Draining sediment, removing air from the filter (diesel models) (Opel Astra H)

Note: Before performing any maintenance on the fuel filter, thoroughly wipe the area around the filter to prevent dirt from entering the fuel system. To collect any spilled fuel, place a rag under the filter or install a suitable drain container.

Caution: Do not allow diesel fuel to come into contact with the surfaces of the generator, starter, cooling system hoses, engine mounts and electrical wiring harnesses!

1. The fuel filter is installed on the rear bulkhead of the engine compartment.

Draining sludge/water

Caution: If the corresponding indicator lamp is activated (see Chapter "Controls and operating techniques", Section 16) drain the water from the fuel filter as soon as possible! Follow the rules for disposal of drained diesel fuel!

2. Before draining the sediment from the fuel filter, it is necessary to disconnect the terminal clamps from the battery, observing the requirements given in Chapter 5.

3. On engines with a working volume of 1.3 and 1.9 l (see accompanying illustration) disconnect the plug connectors of the fuel heating system and the fuel temperature sensor (with appropriate equipment). Then, without disconnecting the fuel hoses, remove the filter housing from the mounting clamp. Place a suitable container underneath it to drain the sediment/water.

Note: Try not to shake the filter so that the sediment does not mix with the top layer of fuel.

Loosen the drain plug about 1 turn and allow the fuel to drain into the prepared container. Do not tighten the plug until clean fuel starts to flow out of the hose - usually about 100 ml is enough to drain.

Caution: The fuel must not be drained completely from the filter.

Once the operation is complete, secure the filter housing in its original place and connect the plug connectors.

4. On Z17DT(L/H) engines, to drain sediment/water from the fuel filter, it is necessary to put it on the drain valve (see accompanying illustration) at the bottom of the filter housing, a section of hose of a suitable size - lower the other end of the hose into a clean container with transparent walls. Slightly loosen the clamping bolt on the filter cover, and then the valve. Drain the sediment/water as described above. When the operation is complete, close the valve and tighten the clamping bolt on the filter cover (6 Nm).

Note: Do not apply too much force when tightening, otherwise the sealing gasket may be damaged and leakage may occur.

After draining the sediment/water, it is not necessary to bleed the fuel system to remove air (see paragraph 17).



5. Remove the drain pan. Use a clean rag to wipe up any spilled fuel. Reconnect the battery. Finally, check all loose components for signs of developing leaks.

Replacing the working element of the fuel filter

6. Disconnect the battery and completely drain the fuel from the filter (see above).

7. Disconnect all system plug connectors (if they were not disconnected when draining the fuel).

8. Disconnect the fuel hoses from the filter housing (see accompanying illustration) - try not to damage the special connectors, use a special tool for this (KM-796-A or HAZET 4501-1). To prevent fuel spillage and air from entering the fuel system after disconnecting, close the free ends of the hoses with plugs.



9. Remove the fuel filter housing from the mount by pushing it upwards.

10. To replace the filter element of engines with a working volume of 1.7 l, it is necessary to unscrew the tightening bolt (see accompanying illustration) and disassemble the filter. There is some fuel left in the replaceable element - after removing it, place it in a suitable container, and drain the remaining fuel from the filter housing there. Wipe the cover and filter housing with a clean rag.





11. Insert a new replaceable filter element into the housing and fill the filter almost to the top edge of the housing with clean diesel fuel (about 200 ml).

Caution: If sand and dirt get on the inner surface of the replaceable element, it may cause the high-pressure fuel pump (HPFP) to fail.

Replace the sealing gaskets, carefully assemble the filter and tighten the clamping bolt to 6 Nm.

Note: Do not apply too much force when tightening, otherwise the filter cover sealing gasket may be damaged.

12. The design of the filter for Z 13 DTH/Z 19 DT(J/H) engines is shown in the accompanying illustration 8.12a. To replace the filter element, it is necessary to use a special device (Opel-EN-46784-020) clamp the filter housing in a vice, then using a special key (Opel-EN-46784-010) (see accompanying illustration 8.12b) release the filter cover clamping ring. If special devices are not available, secure the fuel filter housing in a vice using suitable pads or shaped jaws and release the clamping ring using a hammer and a wooden block - strike the block carefully, alternately adjusting it to the various protrusions of the ring.

Attention: When disassembling the filter without using a special tool, be especially careful - you can damage the threads or edges of the pressure ring, which in turn will lead to a loss of seal tightness!

13. Remove the filter cover with the replaceable element, remove the sealing ring and, turning the replaceable element 50° counterclockwise, detach it from the cover. Wipe the cover and filter housing with a clean rag.

14. After replacing the replaceable element, assemble the filter in the reverse order - do not forget to replace the sealing gasket and fill the filter with fuel.

Note: The filter cover can only be installed into the housing in one position to avoid incorrect assembly.

The clamping ring is tightened with a force of 30 Nm.



15. After assembling the filter, carefully install it into the mount, remove the plugs and connect the fuel hoses, then connect the electrical wiring to the filter and connect the battery.

16. After completing all operations with the fuel filter, it is necessary to start the engine and let it idle. Check the fuel system for leaks.

Removal air from the fuel system

See also Chapter 4, Section 4.

17. Air will be removed from the system automatically when the ignition is turned on and the engine is started. If there is too little fuel in the filter, the engine may not start or the engine may stop shortly after starting. In this case, turn the ignition on and off three times, leaving it on for 15 seconds each time. When the ignition is turned on, the electric fuel pump is activated, with the help of which the fuel circulates throughout the entire fuel system circuit, air is removed and the fuel filter is filled. Repeat starting the engine - hold the ignition key until it starts, but not more than 30 seconds. If the engine does not start again, turn off the ignition and after a while repeat the air removal procedure.