Removal, repair and installation of the fuel pump Opel Astra H

Tools:

Screwdriver with a flat blade
Hammer

Parts and consumables:

Tank for draining fuel from the fuel pump module
Cloth gloves
rags
Wooden or plastic punch

Note:

If the engine power drops, there is increased noise, or howls are periodically heard during the operation of the fuel pump, then the Astra fuel pump most likely failed.

Preliminarily check the pressure in the fuel supply system (see Checking the pressure in the power supply system). If the pressure in the system is less than 300 kPa (3.0 kgf / cm²), then the fuel pressure regulator, the electric fuel pump itself, or the fuel filter are probably clogged. To eliminate these malfunctions, it is necessary to remove and disassemble the Opel fuel module.

Removal, repair and installation of the fuel pump Opel Astra H

1. Reduce the pressure in the supply system (see Reducing the pressure in the supply system).

2. Disconnect a wire from the minus plug of the storage battery.

3. Remove a pillow of a back seat (Removal and installation of a back seat see).

4. The manhole cover in the base of the body above the fuel module is located under the floor mat. Pull the mat forward.

5. Pry off the hatch cover with a screwdriver.

6. Remove the hatch cover in the base of the body above the fuel module.

7. Press down on the wire harness tab.

8. Disconnect the block.

9. Pressing the lock with a screwdriver.

10. Disconnect the high pressure fuel line tip from the module fitting.

11. Turn the fuel pump module bayonet clamping ring counterclockwise until the ring protrusions come out from under the fuel tank flange retainers, and remove the ring.

Note:

There is a special tool for turning the pressure ring of the fuel pump module. In the absence of this device, remove the ring from its place with light hammer blows through a wooden or plastic drift, applying force alternately to the diametrically located protrusions of the ring. To avoid sparking, do not use a steel tool for this purpose!

12. Remembering the position of the fuel pump module adapter flange relative to the fuel tank (to facilitate its installation during reassembly), remove the flange.

13. Carefully remove the module and drain the fuel from it into a previously prepared container.

Notes:

Please note that the fuel pump module is fixed in a special holder (shown in the photo by an arrow) installed inside the fuel tank. To remove the module, you need to press the three holder latches to the sides. When reinstalling the module, position it correctly in this holder, otherwise the module will not lock into position.

The adapter flange of the fuel module is sealed with a rubber ring.

Be sure to replace this ring each time the pump is removed.

14. To replace the Opel Astra fuel gauge sensor, squeeze out the two latches of its fastening.

15. Remove the sensor by disconnecting its wires from the block on the module flange.

16. To remove the Opel Astra electric fuel pump, disconnect the wiring harness block from it.

17. Press the latch of the electric fuel pump with a screwdriver.

18. Remove the pump from the module cup. Disconnect the fuel supply hose from the cup fitting (shown by the arrow in the photo) and remove the pump.

19. To replace the fuel pressure regulator, disconnect the wire from it.

20. Remove the regulator from the socket of the fuel module cup by depressing the two latches of its fastening (shown by arrows in the photo).

Note:

In the Opel Astra car, the fuel pressure regulator fitting is sealed with a rubber ring. Replace this ring each time the joint is disassembled.

21. If the fuel filter is clogged, unscrew it from the module cup and wash the screen in gasoline. If the mesh cannot be flushed, replace the filter.