GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2008 🢒 Astra 🢒 Engine 🢒 Engine Controls and Fuel - 1.8L (2H0) 🢒 Fuel Pump Fuel Feed Hose Replacement - Front

Special Tools

    • J 34730-1A /KM-J-34730-91 Fuel Pressure Gage
    • J 43178 /KM-37088-2A Fuel Line Disconnect Tool
    • KM-807 Closure Plugs
    • SA9805E /KM-796-A Fuel Line Separator

Removal Procedure

    Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

    Important: 

       • In the presence of fuel vapors or escaping fuel - observe safety regulations and national legislation. Store drained fuel in a suitable, sealable container.
       • The vehicle fuel system is designed in petrol engines as a return-free fuel system.

  1. Open the hood.
    2. • Disconnect the ground clamp from the negative terminal.
    • Loosen the nut.

    Caution: Refer to Battery Disconnect Caution in the Preface section.

  2. Remove the battery.

    3. Object Number: 1945805 Size: SH
  3. Reduce the fuel pressure with a pressure tester J 34730-1A /KM-J-34730-91 (1) via test connection - collect escaping fuel in suitable container - observe safety regulations and national legislation.

    4. Object Number: 1998454 Size: SH
  4. Remove the fuel supply line (1) from the fuel distributor pipe (2).
    5. • Remove the quick-release fitting (3) with J 43178 /KM-37088-2A .
    • Seal off with a closure plug KM-807 .
    • Remove the fuel supply line in engine compartment and uncover.
  5. Remove the front frame. Refer to Front Frame Replacement .

    6. Object Number: 1998455 Size: LH
  6. Remove the 2 fuel line brackets (4) from the underbody.
    7. • Remove the 2 bolts.
    • Remove the fuel supply line (2).
  7. Detail the fuel supply line (2) to the quick-release fitting (3) using SA9805E /KM-796-A .

    8. Seal the fuel line with KM-807 .

  8. Remove the fuel pump feed hose from the 2 dash brackets (1).

Installation Procedure
  1. Insert the fuel pump feed hose and clip into the 2 dash brackets.
  2. Install the fuel pump feed hose to the intermediate fuel line.
    3. • Remove the closure plug KM-807 .
    • Connect the quick-release fitting. Refer to Plastic Collar Quick Connect Fitting Service .

    Notice: Refer to Fastener Notice in the Preface section.

  3. Install the 2 fuel line brackets to the underbody.

    4. Install the fuel line.

    Tighten
    Tighten the 2 bolts.

  4. Install the front frame. Refer to Front Frame Replacement .
  5. Attach the fuel supply line to the fuel rail.
    6. • Remove the closure plug KM-807 .
    • Connect the quick-release fitting.
    • Move the fuel supply line in the engine compartment and install.
  6. Install the battery.

    7. Connect the ground clamp to the negative terminal.

    Tighten
    Tighten the ground clamp nut to 5 N·m (44 lb in).

  7. For programming procedures, refer to Control Module References .
  8. Close the hood.