How to Replace (G9U 730) the Starter Opel Vivaro A

Remove

1. 1. Disconnect battery • Remove floor covering – Slide seat backwards – Remove 2x clip (1) • Remove battery cover – Release 4x screw (2) • Disconnect negative lead – Release bolt (3)

2. 2. Remove air cleaner assembly from engine compartment – see operation “Air Cleaner Assembly, Remove and Install (G9U 730)”
3. 3. Remove drain hose from engine top cover • Release 2x clip
4. 4. Disconnect intercooler hose from between intercooler and intake manifold, then move to side • Release clip

5. 5. Raise vehicle
6. 6. Remove engine undershield • Remove 6x bolt (1)

7. 7. Disconnect harness connector from charge pressure sensor • Release integral clip
8. 8. Disconnect harness connector from cooling fan motor, then move to side • Release integral clip – Position connector to side

Important. Take care not to damage charge pressure sensor and surrounding components when removing intercooler hose.

9. 9. Remove intercooler hose from engine compartment • Disconnect intercooler hose from intake manifold, then move upwards • Release clip

10. 10. Lower vehicle
11. 11. Remove intercooler hose from engine compartment
12. 12. Remove accessible bolt from starter

Note. The remaining starter bolts are removed at later stage.

13. 13. Raise vehicle
14. 14. Disconnect harness connector from oil pressure switch • Release integral clip

15. 15. Disconnect 2x harness connector (1) from starter (2), then move to side • Remove 2x nut (3)

16. 16. Remove accessible bolt from starter

Note. Remaining bolt is removed at later stage.

17. 17. Release harness from support bracket • Release clip
18. 18. Release support bracket from transmission housing • Remove bolt
19. 19. Remove starter from transmission housing • Remove remaining bolt – Guide starter through opening between lower reinforcement panel, cylinder block and oil filter housing

Install

20. 20. Install new starter to transmission housing • Install upper bolt, finger-tight – Guide starter through opening between lower reinforcement panel, cylinder block and oil filter housing

21. 21. Install 2x lower bolt to starter motor, then tighten 3x bolt ( 44 Nm )
22. 22. Install support bracket to transmission housing • Install bolt
23. 23. Secure harness to support bracket • Secure clip
24. 24. Connect 2x harness connector (1) to starter motor (2) • Install 13mm nut (3) ( 9 Nm ) • Install 8mm nut (3) ( 5 Nm )

25. 25. Connect harness connector to oil pressure switch • Secure integral clip

26. 26. Lower vehicle

Important. Take care not to damage charge pressure sensor and surrounding components when installing intercooler hose.

27. 27. Install intercooler hose to engine compartment
28. 28. Raise vehicle
29. 29. Connect intercooler hose to between intercooler and intake manifold • Secure clip

30. 30. Connect harness connector to cooling fan motor • Secure integral clip
31. 31. Connect harness connector to charge pressure sensor • Secure integral clip
32. 32. Install engine undershield • Install 6x bolt (1) ( 6 Nm )

33. 33. Lower vehicle
34. 34. Connect intercooler hose to intercooler • Secure clip

35. 35. Install drain hose to engine top cover • Secure 2x clip
36. 36. Install air cleaner assembly – see operation “Air Cleaner Assembly, Remove and Install (G9U 730)”
37. 37. Connect battery • Install negative lead (3) ( 5 Nm ) • Install battery cover – Tighten 4x screw (2) ( 8 Nm ) • Install floor covering – Secure 2x clip (1) • Slide seat back to original position

38. 38. Program all volatile memories