Vauxhall Workshop Service and Repair Manuals

Note:   This procedure is described for the X 20 DTH engine. Proceed similarly for other engine variants.

Caution

Fuel escapes – observe safety measures and national legislation.

For vehicles with petrol engines: reduce fuel pressure with Pressure Tester KM-J-34730-91 via testing port – collect escaping fuel in suitable container.

  Remove

Open bonnet, disconnect battery

Detach fuel return line and fuel supply line (3) from centre fuel lines using KM-796-A - close off fuel lines using KM-807 or KM-6015 and KM-6320.

Remove clips (1) from fuel lines. Unclip fuel lines from bracket. Detach rubber cover (2) from crossmember and pull out fuel lines from crossmember.

On vehicles with a petrol engine: disconnect fuel lines from fuel distribution pipe/fuel pressure regulator.

Detach fuel supply line (1) from fuel filter housing using KM-796-A - close off fuel lines using KM-807 or KM-6015 and KM-6320

Disconnect fuel line for additional heater from fuel supply distribution piece.

Disconnect fuel return line from fuel hose (2).

Unclip fuel filter housing from bracket and lay to one side.

Pull fuel lines through side member and remove.

  Install

Insert fuel lines and guide through side member – observe correct routing.

Clip fuel filter housing into bracket.

Remove closure plug KM-807 or plugs KM-6015 and KM-6320.

Push fuel line for additional heater onto fuel supply distribution piece.

Remove clip (2) from fuel supply line, and insert it into bush (3), ensuring that it clips in on both sides. Push fuel supply line (1) onto fuel filter housing connector until fuel line is felt and seen to engage.

Guide fuel lines through crossmember and attach rubber seal to crossmember. Attach clips to fuel lines and clip fuel lines into bracket.

Remove clip (2) from fuel supply line and fuel return line, and insert them into bush (3), ensuring that they engage on both sides. Push fuel supply line (1) and fuel return line (1) onto connectors until fuel lines are felt and seen to engage.

Bleed fuel system – see operation "Fuel System, Bleed (X 20 DTH, Y 22 DTH)" or "Fuel System, Bleed (25 DT, X 25 DT)".