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Fuel Feed Pipe Replacement > < Exhaust Gas Recirculation Vacuum Regulator Valve Solenoid Replacement

Astra J

Fuel Return Pipe Replacement

Special Tools

EN-6015   Closure Plugs

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.
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. Disconnect the fuel return pipe (2) from the diesel fuel separator connector (1). Refer to Plastic Collar Quick Connect Fitting Service .
4. Close all connections with EN-6015   plugs .
5. Open the bracket clip (3) and remove the fuel return pipe (2).
6. Unclip the fuel return pipe from the upper bulk head clip.
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

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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).

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

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

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14. Disconnect the fuel return pipe (3) from the fuel return pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service .
15. Close all connections with EN-6015   plugs .
16. Remove the fuel return pipe (3).

Installation Procedure


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1. Install and position the fuel return pipe (3).
2. Clip in the fuel return pipe (3) to the rear bracket clip (2).
3. Remove the EN-6015   plugs from all connections.
4. Connect the fuel return pipe (3) to the fuel return 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.
14. Clip the fuel return pipe to the upper bulk head clip.

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15. Reposition the fuel return pipe (2) and lock the bracket clip (3).
16. Remove the EN-6015   plugs from all connections.
17. Connect the fuel return pipe (2) to the diesel fuel separator connector (1). Refer to Plastic Collar Quick Connect Fitting Service .
18. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
19. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Fuel Feed Pipe Replacement > < Exhaust Gas Recirculation Vacuum Regulator Valve Solenoid Replacement