Replace Fuel Pressure Regulator Opel Astra H

Warning: Fuel escapes. Observe safety regulations and national legislation.

Remove

1. 1. Remove air intake manifold • Unscrew bolt (2)
2. 2. Remove engine vent hose from cylinder head cover • Release clamp (4)
3. 3. Detach air intake pipe from air intake hose • Release clamp (1) – Release clamp
4. 4. Detach air intake pipe from turbocharger • Release clamp (3)

Note. Seal air intake pipe at turbocharger

5. 5. Remove air intake pipe

6. 6. Release fuel pressure using pressure tester KM-J-34730-91 via test connection.
7. 7. Collect escaping fuel in a suitable container.
8. 8. Disconnect vacuum line (1) from fuel pressure regulator (2). Remove fastening clamp (5) from fuel pressure regulator and fuel rail.
9. 9. Mark installation position and carefully remove fuel pressure regulator from fuel rail

Note. Extreme cleanliness is extremely important at this point

10. 10. Replace seal rings (3) and (4)

Install

11. 11. Coat seal rings with thin layer of silicone grease (white) before installing
12. 12. Note installation position of fuel pressure regulator. Insert fuel pressure regulator into fuel rail

Note. Extreme cleanliness is extremely important at this point

13. 13. Fit fastening clamp to fuel pressure regulator and attach fuel rail 5 Nm
14. 14. Connect vacuum hose to fuel pressure regulator
15. 15. Remove seal from turbocharger air intake pipe
16. 16. Attach engine vent hose to cylinder head cover • Fasten clamp
17. 17. Attach air intake pipe to turbocharger • Fasten clamp
18. 18. Attach air intake pipe to air intake hose • Fasten clamp
19. 19. Screw in bolt