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Contents Wiring diagrams Section: Fuel Injection Systems All sections

How to Replace the High Pressure Pipe Opel Vivaro A

Fuel Injection Systems 14 illustrations ~1106 words

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)
  1. 4. Disconnect hose (2) from mass air flow meter (1) • Release clip
  2. 5. Disconnect harness connector (3) from mass air flow meter
  1. 6. Remove air intake duct (1) from air cleaner (2) and vehicle body • Release 2x clip
  1. 7. Remove air cleaner assembly from support frame • Pull off 4x locating peg (1)
  1. 8. Release coolant preheater harness (1) (if installed) from air cleaner support frame (3) • Release clip (2)
  1. 9. Release coolant preheater and bracket (1) (if installed) from air cleaner support frame • Release clip (2) • Remove bolt (3)
  1. 10. Remove support frame (1) from engine compartment • Remove 2x nut (2), 2x bolt (3)
  2. 11. Remove radiator grille from vehicle • Remove 5x bolt • Release 10x retaining clip
  1. 12. Disconnect inlet hose from intercooler • Release clip
  1. 13. Remove intercooler outlet pipe assembly • Release 2x clip (1) • Remove bolt (2)
  2. 14. Remove O ring from intercooler pipe • Prise out using suitable tool
  1. 15. Remove intercooler from upper front panel • Remove 2x bolt (1) • Release 2x locating pin of intercooler from 2x rubber guide – Pull upwards
  1. 16. Disconnect breather hose from engine • Release 2x integral clip from engine cover • Release from turbocharger intake hose – Pull off • Install new blanking plug
  1. 17. Remove oil filler hose with adapter from cylinder head cover • Rotate anti-clockwise, then pull off
  1. 18. Disconnect harness for oxygen sensor and turbocharger temperature sensor from engine harness • Disconnect 2x harness connector
  1. 19. Release oxygen sensor and turbocharger temperature sensor harness from fuel rail protector and bracket • Release 4x clip
  1. 20. Remove fuel rail cover from engine • Remove blanking plug • Release 4x clip • Install blanking plug
  1. 21. Disconnect 4x harness connector from 4x fuel injector (1)

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

  1. 22. Disconnect fuel return pipe from fuel temperature sensor • Release 2x integral clip (1) • Install 2x new blanking plug
  1. 23. Disconnect fuel leak-off pipe (1) from 4x fuel injector • Release 4x clip – Push in • Install 8x new blanking plug
  1. 24. Disconnect fuel leak-off pipe (1) from common rail • Release 2x integral clip • Install 2x new blanking plug
  1. 25. Release fuel leak-off pipe from cylinder head cover, then move to one side • Release 3x clip
  2. 26. Disconnect high pressure pipe from high pressure pump • Release pipe union (4) • Install 2x new blanking plug
  3. 27. Remove fuel leak-off pipe (5) with fuel temperature sensor from high pressure pump • Release integral clip
  4. 28. Remove high pressure pipe (1) from common rail and cylinder head cover • Release pipe union – Use Pipe Spanner KM-812 • Remove bolt (2) • Release from clip (3) • Install 2x new blanking plug

Install

  1. 29. Release common rail from cylinder head • Release 2x bolt (1)
  1. 30. Connect high pressure pipe (1) to common rail; do not tighten at this stage • Remove 2x blanking plug
  1. 31. Secure high pressure pipe to cylinder head cover • Secure to clip (3) • Install bolt (2); do not tighten at this stage
  2. 32. Install new high pressure pipe to common rail and high pressure pump • Remove 4x blanking plug • Connect 2x pipe union (1, 4); do not tighten at this stage • Secure high pressure pipe to clip (3) • Install bolt (2); do not tighten at this stage
  3. 33. Secure common rail to cylinder head • Secure 2x bolt 25 Nm
  4. 34. Secure high pressure pipe to common rail and high pressure pump • Secure 2x pipe union (1, 4) 27 Nm – Use Pipe Spanner KM-812 • Secure bolt (2) 3 Nm
  5. 35. Install new fuel leak-off pipe (5) to high pressure pump • Remove 2x blanking plug • Secure integral clip
  1. 36. Connect fuel leak-off pipe to common rail • Remove 2x blanking plug • Secure integral clip
  2. 37. Connect fuel leak-off pipe to 4x fuel injector • Remove 8x blanking plug • Secure 4x clip
  3. 38. Secure fuel leak-off pipe to cylinder head cover • Secure to 3x clip
  1. 39. Connect fuel return pipe to fuel temperature sensor • Remove 2x blanking plug • Secure 2x integral clip (1)
  1. 40. Connect 4x harness connector to 4x fuel injector (1)
  1. 41. Install fuel rail cover to engine • Remove blanking plug • Secure 4x clip • Install blanking plug
  1. 42. Secure oxygen sensor and turbocharger temperature sensor harness to fuel rail protector and bracket • Secure 4x clip
  1. 43. Connect harness for oxygen sensor and turbocharger temperature sensor to engine harness • Connect 2x harness connector
  1. 44. Install oil filler hose with adapter to cylinder head cover • Push on, then rotate clockwise
  1. 45. Connect breather hose to engine • Remove blanking plug • Secure 2x integral clip • Secure to turbocharger intake hose – Push on
  1. 46. Install intercooler to upper front panel • Secure 2x locating pin of intercooler to 2x rubber guide – Push downwards • Install 2x bolt (1) 8 Nm
  1. 47. Install intercooler outlet pipe assembly • Install new O ring to intercooler pipe • Install 2x clip (1) • Install bolt (2)
  1. 48. Connect inlet hose to intercooler • Secure clip
  1. 49. Install radiator grille to vehicle • Secure 10x retaining clip • Install 5x screw 4 Nm
  1. 50. Install air cleaner assembly support frame (1) to engine compartment • Install 2x bolt (3), 2x nut (2)
  2. 51. Secure coolant preheater and bracket (1) (if installed) to air cleaner support frame • Install bolt (3) • Secure clip (2) • Push on 4x locating peg
  1. 52. Secure coolant preheater harness (1) (if installed) to air cleaner support frame (3) • Secure clip (2)
  1. 53. Install air cleaner assembly to support frame • Push on 4x locating peg (1)
  1. 54. Install air intake duct (1) to air cleaner (2) and vehicle body • Secure 2x clip
  1. 55. Connect harness connector (3) to mass air flow meter
  2. 56. Connect hose (2) to mass air flow meter (1) • Secure clip
  1. 57. Connect hose (1) to oil filler on air cleaner assembly • Secure clip (2)
  1. 58. Connect battery negative lead
  2. 59. Program all volatile memories

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