Replacing the fuel filter — diesel models produced before 09.2000 (Opel Astra G)

Fuel filter design



1. Drain diesel fuel from the fuel filter (see Removal sediment from a diesel engine fuel filter).

2. Disconnect the electrical wiring from the temperature-sensitive switch and the filter heating element installed between the fuel filter and its support bracket.

3. Slightly loosen the central filter mounting bolt, disconnect the quick-connect fittings and disconnect the hoses from the filter.



4. Remove the filter housing from the support bracket.

5. Lower the filter housing into a suitable drain container, then unscrew the central bolt, loosen the lower nut and drain the remaining fuel (see illustration Fuel filter design).



6. Remove the cover and O-ring, remove the filter element, spring and lower seal — the sealing elements must be replaced without fail (see illustration Fuel filter design).

7. Clean the filter housing thoroughly.

8. Place the lower seal and spring into the housing; if designed accordingly, insert the lower nut into the housing (one type of nut is built into the lower seal, the other is screwed onto the end of the central bolt).

9. Insert a new filter element into the housing, then, if possible, fill the filter housing with clean diesel fuel to facilitate the task of removing air from the fuel system tract - ideally, the level of the filled fuel should reach the top edge of the housing.

10. Place the cover on the body (don't forget to install a new sealing ring), then install the central bolt, - also check the position of the sealing ring. Tighten the bolt with the required force, - do not allow the cover to deform.

11. Start the engine and bleed the fuel system (see Chapter Power and exhaust systems).