Astra G Fuel Filter removal

I originally posted this to uk.rec.cars.maintenance, but I wondered if
there is any specific knowledge of disconnecting the fuel lines from
the fuel filter in this group?

Car is 2002 Astra Club estate 1.6i 8-valve.

If you haven't replaced the fuel filter on one of these vehicles then
stop reading here.


Have purchased fuel filter from local VX garage, complete with the
little plastic clipsclips. But I'm not sure how to disconnect the fuel
lines, and it isn't the sort of job that I would like to go wrong!
Maybe someone out there can help with a little advice ...

I've got 2 problems


1) Examining the filter thats on the car, it looks as if the fuel lines

have the plastic clips moulded into them - I don't want to risk
breaking the clip (thus immobilising the car!), and would like the
Vauxhall tool to disengage the clip.

But - the VX garage says that VX supply the special tool to thier
dealers for use in the workshop - but don't make it available for sale!

I've successfully practised putting the new clips on the new filter
and removing them with a small screwdriver - off the car of course, but

trying this on the car itself is a different matter, and a small slip
might leave me with a disabled car!


So - Anyone done this job, is there a knack to it, how do the clip fit
onto the ends of the pipe - and where can I get the special tool
from/or can it be made-up from e.g. a circlip remover?


2) Depressurising the system - My haynes book says "disconnect the
purple relay in the relay box" - but there are 2 of the damn things!
Removing one of them then starting the engine has no effect whatsoever
except to leave one of the warning lights on. Removing the other the
engine turns over but won't start at all, and I was expecting it to
start, run for a few secs, and die! So the obvious choice would be the
second relay - or would it?


Appreciate your help, thanks

 

the tools is only a pair of pliers with flat inwards pointing blades on the
end - a lot of motorist type shops and Halfords sell them for about £5 but
you don't really need them as a small screw driver will do the job.

The clips come off with the old filter and you put the clips on the filter
first.

Undo the bolt for the filter. You need to squeeze the clip on both sides
where it comes through the square hole in the pipe while pulling the pipe.
You can push the clip in with a small screw driver instead of using the
pliers.

When you put the new filter on just line the squares on the clip up with the
holes on the pipe and push the pipe on.

Yes you are meant to release the fuel pressure but I have changed hundreds
of filters and have never had the need - you leak a really small amount of
fuel out so as long as you make sure ignition is off and shut your eyes as
you pull the pipe of so you don't get any in your eyes - only stings for a
second or 2 - you will be ok.

If you are still unsure about doing this job yourself just go to any garage
and ask them to change it - will probably charge you £10 max if they charge
you anything at all!!!

 

I've done a-plenty of 1.8 16v - does that count :-o

Wise move buying the clips - often the dealer will only sell you
the filter. You can sometimes get away without replacing the
clips, but if you over stress them when trying to release the old
filter from the pipes, they can sometimes leak.

The outer *housing* for the fuel filter clips is moulded and part
of the fuel line. The smaller clips click into the ends of the
fuel line, and then onto the ends of the filter.

At worst, you will probably break the green/blue clips in the end
of the fuel line (unless you are extremely hash handed).

Try to time fuel filter replacement when the tank is nearly dry,
ie reserve light on.

Jack only one side of the car (fuel filter side obviously) as
high as safely possible, so that remaining fuel in tank runs away
from filter.

I think the relay is purple, but don't hold me to it (whoops -
just re-read above doh). Anyway, the relay which prevents the
car from firing up on the starter is the correct one.

Regarding depressurising - it is worth doing, beacuse you will be
underneath the filter and could get a nasty spray in your eye -
not nice! On the top of the engine, you may need to remove the
plastic top cover first, look for the bright silver fuel rail
feeding the fuel injectors. Somewhere in the top of the rail
will be a schrader valve (tyre type thingy), hopefully under a
black plastic screw on cap. With the ignition off and the relay
removed, depress the centre of the valve core to depressure the
fuel rail. You won't get much volume of fuel released, but it
will squirt quite a distance, so don't look straight at the valve
as you press it!

Even after depressurising, when you release the pipe clips from
the fuel filter, you still need to be prepared for fuel leakage,
probably a gentle trickle down your arm ;-/

The way I found to minimise leaking was to unscrew the clamp,
wiggle the filter free to get some more slack in the fuel lines,
remove the rearmost line from the existing filter, then
immediately attach the new filter to the open line, pull the
existing filter down (perhaps 3 inches or so) to get a better
angle of attack on the front line clip, remove the front line
from the old filter, and connect to the new one. Wiggle new
filter back into support bracket, making sure fuel lines arn't
streched or twisted, tighten clamp bolt, lower car to ground,
turn ignition on (but don't immediately start) for a few seconds
to prime fuel lines, start engine and check for leaks at filter.

It's a good idea to then brim the fuel tank straight away, and
double check fuel filter for leaks.

HTH

Regards,

Sean