Removal and installation the fuel rail (Opel Astra J)

The fuel rail is removed for replacement if damaged (breakage of fittings), to replace injectors or gain access to other components.

You will need: TORX E10 key, flat-blade screwdriver.

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

2. Disconnect the wire from the negative terminal of the battery.



3. Disconnect the left… from the cylinder head cover



4. ...and the rear ramp of the engine wiring harness, overcoming the elastic resistance of their clamps.



5. Use a screwdriver to press the fuel supply line hose tip retainer…





6. …and disconnect the line from the fuel rail fitting.

Note: Some fuel may leak out when you remove the hose. Wipe it off with a rag.

7. Pressing the spring clips of the engine wiring harness pads, disconnect the pads from the injector connectors.



8. Remove the two bolts securing the fuel rail to the intake pipe…





9. …and remove the ramp, removing the injectors from the holes in the intake pipe.

Caution! If any injector remains in the intake manifold when removing the ramp, be sure to replace the retainer for that injector.

10. If necessary, remove the injectors from the rail (see Removal, inspection and installation of injectors).

Note: Replace the injector sealing rings with new ones each time the fuel rail is removed or disassembled.

11. Install the fuel rail in the reverse order of disassembly and removal, lubricating the injector sealing rings with engine oil.

12. After connecting the fuel hose to the rail, start the engine and check the tightness of the hose connection to the rail and the injector seals.