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Fuel Tank Fuel Pump Module Replacement > < Camshaft Position Sensor Replacement

Astra J

Fuel Tank Replacement

Special Tools

•  CH-807   Plug
•  EN-6015   Plug

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Open the hood.
2. Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection .
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. Remove the right rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
6. Remove the rear wheel housing liner panel. Refer to Rear Wheelhouse Panel Liner Replacement .

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7. Disconnect the fuel tank harness inline connector (1).

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8. Disconnect the fuel tank feed pipe connector (1) from fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
9. Close the fuel feed pipe and fuel tank feed pipe with CH-807   plugs .

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10. Disconnect the evaporative emission canister fuel vent pipe connector (1) from fuel tank vent pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
11. Close the fuel tank vent pipe and emission canister fuel vent pipe with CH-807   plugs .

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Warning: Do not breathe the air through the EVAP component tubes or hoses. The fuel vapors inside the EVAP components may cause personal injury.


12. Remove the clamp (2).
13. Remove the fuel tank filler hose (3) from the fuel tank filler pipe (1).

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14. Disconnect the fuel tank filler vent pipe connector (6).
15. Install the EN-6015   plug into the fuel tank filler vent pipe.
Warning: To help avoid personal injury, always use jack stands when you are working on or under any vehicle that is supported only by a jack.


Caution: When you are jacking or lifting a vehicle at the frame side rails or other prescribed lift points, be certain that the lift pads do not contact the catalytic converter, the brake pipes or the fuel lines. If such contact occurs, vehicle damage or unsatisfactory vehicle performance may result.

16. Place a suitable adjustable jack under the fuel tank.
17. Remove the 2 fuel tank strap bolts (4).
18. Remove the 2 fuel tank straps (5).

Note:  A second technician is required.

Note:  Retract jack.
19. Remove fuel tank.

Disassemble Procedure

1. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement .

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Warning: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.


2. Disconnect the fuel tank vent pipe (2).
3. Disconnect the evaporative emission canister wiring harness plug.
4. Disconnect the evaporative emission canister purge pipe (4).
5. Remove the evaporative emission canister (1) from the evaporative emission canister bracket (3).

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6. Push the fuel tank upper baffle plate (2) down until the clip (1) lock into the lower baffle plate.
7. Remove the 2 fuel tank baffles (3) from the fuel tank baffle holder (4) through the fuel tank fuel pump module opening as shown in the sectional view.

Assemble Procedure


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1. Install the 2 fuel tank baffles (3) to the fuel tank baffle holder (4) through the fuel tank fuel pump module opening as shown in the sectional view.
2. Unclip the fuel tank upper baffle plate (1) from the fuel tank lower baffle plate.

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3. Install the evaporative emission canister (1) to the evaporative emission canister bracket (3).
4. Connect the evaporative emission canister purge pipe (4).
5. Connect the evaporative emission canister wiring harness plug.
6. Connect the fuel tank vent pipe (2).
7. Install the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement .

Installation Procedure


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Note:  A second technician is required.

Note:  Extend jack.
1. Install fuel tank.
2. Install the 2 fuel tank straps (5).
3. Install the 2 fuel tank strap bolts (4).
4. Remove the EN-6015   plug from the fuel tank filler vent pipe.
5. Connect the fuel tank filler vent pipe connector (6).

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6. Remove the CH-807   plugs from fuel feed tank pipe and fuel feed pipe.
7. 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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8. Remove the CH-807   plugs from emission canister fuel vent pipe and fuel tank vent pipe.
9. Connect the emission canister fuel vent pipe (1) to fuel tank vent pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .

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10. Install the fuel tank filler hose (3) to the fuel tank filler pipe (1).
11. Install the clamp (2).

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12. Connect the to fuel tank harness inline connector (1).
13. Install the rear wheel housing liner panel. Refer to Rear Wheelhouse Panel Liner Replacement .
14. Lower the vehicle.
15. Install the right rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
16. Connect the battery. Refer to Battery Negative Cable Disconnection and Connection .
17. Close the hood.

Fuel Tank Fuel Pump Module Replacement > < Camshaft Position Sensor Replacement