How to Replace the Fuel Return 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 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 for coolant heater assembly (if installed) from support frame • Release clip (2)
12. 12. Release bracket with coolant heater assembly (1) (if installed) from support frame • Remove bolt (3)

13. 13. Remove support frame for air cleaner assembly from engine compartment • Remove 2x bolt (3), 2x nut (2)
14. 14. Remove intercooler outlet pipe from engine compartment • Release 3x clip • Disconnect harness connector

Important. When removing duct assembly, release securing clips last.

15. 15. Remove duct assembly (2) from intercooler and turbocharger • Remove bolt (3) • Release 2x clip (1)
16. 16. Remove O ring from duct assembly

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

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

20. 20. Disconnect fuel return hose from fuel leak off pipe • Release integral clip • Install 2x new blanking plug
21. 21. Release fuel return pipe from cylinder head • Remove bolt (1)

22. 22. Remove fuel return pipe from cylinder head • Release 4x harness connector (1) – Pull up

Install

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

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

25. 25. Connect fuel return hose to fuel leak off pipe • Remove 2x blanking plug • Secure integral clip
26. 26. 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

27. 27. Secure breather hose to turbocharger intake hose • Push in
28. 28. Install cover (1) to cylinder head • Install 6x bolt (2) • Secure harness to clip (3)

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

29. 29. 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

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

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

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

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

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

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

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

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

42. 42. Connect battery negative lead
43. 43. Program all volatile memories