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Uprated Fuel Pump - Astra G/H and Zafira A/B

Uprated Fuel Pump

High Flow Uprated In Tank 340 Series Stealth Fuel Pump for most petrol turbo applications.

For Astra G/H and Zafira A/B Turbo models inc VXR running big horsepower and higher boost levels, fuelling is critical. The replacement Protec 340 Stealth high output in-tank electric fuel pump offers the solution. 340 lph at 40psi. Offset Inlet, Inline with Outlet. Will fit into original in-tank housing with slight modification. Suitable for cars from 300bhp up to approximately 450bhp. Features a vapour-purge port as on an OE pump, so less prone to fuel starvation at low fuel levels.

£99.00 Convoluted Flexi Fuel Hose also available
This 340 Fuel Pump is a high-output, in-tank electric fuel pump which is a compact, lightweight pump that bolts into the existing OE fuel pump assemby with just minor modification. This pump is ideal for applications requiring more flow while retaining the factory fuel lines and mounting provisions available in the Original Equipment (O.E.) configuration.

Features an offset inlet, inline with outlet.

• Fits Astra G/H 2.0 Turbo, Zafria A/B 2.0 Turbo, Corsa D 1.6 Turbo with minor modification to the OE fuel pump housing.
• Internal Check Valve
• Vapour Purge Port in base of pump
• Designed for in-tank use only
• Turbine pump mechanism increases durability.
• Suitable for standard and modified cars.

Specifications:
Flow Rate - 340 lph @ 40psi :: 300 lph @ 50psi :: 275 lph @ 60psi
Weight - 355 grams
External Materials - Black Steel Body
Inlet Fitting - Offset Inlet Inline with Outlet
Outlet Fitting - 8.5mm OD
Impeller Design - Regenerative Turbine
Terminal Post - Spade Terminal OE Fitment (6.2mm)
Min Voltage Input - 6 vdc
Max Voltage Input - 18 vdc
Current Draw - (40 psi) 12 amps (13.8vdc)

Dimensions*:
Pump Overall Height (including outlet) - 120mm
Pump Body Height - 80mm
Pump Body Diameter- 39mm
Outlet Length - 21mm
Outlet Diameter - 8.5mm
*All dimensions are approximate

Fitting Information/Guidelines for in-tank pump - Astra G.

The uprated fuel pump is slightly fatter and longer than the standard pump, but will fit into the existing fuel pump housing with slight careful modification. It is recommended that this work is carried out on the bench with the pump and housing out of the fuel tank. Please be aware that Astra H requires similar (see below) but not exact modification. Remember measure twice and cut once.

Disconnect the battery! Remove the rear seat base (Astra G) and cover to access the pump assembly. Unclip the wiring plug plug and fuel lines (soak any excess fuel up). Remove the retaining ring anti-clockwise and the cover will spring up. Unclip the lower housing from inside the tank and remove the whole assembly. Be careful of fuel spillage, and carefully soak up any excess. Much easier with a small quantity of fuel in the tank. Remove the fuel pipe from the pump, remove the pump. Rework the housing as directed, fit the new pump, refit the assembly into the tank, re-secure the cover to the assembly watch the fuel pipes and wiring and be careful with the seal, ensure it is correctly seated and seals and reconnect everything. Refit plastic cover and rear seat.

A Dremal or similar is ideal for re-working the fuel pump housing. As shown in the picture below, simply remove the protrusions (arrowed) from the cage to allow the pump to locate snugly.
On the other part of the housing, again as shown in the picture below, remove the protrusions (arrowed - arrows pointing outwards) as already done on the first half of the housing. Also on this part of the housing about 5-7mm of height needs to be removed from the housing to make room for the slightly longer pump. Carefully remove about 5-7mm from the inner plastic ring of the fuel pump housing until the pump locates correctly. This is shown arrowed (arrows pointing inwards show the plastic ring that needs to be re-worked.)

Fitting Guidelines - Astra H

Disconnect the battery! Remove the rear seat base (Astra H) and cover to access the pump assembly. Unclip the wiring plug plug and fuel lines (soak any excess fuel up). Remove the retaining ring anti-clockwise and the cover will spring up. Unclip the lower housing from inside the tank and remove the whole assembly. Be careful of fuel spillage, and carefully soak up any excess. Much easier with a small quantity of fuel in the tank. Remove the fuel pipe from the pump, remove the pump. Rework the housing as directed, fit the new pump, refit the assembly into the tank, re-secure the cover to the assembly watch the fuel pipes and wiring and be careful with the seal, ensure it is correctly seated and seals and reconnect everything. Refit plastic cover and rear seat.

On Astra H only the top cover needs careful rework to fit the wider replacement pump. Try and leave a small lip as the cap is opened out to secure onto the top of the pump and prevent it from lifting. Sometime with the age of the plastic it becomes brittle, so care is advised.

Swirl Pot and External Fuel Pump

For big horsepower conversions, above around 450bhp an external swirl pot and high pressure fuel pump will be required to provide suitable fuel flow to the engine. We can supply and fit this set up. Please contact us for more information.

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