Installation Procedure

1. Remove the CH-6015   plugs from fuel feed tank pipe and fuel feed pipe.

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2. Install the fuel feed pipe (3) and close the fuel pipe clip (2).
3. Connect the fuel tank feed pipe connector (1) to fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .

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4. Install the lower bulk head clip.
5. Close the 4 fuel pipe clips (2).

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6. Rotate the right frame reinforcement to its original position.
7. Install the exhaust front hanger bracket bolt (3).
8. Install the frame reinforcement bolt (2).

Caution: Refer to Fastener Caution .
9. Tighten the NEW exhaust front hanger bracket bolt (3) to 22 N·m (16 lb ft) .
10. Tighten the NEW frame reinforcement bolt (2) to 60 N·m (44 lb ft) .
11. Tighten the drivetrain and front suspension frame bolt (1) to 160 N·m (118 lb ft) .
12. Lower the vehicle.

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13. Install the fuel feed pipe (2) to the upper bulkhead clip.
14. Close the upper bulk head clip (1).

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15. Remove the CH-807   plug from fuel feed pipe connector.
16. Install the fuel feed pipe (2) to the fuel injector rail.
17. Clip in the fuel feed pipe (2) to the retainer clip (1).
18. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Evaporative Emission Canister Replacement > < Fuel Pressure Relief