How to Replace the Inlet Coolant Pipe Opel Vivaro A

Remove

1. 1. Disconnect battery negative lead
2. 2. Remove cap from coolant expansion tank
3. 3. Remove air cleaner assembly (1) from engine compartment • Disconnect harness connector (3) from mass air flow meter – Release clip • Release harness for mass air flow meter from air cleaner assembly – Release clip • Disconnect hose (2) from mass air flow meter – Release clamp • Disconnect air intake duct (4) from air cleaner assembly – Pull off • Disconnect 2x hose (5) from air cleaner assembly – Pull off • Remove air cleaner assembly from engine cover – Pull off right side from 2x grommet, then slide to right to release from locating peg

4. 4. Raise vehicle to suitable working height
5. 5. Remove front wheel, right side • Remove wheel cover • Remove 5x bolt
6. 6. Raise vehicle
7. 7. Remove engine and transmission undershield • Remove 6x bolt
8. 8. Remove splash panel, right side • Release washer hose (if installed) from 2x clip • Remove 2x bolt , screw

Note. Splash panel is removed to ease access to the primary catalytic converter nuts.

Important. Observe the relevant environmental regulations when disposing of used coolant.

9. 9. Drain cooling system • Place collecting container below • Disconnect lower coolant hose (1) from radiator – Release clip • Allow coolant to drain into collecting container

10. 10. Connect lower coolant hose to radiator • Secure clip
11. 11. Remove secondary catalytic converter • Remove clamp • Remove 2x nut • Remove gasket

12. 12. Remove heat shield (1) from chassis • Remove 2x clip (2)

13. 13. Remove heat shield (1) from subframe • Remove 2x bolt

14. 14. For right drive vehicles, remove heat shield (1) from steering gear • Remove 2x bolt (2)

15. 15. Release wiring harness from steering gear • Remove bolt (1) • Remove support bracket

16. 16. Remove support bracket from primary catalytic converter and engine, left side • Remove 2x bolt (1)

17. 17. Remove support bracket (1) from primary catalytic converter and engine, right side • Remove 2x bolt

18. 18. Remove primary catalytic converter from turbocharger • Remove 4x nut

Note. Removal of the primary catalytic converter is difficult due to restricted access.

Important. Take care not to distort the oil return pipe when removing.

19. 19. Remove oil return pipe (1) from turbocharger and engine • Place collecting container below • Remove 2x bolt • Pull out from engine • Remove gasket, O ring • Install 4x new blanking plug

20. 20. Remove oil feed pipe from turbocharger and engine • Remove bolt (1) • Release pipe union (2) • Install 4x new blanking plug

21. 21. Disconnect hose (2) from wastegate actuator • Pull off
22. 22. Disconnect intake hose from turbocharger • Release clamp (1)
23. 23. Disconnect outlet hose from turbocharger • Release clamp (3)

24. 24. Remove turbocharger from exhaust manifold • Remove 3x nut

Note. Removal of the turbocharger nuts is difficult due to restricted access; suitable tooling will be required.

Note. Illustration of 3x nut shown from above for clarity.

25. 25. Remove coolant pipe (3) from coolant pump housing (4) and thermostat housing (1) • Remove bolt (2) • Pull off • Remove O ring from thermostat housing

Install

26. 26. Install new coolant pipe (3) to coolant pump housing (4) and thermostat housing (1) • Install new O ring to thermostat housing • Install new O ring to coolant pipe • Push fit

Note. Ensure coolant pipe is secured to coolant pump then to thermostat housing.

27. 27. Secure coolant pipe to engine • Install bolt (2)

28. 28. Install turbocharger to exhaust manifold • Clean mating surfaces • Install 3x new nut 27 Nm

Note. Installation of the turbocharger nuts is difficult due to restricted access; suitable tooling will be required.

29. 29. Connect hose (2) to wastegate actuator • Push on
30. 30. Connect intake (1) hose to turbocharger • Secure clamp
31. 31. Connect outlet (3) hose to turbocharger • Secure clamp

32. 32. Install new oil feed pipe to turbocharger and engine • Remove 4x blanking plug • Install 2x new sealing washer, new O ring • Install bolt (1) 23 Nm • Secure pipe union (2) 23 Nm

Important. Take care not to distort the oil return pipe when installing.

33. 33. Install oil return pipe (1) to turbocharger and engine • Remove 4x blanking plug • Install new gasket, new O ring • Push in to engine • Install 2x bolt 8 Nm

34. 34. Install primary catalytic converter to turbocharger • Clean mating surfaces • Install 4x new nut 24 Nm

Note. Installation of the primary catalytic converter is difficult due to restricted access.

35. 35. Install support bracket (1) to primary catalytic converter and engine, right side • Install 2x bolt 24 Nm

36. 36. Install support bracket to primary catalytic converter and engine, left side • Install 2x bolt (1) 24 Nm

37. 37. Secure wiring harness to steering gear • Install support bracket • Install bolt (1)

38. 38. For right drive vehicles, install heat shield (1) to steering gear • Install 2x bolt (2) 8 Nm

39. 39. Install heat shield (1) to subframe • Install 2x bolt 15 Nm

40. 40. Install heat shield (1) to chassis • Install 2x clip (2)

41. 41. Install secondary catalytic converter • Clean mating surfaces • Install new gasket • Install 2x new nut; do not tighten at this stage • Install new clamp 21 Nm • Secure 2x nut 21 Nm

42. 42. Install splash panel, right side • Install 2x bolt 8 Nm , screw 6 Nm • Secure washer hose (if installed) to 2x clip

43. 43. Lower vehicle to suitable working height
44. 44. Install front wheel, right side • Install 5x bolt; do not tighten at this stage
45. 45. Lower vehicle
46. 46. Secure front wheel, right side • Secure 5x bolt 140 Nm • Install wheel cover
47. 47. Install air cleaner assembly (1) to engine compartment • Install air cleaner assembly to engine cover – Slide left into locating peg, then push right side into 2x grommet • Connect breather hose assembly (5) to air cleaner assembly – Push on • Connect air intake duct (4) to air cleaner assembly – Push on • Connect hose (2) to mass air flow meter – Secure clamp • Secure harness for mass air flow meter to air cleaner assembly – Secure clip • Connect harness connector (3) to mass air flow meter – Secure clip

48. 48. Connect battery negative lead

49. 49. Remove fuse box cover from instrument panel • Release 4x clip
50. 50. Remove engine immobiliser/instrument panel fuse from fuse box
51. 51. Crank engine for five seconds

52. 52. Install engine immobiliser/instrument panel fuse to fuse box
53. 53. Install fuse box cover to instrument panel • Secure 4x clip
54. 54. Bleed cooling system – see operation “Cooling System, Drain and Refill”
55. 55. Program all volatile memories
56. 56. Raise vehicle
57. 57. Install engine and transmission undershield • Install 6x bolt 6 Nm
58. 58. Lower vehicle