vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Fuel Tank Vent Pipe Replacement - LDE with Electrical Power Steering > < Engine Coolant Temperature Sensor Replacement - Radiator Side

Astra J

Fuel Feed Pipe Replacement (1.6L LDE)

Special Tools

CH-807   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 .

           2028306


2. Unclip the fuel feed pipe (1) from the fuel feed pipe clip (2).
3. Release the fuel feed pipe (1) from the multiport fuel injection fuel rail (3) and remove the fuel feed pipe.
4. Close the fuel feed pipe with CH-807   plug .

           2191616


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

           2538049


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

           2538051


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

           2191622


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

           2028100


14. Disconnect the fuel tank feed pipe connector (1) from the fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
15. Close the fuel feed pipe and fuel tank feed pipe with CH-807   plugs .
16. Open the fuel pipe clip (2) and remove the fuel feed pipe.

Installation Procedure

1. Remove the CH-807   plugs from fuel feed tank pipe and fuel feed pipe.

           2028100


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

           2191622


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

           2538049


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.

           2191616


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

           2028306


15. Remove the CH-807   plug from the fuel feed pipe (1).
16. Install the fuel feed pipe (1) to the multiport fuel injection fuel rail (3).
17. Clip in the fuel feed pipe (1) to the fuel feed pipe clip (2).
18. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Fuel Tank Vent Pipe Replacement - LDE with Electrical Power Steering > < Engine Coolant Temperature Sensor Replacement - Radiator Side