How to Replace the High Pressure Pump 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 hose (1) from turbocharger • Release clip • Disconnect breather hose – Pull out • Release vacuum pipe from hose – Release from 3x retainer

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

20. 20. Disconnect harness connector from fuel temperature sensor

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

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

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

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

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

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

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

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

29. 29. Release breather hose for transmission from engine harness trunking • Release from clip, then move to one side
30. 30. 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.

31. 31. 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

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

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. Disconnect fuel drain hose from high pressure pump • Pull off
36. 36. Remove shield (2) from high pressure pipe union (1) at high pressure pump • Release 4x clip (3)

37. 37. 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

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

39. 39. Remove high pressure pump from cylinder head • Remove 3x bolt

40. 40. Install high pressure pump to soft-jawed vice • Secure gear in soft-jawed vice
41. 41. Remove gear from high pressure pump • Release gear from high pressure pump; do not remove at this stage – Release nut (1) • Reposition high pressure pump to soft-jawed vice • Remove nut and gear (2) from high pressure pump – Use commercially available puller

42. 42. Remove high pressure pump from soft-jawed vice

Install

43. 43. Install gear to new high pressure pump • Secure gear in soft-jawed vice • Degrease mating surface of pump shaft and gear • Position high pressure pump to gear • Secure high pressure pump to gear – Install new nut 90 Nm

44. 44. Prime high pressure pump • Connect suitable hose to high pressure pump inlet port – Remove blanking plug from inlet port • Position collecting container below • Fill hose with diesel fuel • Install Pressure and Vacuum Pump MKM-667 – Use suitable adaptor • Remove blanking plug from high pressure pump outlet port Warning: Maximum pressure must not exceed 1.5 bar . • Apply pressure until diesel fuel flows from outlet port and is clear and free from bubbles • Install blanking plug to high pressure pump outlet port • Remove Pressure and Vacuum Pump MKM-667 and adaptor from hose • Remove hose from high pressure pump inlet port • Install blanking plug to high pressure pump inlet port

45. 45. Remove high pressure pump from soft-jawed vice
46. 46. Install new seal (1) to high pressure pump

47. 47. Install high pressure pump to cylinder head

Note. Ensure correct alignment of 3x bolt hole at rear of high pressure pump.

48. 48. Secure high pressure pump to cylinder head • Install 3x new bolt 5 Nm , then 25 Nm in sequence shown – Apply locking compound to thread of 3x bolt – see “Sealants, Lubricants and Locking Compounds”

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

50. 50. Release common rail (1) from camshaft bearing block • Release 3x bolt (2)

51. 51. 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

52. 52. Secure common rail to camshaft bearing block • Secure 3x bolt 25 Nm
53. 53. Secure high pressure pipe to common rail and high pressure pump • Secure 2x pipe union (1) 32 Nm – Use Pipe Spanner KM-812
54. 54. Secure high pressure pipe to camshaft bearing block • Secure bolt (2) 10 Nm

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

56. 56. Connect fuel drain hose to high pressure pump • Push on
57. 57. 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

58. 58. 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.

59. 59. Install rear lifting eye to cylinder head • Install 2x bolt

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

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

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

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

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

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

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

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

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

70. 70. Connect harness connector to fuel temperature sensor

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

74. 74. Install hose (1) to turbocharger • Secure 2x clip • Connect breather hose – Push in • Secure vacuum pipe to hose – Secure to 3x retainer

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

75. 75. 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

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

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

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

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

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

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

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

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

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

89. 89. Connect battery negative lead
90. 90. Program all volatile memories