See the warning at the beginning of the section Relieving pressure in the power supply system of gasoline engines.
A new fuel pump cover O-ring will be required upon installation.
Removing
Astra models
1. Relieve the pressure in the supply system (see Relieving pressure in the power supply system of gasoline engines). Disconnect the negative cable from the battery.
2. To gain access to the hatch in the floor panel, raise the rear seat cushion and fold back the carpet.
3. Prying off the plastic hatch cover with a screwdriver, access to the fuel pump cover should open.
4. Disconnect the electrical wiring from the fuel pump cover, - fix the harness by gluing it with adhesive tape to the floor panel.
Wiring connector -2- and fuel hoses -1- connected to the fuel pump cover.
5. Clearly mark both hoses leading to the cover. Loosen the mounting clamps and disconnect the hoses from the fittings on the cover of the pump assembly, - in order to prevent spillage of fuel, immediately plug the hoses with bolts of a suitable size.
If quick connectors are used to secure the hoses, follow the instructions (see Check of a condition and replacement of fuel lines and their union connections).
6. Unscrew and remove the threaded retaining ring, - the ring has a right-hand thread and is equipped with special protrusions, which, when retracted, can abut the drift.
7. If you have not done this before, disconnect the hoses and electrical wiring from the cover (see item 5 above), then carefully remove the cover assembly with the sealing ring, the sealing ring must be replaced without fail.
8. Squeezing the latches (1), carefully remove the pump assembly from the fuel tank, - try not to allow the strainer installed in the base of the assembly to move. Remove any spilled fuel on the floor panel immediately with a clean, dry cloth.
9. Check the condition of the strainer (1), replace if necessary.
10. If necessary, the pump can be removed from the assembly frame - try to remember the order of connecting the appropriate electrical wiring.
Models Zafira
1. Remove the fuel tank (see Removal and installation of the fuel tank).
2. Then proceed in the order described above.
Installation
1. If necessary, install the pump in its regular place in the assembly frame - make sure that the electrical wiring is connected correctly.
2. Make sure the strainer is firmly seated in the pump base, then carefully place the assembly into the tank.
3. Place a new O-ring on the cover of the pump assembly.
4. Install retaining ring and tighten securely with a punch.
5. Restore the original connection of the fuel lines and electrical wiring, - make sure that the hoses are securely fixed with fixing clamps.
6. On Zafira models reinstall the fuel tank.
7. Connect the negative cable to the battery, start the engine and check the unions on the pump cover for signs of leaks.
8. If everything is in order, install the hatch cover with gasket and close the carpet valve, and lower the rear seat cushion to its original position.
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