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Fuel Injection Pump Bracket Replacement > < Fuel Return Pipe Replacement

Astra J

Fuel Feed Pipe Replacement

Special Tools

•  EN-6015   Closure Plugs
•  EN6368   Set Of Plugs
•  GE-47622   Hose Clamp Pliers

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning:  Refer to Gasoline/Gasoline Vapors Warning .

Warning: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .

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3. Remove the fuel feed pipe clamp (2) by using GE-47622   hose clamp pliers .
4. Remove the fuel feed pipe (3) from the fuel injection fuel pump (1).
5. Close all connections with EN-6015   plugs .
6. Close the connection from fuel injection pump by using EN-6368   plugs .
7. Open the upper bulk head retainer (4) and unclip the fuel feed pipe (3).
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 drivetrain 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 feed pipe (3) from the fuel feed pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service .
16. Close all connections with EN-6015   plugs .
17. Remove the fuel feed pipe (3).

Installation Procedure


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1. Install and position the fuel feed pipe (3) to the vehicle.
2. Clip in the fuel feed pipe (3) to the rear bracket clip (2).
3. Remove the EN-6015   plugs from all connections.
4. 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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5. Install the lower bulk head clip.
6. Close the 4 fuel pipe clips (2).

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

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

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14. Reposition the fuel feed pipe (3) and clip to the upper bulk head clip (4).
15. Remove the EN-6015   plugs from all connections.
16. Remove the EN-6368   plugs from the fuel injection pump.
17. Connect the fuel feed pipe (3) to the fuel injection pump (1).
18. Reposition the fuel feed pipe clamp by using the GE-47622   hose clamp pliers .
19. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
20. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Fuel Injection Pump Bracket Replacement > < Fuel Return Pipe Replacement