How to Replace the Fuel Return Pipe 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 4x harness connector (1) from 4x fuel injector

20. 20. Release engine harness from oil separator, then move to one side • Release from clip
21. 21. Release breather hose from oil separator, then move to one side • Release clip
22. 22. Remove rear lifting eye from cylinder head • Remove 2x bolt

23. 23. Remove oil separator (1) with heat shield from camshaft bearing block • Remove 8x bolt • Remove 5x seal • Install 4x new blanking plug

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.

24. 24. Disconnect fuel return hose from fuel leak-off pipe • Release integral clip • Install 2x new blanking plug
25. 25. 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.

Install

26. 26. 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

27. 27. Connect fuel return hose to fuel leak-off pipe • Remove 2x blanking plug • Secure integral clip
28. 28. 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.

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

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

32. 32. Secure engine harness to oil separator • Secure to clip
33. 33. 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.

34. 34. 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

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

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

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

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

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

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

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

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

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

48. 48. Connect battery negative lead
49. 49. Program all volatile memories