Removal, repair and installation of the fuel pump (Opel Astra J)

If the engine power drops, there is increased noise, or periodic whining sounds are heard when the fuel pump is running, then most likely the fuel pump has failed. First check the pressure in the fuel supply system (see Checking the pressure in the fuel 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 is probably faulty. To eliminate these faults, the fuel module must be replaced as an assembly, since its design is non-separable. Only the fuel level indicator sensor can be replaced.

You will need: flat-blade screwdriver, container for draining fuel from the fuel pump module.

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.

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

3. Remove the fuel tank (see Replacing the fuel tank and its filler pipe).

4. By pressing the lock…

5. …disconnect the high-pressure fuel line tip from the module fitting.

6. Turn the fuel pump module bayonet mount clamping ring counterclockwise until the ring protrusions come out from under the fuel tank flange clamps…

Note: There is a special device for turning the fuel pump module mounting clamping ring. If this device is not available, loosen the ring with light blows of a hammer through a screwdriver, applying force alternately to the diametrically located protrusions of the ring.

Note: There is a special device for turning the fuel pump module mounting clamping ring. If this…

7. …and remove the ring.

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