Replacing Vectra C Fuel Pump: Step-By-Step Guide For Diyers

Changing the fuel pump on a Vectra C can be a challenging task. Some people suggest using a screwdriver and hammer to tap the pump anticlockwise, while others recommend creating a tool with metal strips and bolts to provide more force for opening. It's important to note that there may be an access plate above the fuel tank area, which could be under the seat or in the trunk, so checking for this before starting work is essential. If there is no access plate, removing the fuel tank may be necessary. Additionally, ensuring that there is no air in the system is crucial, especially for diesel engines, as even a small amount of air can cause significant issues.

Check for an access plate above the fuel tank

To check for an access plate above the fuel tank of a Vauxhall Vectra, you will need to lift the back seats. You should then see a plastic nut of about 4" that holds the fuel pump in place. Remove this and lift it out to access the fuel tank.

If you are unable to locate the access plate, you may need to remove the rear seats completely to expose the fuel tank. This will involve removing the bolts and brackets that secure the seats to the floor. Once the seats are removed, you should be able to see the fuel tank and locate the access plate.

If you are still unable to locate the access plate, it may be necessary to refer to a repair manual or seek assistance from a qualified mechanic. It is important to note that working on fuel systems can be dangerous, and proper safety precautions should always be followed.

If you are attempting to access the fuel tank to change the fuel pump, there are alternative methods that do not require removing the access plate. These include:

• Siphoning the fuel from the tank through the filler pipe or the access hole for the fuel pump.
• Removing the tank outlet pipe and draining the fuel into a suitable container.
• Disconnecting the fuel filter and using a power source to run the pump and drain the fuel.
• Cutting the fuel line under the bonnet and powering up the pump to drain the fuel.

Use a screwdriver and hammer to remove the pump

To remove the fuel pump from a Vectra, you will need to use a screwdriver and a hammer. First, try tapping the screwdriver anti-clockwise with the hammer. Make sure to use a blunt-edged screwdriver. If this doesn't work, you can try to make a tool by taking two strips of metal and two long bolts. Put them together like a ladder and tighten the bolts so they fit snugly. Then, use more force to open the pump. Alternatively, you can try to bend or break the tabs and turn them anti-clockwise.

If these methods don't work, you may need to use more force. One option is to keep hitting the pump with a hammer and a chisel until it comes off. This method may require you to replace the seal, as you may need to abuse it until it comes off. Another option is to use a sharp punch, a big hammer, and a bucket to catch any fuel. You can also try unclipping the hose and letting the fuel pump do the work. If you are unable to remove the pump, you may need to remove the fuel tank. Look above the fuel tank area to see if there is an access plate under the seat or in the trunk. If there is no access plate, you will need to remove the fuel tank.

Use a bleed tool to remove air from the system

To bleed your Vectra C's fuel system, you will need to purchase an aftermarket bleed tool from a local car accessory shop. This is because Vauxhall vehicles are known to be particularly difficult to bleed, and a bleed tool will make the process much easier.

Once you have your bleed tool, fit it into the line after the fuel filter. Then, slack the feed pipe to the pump and bleed the system until you get a full flow of diesel with no air. You may need to crank the engine in short bursts to get the diesel flowing.

Once you have bled the system, leave the bleeder in place to avoid any further issues. Then, go ahead and crank the engine in five-second bursts, with five-second intervals in between, until the engine fires up.

If you continue to have issues with air in the system, you may need to take your Vectra to a Vauxhall service centre, as they have an electric pump to bleed the system. However, the methods described above should be effective in most cases.

Undo injector pipes and crank the engine

To undo the injector pipes and crank the engine of a Vectra, start by cracking open (undoing) each of the injector pipes at the injectors. Once all the pipes are undone, crank the engine until diesel fuel starts to come out of the pipes. As soon as this happens, tighten the pipes as fast as you can and continue to crank the engine. The car should start now. If it doesn't, you may need to bleed the system using a bleed tool from a local car accessory shop.

Fit the tool into the line after the fuel filter and bleed it using that tool until you get a full flow of diesel, with no air at all. Leave the bleeder in the line and crank the engine in five-second bursts, with five-second intervals in between. The engine will soon fire up.

If the car still doesn't start, you will need to open the injectors and bleed the fuel through, then crank and bleed until it flows. Lock the injectors and continue to crank until the engine starts. This process can be time-consuming, but it will work.

If all else fails, you will need to take the car to a Vauxhall garage to have the system bled with their electric pump arrangement.

Seal the pump with a new metal ring

To seal the pump with a new metal ring, you will need to purchase a new seal kit. This will come with a new metal ring that can be used to reseal the pump.

First, locate the pump. For a 2002 Vectra DTi, the pump is located in the boot. For a 2003 Vectra, the pump is located under the rear seats.

Once you have located the pump, use a screwdriver and hammer to tap it anticlockwise. You may need to use some force to open it. If this doesn't work, you can try to bend or break the tabs and turn anticlockwise. You will see ramps on the inner part that will push the tabs out of the way, and a lock tab that prevents unscrewing.

Once you have removed the old pump, you can install the new one and seal it with the new metal ring from the seal kit. Make sure to follow any additional instructions provided with the seal kit.

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