How to Replace the Fuel Temperature Sensor Opel Vivaro A

Remove

1. 1. Disconnect battery negative lead
2. 2. Remove engine cover – see operation “Engine Cover, Remove and Install (G9U 730)”
3. 3. Disconnect hose from intercooler • Release clip

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

5. 5. Remove radiator grille from reinforcement panel • Remove 5x bolt (1) • Release 2x clip

6. 6. Remove bracket from power steering pump and housing of exhaust gas recirculation (EGR) valve • Remove 2x bolt

7. 7. Remove guide tube for oil level dipstick from engine compartment • Remove oil level dipstick • Remove 2x bolt
8. 8. Remove fuel rail cover (1) from engine compartment • Disconnect breather hose (2) from connection – Release clip • Release 4x clip

Important. Clean all connections before disconnecting; use only lint-free cleaning cloths. Use new thinner, clean brushes and compressed air. Do not use a high pressure washer.

9. 9. Disconnect fuel leak-off pipe (1) from common rail • Release integral clip

10. 10. Disconnect fuel leak-off pipe from 4x fuel injector • Release 4x clip • Install 4x new blanking plug to 4x fuel injector
11. 11. Release fuel leak-off pipe from cylinder head cover • Release from 2x clip

12. 12. Disconnect harness connector (1) from fuel temperature sensor • Release integral clip

13. 13. Disconnect fuel temperature sensor from fuel return line • Release integral clip (1)

14. 14. Disconnect fuel leak-off pipe (1) from high pressure pump • Release integral clip • Install new blanking plug to high pressure pump

15. 15. Remove fuel leak-off pipe and temperature sensor assembly from engine compartment

Install

16. 16. Position new fuel leak-off pipe and temperature sensor assembly to engine compartment
17. 17. Connect fuel leak-off pipe (1) to high pressure pump • Remove blanking plug • Secure integral clip

18. 18. Connect fuel temperature sensor to fuel return line • Secure integral clip (1)

19. 19. Connect harness connector (1) to fuel temperature sensor • Secure integral clip

20. 20. Connect fuel leak-off pipe to 4x fuel injector • Remove 4x blanking plug from 4x fuel injector • Secure 4x clip
21. 21. Secure fuel leak-off pipe to cylinder head cover • Secure to 2x clip

22. 22. Connect fuel leak-off pipe (1) to common rail • Secure integral clip

23. 23. Install fuel rail cover (1) to engine compartment • Secure 4x clip • Connect breather hose (2) to connection – Push on

24. 24. Install guide tube for oil level dipstick to engine compartment • Install upper bolt 25 Nm , lower bolt 10 Nm
25. 25. Install oil level dipstick to guide tube
26. 26. Install bracket to power steering pump and housing of EGR valve • Install 2x bolt

27. 27. Install intercooler to reinforcement panel • Install 2x bolt (1) 8 Nm

28. 28. Connect hose to intercooler • Secure clip

29. 29. Install radiator grille to reinforcement panel • Install 5x bolt (1) • Secure 2x clip

30. 30. Install engine cover and air cleaner assembly – see operation “Engine Cover, Remove and Install (G9U 730)”
31. 31. Connect battery negative lead
32. 32. Program all volatile memories