How to Replace the Fuel Injector 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 (2) and vehicle body • Release 2x clip

7. 7. Remove air cleaner assembly from support frame • Pull off 4x locating peg (1)

8. 8. Release air flow meter harness (1) from air cleaner support frame (2) • Release clip (3)

9. 9. Release coolant preheater harness (1) (if installed) from air cleaner support frame (3) • Release clip (2)

10. 10. Release coolant preheater and bracket (1) (if installed) from air cleaner support frame • Release clip (2) • Remove bolt (3)

11. 11. Remove support frame (1) from engine compartment • Remove 2x nut (2), 2x bolt (3)
12. 12. Remove radiator grille from vehicle • Remove 5x bolt • Release 10x retaining clip

13. 13. Disconnect inlet hose from intercooler • Release clip

14. 14. Remove intercooler outlet pipe assembly • Release 2x clip (1) • Remove bolt (2)
15. 15. Remove O ring from intercooler pipe • Prise out using suitable tool

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

17. 17. Remove breather hose from cylinder head cover • Release 2x integral clip • Release from turbocharger intake hose – Pull off • Install new blanking plug to cylinder head cover

18. 18. Remove oil filler hose with adapter from cylinder head cover • Rotate anti-clockwise, then pull off

19. 19. Disconnect harness for oxygen sensor and turbocharger temperature sensor from engine harness • Disconnect 2x harness connector

20. 20. Release oxygen sensor and turbocharger temperature sensor harness from fuel rail protector and bracket • Release 4x clip

21. 21. Remove fuel rail cover from engine • Remove blanking plug • Release 4x clip • Install blanking plug

22. 22. Disconnect harness connector from fuel pressure sensor

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

24. 24. Disconnect 4x harness connector from 4x glow plug
25. 25. Disconnect harness connector (1) from coolant temperature sensor • Release clip

26. 26. Disconnect harness connector (1) from fuel temperature sensor
27. 27. Disconnect harness connector (2) from fuel pressure regulator

28. 28. Disconnect harness connector (1) from camshaft sensor

29. 29. Disconnect engine harness from EGR control solenoid harness • Release from clip (1) • Disconnect harness connector (2)

30. 30. Disconnect harness connector (1) from EGR vacuum control solenoid (2)

31. 31. Release engine harness cover from intake manifold, then move to side • Remove screw (1)

32. 32. Remove oil level dipstick (3) from guide tube (4)
33. 33. Release harness from oil level dipstick guide tube • Release from clip (1)
34. 34. Remove upper section of guide tube (4) from engine • Remove bolt (2) • Release 2x clip • Remove O ring • Install new blanking plug

Important. Clean all connections before disconnecting; use only lint-free cleaning cloths.

35. 35. Disconnect fuel return pipe from fuel temperature sensor • Release 2x integral clip (1) • Install 2x new blanking plug

36. 36. Disconnect fuel feed pipe (1) from high pressure pump, then move to one side • Release from clip on engine lifting eye • Release 2x integral clip (2) • Install 2x new blanking plug

37. 37. Disconnect fuel leak-off pipe (1) from 4x fuel injector • Release 4x clip from 4x fuel injector – Push in • Install 8x new blanking plug

Important. Clips are not to be removed from injectors; if they are they must be replaced.

38. 38. Disconnect fuel leak-off pipe (1) from common rail • Release 2x integral clip • Install 2x new blanking plug

39. 39. Release fuel leak-off pipe from cylinder head cover, then move to one side • Release 3x clip
40. 40. Remove 2x insulation (2) from cylinder head cover
41. 41. Remove 4x high pressure pipe (1) from 4x fuel injector and common rail • Release 8x pipe union – Use Pipe Spanner KM-812 ; counterhold nut on fuel injector using suitable spanner • Install 16x new blanking plug

42. 42. Remove fuel leak-off pipe (1) with fuel temperature sensor from high pressure pump • Install new blanking plug • Release 2x integral clip • Install 2x new blanking plug

Install

Important. The common rail must be released to prevent excess stress being applied to the new fuel injector pipes.

43. 43. Release common rail from cylinder head • Release 2x bolt (1)

44. 44. Install 4x new high pressure pipe (1) to common rail and 4x fuel injector; do not tighten at this stage • Remove 16x blanking plug
45. 45. Secure 4x high pressure pipe to common rail • Secure 4x pipe union 22 Nm – Use Pipe Spanner KM-812

46. 46. Secure common rail to cylinder head • Secure 2x bolt (1) 25 Nm

47. 47. Secure 4x high pressure pipe to 4x fuel injector • Secure 4x pipe union (1) 25 Nm – Use Pipe Spanner KM-812 ; counterhold nut on fuel injector using suitable spanner
48. 48. Install 2x insulation to cylinder head cover

Note. Replace 2x insulation if deteriorated.

49. 49. Secure 4x high pressure pipe to common rail • Secure 4x pipe union (1) 27 Nm – Use Pipe Spanner KM-812

50. 50. Install new fuel leak-off pipe (1) with fuel temperature sensor to high pressure pump • Remove 2x blanking plug • Secure integral clip

51. 51. Connect fuel leak-off pipe to common rail • Remove 2x blanking plug • Secure 2x integral clip
52. 52. Connect fuel leak-off pipe to 4x fuel injector • Remove 8x blanking plug • Secure 4x clip to 4x fuel injector – Push in
53. 53. Secure fuel leak-off pipe to cylinder head cover • Secure to 3x clip

54. 54. Connect fuel feed pipe (1) to high pressure pump • Remove 2x blanking plug • Secure 2x integral clip (2) • Secure to clip on engine lifting eye

55. 55. Connect fuel return pipe to fuel temperature sensor • Remove 2x blanking plug • Secure 2x integral clip (1)

56. 56. Install upper section of guide tube (4) for oil level dipstick to lower section and engine • Remove blanking plug • Install new O ring • Push into lower section of guide tube to secure to 2x clip • Install bolt (2) 6 Nm
57. 57. Secure harness to guide tube for oil level dipstick • Secure clip (1)
58. 58. Install oil level dipstick to guide tube • Secure to clip (3)

59. 59. Secure engine harness cover to intake manifold • Install screw (1)

60. 60. Connect harness connector (1) to EGR vacuum control solenoid (2)

61. 61. Connect engine harness to EGR control solenoid harness • Connect harness connector (2) • Secure to clip (1)

62. 62. Connect harness connector (2) to fuel pressure regulator
63. 63. Connect harness connector (1) to fuel temperature sensor

64. 64. Connect harness connector (1) to camshaft sensor

65. 65. Connect harness connector (1) to coolant temperature sensor • Secure clip

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

68. 68. Connect harness connector to fuel pressure sensor

69. 69. Install fuel rail cover to engine • Remove blanking plug • Secure 4x clip • Install blanking plug

70. 70. Secure oxygen sensor and turbocharger temperature sensor harness to fuel rail protector and bracket • Secure 4x clip

71. 71. Connect harness for oxygen sensor and turbocharger temperature sensor to engine harness • Connect 2x harness connector

72. 72. Install oil filler hose with adapter to cylinder head cover • Push on, then rotate clockwise

73. 73. Connect breather hose to cylinder head cover • Remove blanking plug • Secure 2x integral clip • Secure to turbocharger intake hose – Push on

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

75. 75. Install intercooler outlet pipe assembly • Install new O ring to intercooler pipe • Install 2x clip (1) • Install bolt (2)

76. 76. Connect inlet hose to intercooler • Secure clip

77. 77. Install radiator grille to vehicle • Secure 10x retaining clip • Install 5x screw 4 Nm

78. 78. Install air cleaner assembly support frame (1) to engine compartment • Install 2x bolt (3), 2x nut (2)
79. 79. Install air flow meter harness (1) to air cleaner support frame (2) • Secure clip (3)

80. 80. Secure coolant preheater and bracket (1) (if installed) to air cleaner support frame • Install bolt (3) • Secure clip (2)

81. 81. Secure coolant preheater harness (1) (if installed) to air cleaner support frame (3) • Secure clip (2)

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

83. 83. Install air intake duct (1) to air cleaner (2) and vehicle body • Secure 2x clip

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

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

87. 87. Connect battery negative lead
88. 88. Program all volatile memories