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 seal from duct assembly

18. 18. Remove radiator grille from vehicle • Remove 5x bolt • Release 10x retaining clip

19. 19. Remove front panelling from vehicle • Remove 11x screw • Disconnect 2x harness connector from 2x front fog lamp (if installed)

20. 20. Remove impact absorber (2) with air deflector (1) • Remove 4x bolt

21. 21. Remove right air deflector (1) from radiator assembly • Release clip, locator

22. 22. Remove intercooler from upper front panel • Remove 2x bolt (1) • Release 2x locating pin of intercooler from 2x rubber guide – Pull upwards

23. 23. Remove dipstick with guide tube assembly from engine • Remove bolt (1) • Remove O ring • Install new blanking plug

24. 24. Remove throttle valve assembly from engine • Disconnect harness connector • Remove 6x bolt • Remove gasket – Release 2x clip

25. 25. Remove exhaust gas recirculation (EGR) pipe from cooler and control valve • Remove 4x bolt, 2x gasket

26. 26. Remove EGR valve (1) from engine • Disconnect harness connector (2) • Remove 3x bolt (3), gasket
27. 27. Remove intercooler outlet hose support bracket from intake manifold • Remove 2x bolt (4)

28. 28. Remove trim cover (1) from cylinder head • Remove 6x bolt (2) • Release harness from clip (3)

29. 29. Disconnect 2x harness connector (1) from fuel filter housing and water sensor (if installed) • Release harness from bracket for engine damping block – Release clip

30. 30. Release 2x fuel pipe from bracket, then move to one side • Release from 2x clip (1)

31. 31. Disconnect harness connector from fuel temperature sensor

32. 32. Remove 2x fuel pipe from engine • Disconnect 5x integral clip (1) • Release from 8x clip • Install 10x new blanking plug

33. 33. Release breather hose from engine • Release from clip, then move to one side
34. 34. Disconnect 4x harness connector (1) from 4x fuel injector

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

36. 36. Disconnect harness connector (1) from fuel pressure sensor

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

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

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

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

41. 41. Release engine harness from engine lifting eye • Remove nut, bolt, then move to one side
42. 42. Remove cover (2) from high pressure pipe union (1) for high pressure pump • Release 4x clip (3)

43. 43. Release breather hose from turbocharger intake hose • Pull out
44. 44. Remove oil separator (1) from cylinder head • Remove 9x bolt • Remove 5x seal • Install 4x new blanking plug

45. 45. Release fuel return pipe from cylinder head • Remove bolt (1)

46. 46. Remove fuel return pipe from cylinder head • Release 4x harness connector (1) – Pull up • Install 4x new blanking plug

47. 47. Release high pressure pipe from engine • Remove bolt (2)
48. 48. Remove high pressure pipe from high pressure pump and common rail • Release 2x union (1) • Install 4x new blanking plug

49. 49. Remove 4x high pressure pipe from 4x fuel injector and common rail • Release 8x union – Use Pipe Spanner KM-812 • Install 16x new blanking plug

50. 50. Remove common rail (2) from cylinder head • Remove 3x bolt (1)

Note. Cylinder head shown removed for clarity.

Install

51. 51. Install new seal to new common rail
52. 52. Install common rail (2) to cylinder head • Install 3x bolt (1); do not tighten at this stage

Note. Cylinder head shown removed for clarity.

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

Important. Take care not to cross thread unions on the common rail or high pressure pump.

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

55. 55. Secure common rail to cylinder head • Secure 3x bolt 25 Nm
56. 56. Secure high pressure pipe to high pressure pump • Secure pipe union (1) 32 Nm – Use Pipe Spanner KM-812

57. 57. Secure 4x high pressure pipe to 4x fuel injector • Secure 4x pipe union 32 Nm – Use Pipe Spanner KM-812
58. 58. Secure 4x high pressure pipe to common rail • Secure 4x union 32 Nm – Use Pipe Spanner KM-812
59. 59. Secure high pressure pipe to common rail • Secure pipe union (1) 32 Nm
60. 60. Secure high pressure pipe to engine • Install bolt (2) 10 Nm

61. 61. Install fuel return pipe to cylinder head • Remove 4x blanking plug • Secure 4x harness connector (1) – Push down

62. 62. Secure fuel return pipe to cylinder head • Secure bolt (1) 10 Nm

63. 63. Install oil separator to cylinder head • Remove 4x blanking plug • Install 5x new seal • Install 9x bolt 5 Nm in sequence shown • Secure 9x bolt 10 Nm in sequence shown

64. 64. Secure breather hose to turbocharger intake hose • Push in
65. 65. Position engine harness to engine lifting eye • Install nut, bolt; do not tighten at this stage
66. 66. Install cover (2) to high pressure pipe union (1) for high pressure pump • Secure 4x clip (3)

67. 67. Connect 4x harness (1) connector to 4x glow plug

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

69. 69. Connect harness connector (1) to fuel pressure sensor

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

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

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

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

74. 74. Secure engine harness to engine • Secure nut, bolt
75. 75. Secure breather hose to engine • Secure to clip
76. 76. Install 2x fuel pipe to engine • Remove 10x blanking plug • Connect 5x integral clip (1) • Secure to 8x clip

77. 77. Connect harness connector to fuel temperature sensor

78. 78. Install trim cover (1) to cylinder head • Install 6x bolt (2) • Secure harness to clip (3)

79. 79. Secure 2x fuel pipe to bracket • Secure to 2x clip (1)

80. 80. Connect 2x harness connector (1) to fuel filter housing and water sensor (if installed) • Secure harness to bracket for engine damping block – Secure clip

81. 81. Install EGR valve (1) to engine • Install new gasket, 3x bolt (3) 21 Nm • Connect harness connector (2)
82. 82. Install intercooler outlet hose support bracket to intake manifold • Install 2x bolt

83. 83. Install EGR pipe to cooler and control valve • Install 2x new gasket • Install 4x bolt 25 Nm

84. 84. Install throttle valve assembly to engine • Install new gasket – Secure 2x clip • Install 6x bolt 12 Nm • Connect harness connector

85. 85. Install dipstick with guide tube assembly to engine • Remove blanking plug • Install new O ring • Install bolt (1) 10 Nm

86. 86. Install right air deflector (1) to radiator assembly • Secure locator, clip

87. 87. Install impact absorber (2) with air deflector (1) • Install 4x bolt 4 Nm

88. 88. Install front panelling to vehicle • Connect 2x harness connector to 2x front fog lamp (if installed) • Install 10x bolt 4 Nm • Install bolt behind vehicle registration plate 2 Nm

89. 89. Install intercooler to upper front panel • Secure 2x locating pin of intercooler to 2x rubber guide – Push downwards • Install 2x bolt (1) 8 Nm

90. 90. Install radiator grille to vehicle • Secure to 10x retaining clip • Install 5x bolt (1) 4 Nm

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

91. 91. 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

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

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

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

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

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

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

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

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

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

105. 105. Connect battery negative lead
106. 106. Program all volatile memories