How to Replace the Common Rail Opel Vivaro A

Remove

1. 1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently (approximately 30 seconds). This waiting period is absolutely essential for common rail to be depressurised
2. 2. Disconnect battery negative lead
3. 3. Disconnect hose (1) from oil filler on air cleaner assembly, then move to one side • Release clip (2)

4. 4. Disconnect hose (2) from mass air flow meter (1) • Release clip
5. 5. Disconnect harness connector (3) from mass air flow meter

6. 6. Remove air intake duct (1) from air cleaner assembly (2) and front panel • Release 2x clip

7. 7. Remove air cleaner assembly from support frame • Pull off from 4x locating peg (1)

8. 8. Release charge pressure sensor and base adapter (2) from support frame • Pull off
9. 9. Release harness for charge pressure sensor from support frame (1) • Release clip (3)

10. 10. Release fuel pipe (2) from support frame (1) • Release 2x clip

11. 11. Release harness (1) for mass air flow meter from support frame (2) • Release clip (3)

12. 12. Release harness for coolant heater assembly (if installed) from support frame • Release clip (2)
13. 13. Release bracket with coolant heater assembly (1) (if installed) from support frame • Remove bolt (3)

14. 14. Remove support frame for air cleaner assembly from engine compartment • Remove 2x bolt (3), 2x nut (2)
15. 15. Remove intercooler outlet pipe from engine compartment • Release 3x clip • Disconnect harness connector

Important. When removing duct assembly, release securing clips last.

16. 16. Remove duct assembly (2) from intercooler and turbocharger • Remove bolt (3) • Release 2x clip (1)
17. 17. Remove O ring from duct assembly

18. 18. Remove fuel rail cover (1) from engine • Remove 6x bolt (2) • Release harness from clip (3)

19. 19. Disconnect harness connector from fuel temperature sensor

20. 20. Disconnect 4x harness connector (1) from 4x fuel injector

21. 21. Disconnect harness connector (1) from camshaft position sensor

22. 22. Disconnect harness connector from fuel pressure regulator (1)

23. 23. Disconnect harness connector (1) from coolant temperature sensor

24. 24. Disconnect harness connector (1) from vacuum switching valve

25. 25. Disconnect harness connector (1) from throttle valve

26. 26. Disconnect harness connector (1) from exhaust gas recirculation (EGR) valve

27. 27. Disconnect 4x harness connector (1) from 4x glow plug

28. 28. Release breather hose for transmission from engine harness trunking • Release from clip, then move to one side
29. 29. Release engine harness from engine lifting eye • Remove nut, bolt, then move to one side

Important. Clean all connections before disconnecting; use only lint-free cleaning cloths. Use new thinner, clean brushes and compressed air. Do not use a high pressure washer.

30. 30. Release 2x fuel pipe from engine, then move to one side • Disconnect 5x integral clip (1) • Release from 4x clip • Remove bolt • Install 10x new blanking plug

31. 31. Remove rear lifting eye from cylinder head • Remove 2x bolt

32. 32. Release breather hose from oil separator, then move to one side • Release clip
33. 33. Remove oil separator (1) with heat shield from camshaft bearing block • Remove 8x bolt • Remove 5x seal • Install 4x new blanking plug

34. 34. Remove fuel leak-off pipe (1) from cylinder head • Release 4x clip from 4x fuel injector – Push in • Release from locator – Pull up • Install 8x new blanking plug

Important. Clips are not to be removed from injectors; if they are they must be replaced.

35. 35. Remove shield (2) from high pressure pipe union (1) at high pressure pump • Release 4x clip (3)

36. 36. Remove high pressure pipe from high pressure pump and common rail • Remove bolt (2) • Release 2x pipe union (1) – Use Pipe Spanner KM-812 • Install 4x new blanking plug

37. 37. Remove 4x fuel high pressure pipe from 4x fuel injector and common rail • Release 8x pipe union – Use Pipe Spanner KM-812 ; counterhold nut on fuel injector using suitable spanner • Install 16x new blanking plug

38. 38. Remove common rail (1) from camshaft bearing block • Remove 3x bolt (2)

Install

39. 39. Install new seal to new common rail
40. 40. Install common rail (1) to camshaft bearing block • Install 3x bolt (2); do not tighten at this stage

41. 41. Install 4x high pressure pipe to common rail and 4x fuel injector • Remove 16x blanking plug • Secure 8x pipe union; do not tighten at this stage

42. 42. Install high pressure pipe to common rail and high pressure pump • Remove 4x blanking plug • Secure 2x pipe union (1); do not tighten at this stage • Install bolt (2); do not tighten at this stage

43. 43. Secure common rail to camshaft bearing block • Secure 3x bolt 25 Nm
44. 44. Secure 4x high pressure pipe to 4x fuel injector • Secure 4x pipe union 32 Nm – Use Pipe Spanner KM-812 ; counterhold nut on fuel injector using suitable spanner
45. 45. Secure 4x high pressure pipe to common rail • Secure 4x union 32 Nm – Use Pipe Spanner KM-812
46. 46. Secure high pressure pipe to common rail and high pressure pump • Secure 2x pipe union (1) 32 Nm – Use Pipe Spanner KM-812
47. 47. Secure high pressure pipe to camshaft bearing block • Secure bolt (2) 10 Nm

48. 48. Install shield (2) to high pressure pipe union (1) at high pressure pump • Secure 4x clip (3)

49. 49. Install new fuel leak-off pipe (1) to cylinder head • Remove 8x blanking plug • Connect fuel leak-off pipe to 4x fuel injector – Secure 4x clip • Secure to locator

50. 50. Install oil separator with heat shield to camshaft bearing block • Remove 4x blanking plug • Install 5x new seal • Install 8x bolt 10 Nm in sequence shown

Note. Oil separator shown removed for clarity.

51. 51. Secure breather hose to oil separator • Secure clip
52. 52. Install rear lifting eye to cylinder head • Install 2x bolt

53. 53. Secure 2x fuel pipe to engine • Remove 10x blanking plug • Connect 5x integral clip (1) • Secure to 4x clip • Install bolt

54. 54. Position engine harness to engine lifting eye • Install nut, bolt; do not tighten at this stage
55. 55. Connect 4x harness connector (1) to 4x glow plug

56. 56. Connect harness connector (1) to EGR valve housing

57. 57. Connect harness connector (1) to vacuum switching valve

58. 58. Connect harness connector (1) to throttle valve

59. 59. Connect harness connector to fuel pressure regulator (1)

60. 60. Connect harness connector (1) to camshaft position sensor

61. 61. Connect 4x harness connector (1) to 4x fuel injector

62. 62. Connect harness connector (1) to coolant temperature sensor

63. 63. Connect harness connector to fuel temperature sensor

64. 64. Secure engine harness to engine lifting eye • Secure nut, bolt
65. 65. Secure breather hose for transmission to engine harness trunking • Secure to clip
66. 66. Install fuel rail cover (1) to engine • Install 6x bolt (2) • Secure harness to clip (3)

Important. Ensure correct assembly sequence is observed and duct assembly is positioned in correct axis, and to correct side of support bracket.

67. 67. Install duct assembly (2) to engine compartment • Install new O ring to intercooler pipe – Apply suitable lubricant to new O ring, then position to intercooler pipe • Position duct to turbocharger and intercooler in correct axis with no twisting or levering movements • Install bolt (3) – Observe position of duct to support bracket • Secure 2x clip (1) – Clip to be secured last in assembly sequence

68. 68. Install intercooler outlet pipe to engine compartment • Secure 3x clip • Connect harness connector

69. 69. Install air cleaner assembly support frame (1) to engine compartment • Install 2x bolt (3), 2x nut (2)
70. 70. Secure bracket with coolant heater assembly (1) (if installed) to support frame • Install bolt (3)
71. 71. Secure harness for coolant heater assembly (if installed) to support frame • Secure clip (2)

72. 72. Secure fuel pipe (2) to support frame (1) • Secure 2x clip

73. 73. Secure harness (1) for mass air flow meter to support frame (2) • Secure clip (3)

74. 74. Secure harness for charge pressure sensor to support frame (1) • Secure clip (3)
75. 75. Secure charge pressure sensor and base adapter (2) to support frame • Push on

76. 76. Install air cleaner assembly to support frame • Push on 4x locating peg (1)

77. 77. Install air intake duct (1) to air cleaner assembly (2) and front panel • Secure 2x clip

78. 78. Connect harness connector (3) to mass air flow meter
79. 79. Connect hose (2) to mass air flow meter (1) • Secure clip

80. 80. Connect hose (1) to oil filler on air cleaner assembly • Secure clip (2)

81. 81. Connect battery negative lead
82. 82. Program all volatile memories