How to Replace the Oil Separator, Crankcase Ventilation Opel Vivaro A

Remove

1. 1. Disconnect battery negative lead
2. 2. Release coolant hose (1) from resonance chamber • Release from clip (2)

3. 3. Remove air duct and resonance chamber from air cleaner housing (3) • Release strap (1) from support bracket (2), then move to side

4. 4. Remove vacuum hose (1) from intake manifold (2) • Release clip

5. 5. Release fuel vapour line (1) from throttle valve housing (2) • Release clip, then move to side

6. 6. Disconnect harness connector (1) from manifold pressure sensor (2) • Release integral clip

7. 7. Disconnect harness connector (1) from throttle valve housing • Release integral clip

8. 8. Disconnect 4x harness connector (1) from 4x ignition coil (2) • Release 4x integral clip • Release from 4x intake manifold clip, then move to side

9. 9. Disconnect harness connector (1) from air temperature sensor (2) • Release integral clip

10. 10. Remove cover (2) from air cleaner housing • Remove 2x screw (1)

11. 11. Remove air cleaner housing (1) from engine • Remove 2x bolt (2)

12. 12. Remove throttle valve housing (2) from cylinder head • Remove 3x bolt (1) – Discard O ring

13. 13. Remove intake manifold (2) from cylinder head • Remove 7x bolt (1) – Discard seals

14. 14. Remove oil separator (2) from camshaft housing cover (3) • Remove 8x bolt (1)

Note. Cylinder head shown removed for clarity.

Install

15. 15. Install new oil separator (2) to camshaft housing cover (3) • Clean all mating surfaces • Apply continuous bead of sealant to mating face of oil separator – see “Sealants, Lubricants and Locking Compounds” • Install 8x bolt (1) 13 Nm in sequence shown
16. 16. Install intake manifold (2) to cylinder head • Clean all mating surfaces • Install 5x new seal • Install 7x bolt (1); do not tighten at this stage

17. 17. Install throttle valve housing (2) to cylinder head • Install new O ring • Install 3x bolt (1) 9 Nm

18. 18. Secure intake manifold to cylinder head • Install 7x bolt 9 Nm in sequence shown

19. 19. Install air cleaner housing (1) to engine • Install 2x bolt (2) 9 Nm

20. 20. Install cover (2) to air cleaner housing • Secure 2x screw (1)

21. 21. Connect harness connector (1) to air temperature sensor (2) • Secure integral clip

22. 22. Connect 4x harness connector (1) to 4x ignition coil (2) • Secure 4x integral clip • Secure to 4x intake manifold clip

23. 23. Connect harness connector (1) to throttle valve housing • Secure integral clip

24. 24. Connect harness connector (1) to manifold pressure sensor (2) • Secure integral clip

25. 25. Secure fuel vapour line (1) to throttle valve housing (2) • Secure clip

26. 26. Install vacuum hose (1) to intake manifold (2) • Secure clip

27. 27. Install air duct and resonance chamber to air cleaner housing (3) • Push fit • Secure strap (1) to support bracket (2)

28. 28. Secure coolant hose (1) to resonance chamber • Secure to clip (2)

29. 29. Connect battery negative lead
30. 30. Program volatile memories