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Fuel Feed Pipe Replacement - Fuel Junction Block to Fuel Injection Pump - 1.7L Diesel LPL and LPV > < Turbocharger Pressure Sensor Replacement

Astra J

Fuel Tank Replacement

Special Tools

•  EN-6015   Closure Plugs
•  EN-48279   Main Fuel Pump Locking Ring Remover/Installer

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning:  Refer to Gasoline/Gasoline Vapors Warning .

Warning: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.
1. Open the hood.
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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5. Disconnect the fuel return pipe (3) from the fuel return pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service .
6. Close all connections with EN-6015   plugs .
7. Open the bracket clip (2) and unclip the pipe.

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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 slowly down to a height where the fuel pump wiring harness plug (3) is accessible.
18. Disconnect the fuel pump wiring harness plug (3) from the fuel pump module (4).
19. Disconnect the 2 fuel filter wiring harness plugs (1, 2) from the fuel filter (6).
20. Unclip the wiring harness from the clip (5, 7).
21. Lower the fuel tank down at the full height.

Disassembly Procedure


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1. Remove the fuel feed pipe (1) from the fuel tank fuel pump module (4) and the fuel filter housing (3). Refer to Plastic Collar Quick Connect Fitting Service .
2. Remove the fuel return pipe (2) from the fuel tank fuel pump module (4). Refer to Plastic Collar Quick Connect Fitting Service .
3. Close all connections with EN-6015   plugs .

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4. Install the EN-48279   remover/installer (1) to the fuel pump module lock ring (2).

Note:  Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
5. Using the EN-48279   remover/installer and a long breaker-bar, rotate the lock ring in an anticlockwise direction in order to unlock the lock ring.

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6. Remove the fuel pump module lock ring (1).
7. Remove the fuel pump module (2).

Note:  Lift the fuel pump module up slightly.
8. Remove and discard the fuel pump module seal (3).

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9. Remove the fuel filter (2) from the fuel filter bracket (1).
10. Remove the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement .

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

Assembly 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 (2) from the lower baffle plate.
3. Install the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement .

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4. Install the fuel filter (2) to the fuel filter bracket (1).

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5. Install a NEW fuel pump module seal (3).
6. Install the fuel pump module (2).
7. Install the fuel pump module lock ring (1).

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8. Install the EN-48279   remover/installer (1) to the fuel pump module lock ring (2).

Note:  Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
9. Using the EN-48279   remover/installer and a long breaker-bar, rotate the lock ring in a clockwise direction in order to lock the lock ring.

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10. Remove the EN-6015   plugs from all connections.
11. Install the fuel return pipe (2) to the fuel tank fuel pump module (4). Refer to Plastic Collar Quick Connect Fitting Service .
12. Install the fuel feed pipe (1) to the fuel tank fuel pump module (4) and fuel filter housing (3). Refer to Plastic Collar Quick Connect Fitting Service .

Installation Procedure


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1. Raise the fuel tank with a suitable adjustable jack to a height where the fuel pump wiring harness plug (3) is accessible.
2. Clip in the wiring harness to the clip (5, 7).
3. Connect the fuel pump wiring harness plug (3) to the fuel pump module (4).
4. Connect the 2 fuel filter wiring harness plugs (1, 2) to the fuel filter (6).

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

Caution: Refer to Fastener Caution .
6. Install the 2 fuel tank strap bolts (2) and tighten to 22 N·m (16 lb ft) .

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7. Install the fuel filler hose (4) to the fuel filler pipe (2).
8. Install the fuel filler pipe clamp (3).
9. Remove the EN-6015   plugs from all connections.
10. 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 .

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

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13. Remove the EN-6015   plugs from all connections.
14. Connect the fuel return pipe (3) to the fuel return pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service .
15. Clip the fuel feed pipes into the bracket clip (2) and lock the bracket clip.
16. Lower the vehicle.
17. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
18. Close the hood.

Fuel Feed Pipe Replacement - Fuel Junction Block to Fuel Injection Pump - 1.7L Diesel LPL and LPV > < Turbocharger Pressure Sensor Replacement