How to Replace the High Pressure Pump Opel Vivaro A

Remove

1. 1. Before performing ANY work on fuel system or its components, switch OFF vehicle ignition and wait until pressure has dropped sufficiently (approximately 30 seconds). This waiting period is absolutely essential for fuel 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) • Release 2x clip

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

8. 8. Release charge pressure sensor and base adapter (2) from air cleaner support frame (1) • Pull off
9. 9. Release charge pressure sensor harness from air cleaner support frame • Release clip (3)

10. 10. Release fuel pipe (2) from air cleaner support frame (1) • Release 2x clip

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

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

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

14. 14. Remove air cleaner support frame (1) from engine compartment • Remove 2x nut (2), 2x bolt (3)
15. 15. Remove intercooler outlet hose 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 from duct assembly

18. 18. Remove turbocharger intake hose (1) from engine compartment • Release clip • Disconnect breather hose – Pull out • Release vacuum pipe from turbocharger intake hose – Release from 3x retainer

19. 19. Remove fuel rail cover (1) from engine • Remove 6x bolt (2) • Release wiring harness from clip (3)

20. 20. Disconnect harness connector from fuel temperature sensor

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

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.

22. 22. For vehicles without protection cover, disconnect fuel feed pipe for high pressure pump from fuel filter housing • Release integral clip (1) • Install 2x new blanking plug

23. 23. For vehicles with protection cover, disconnect fuel pipe (1) from fuel filter housing • Release clip • Install 2x new blanking plug
24. 24. Release fuel filter housing from support bracket • Release clip, then pull upwards

25. 25. For vehicles with protection cover, disconnect harness connector (2) from fuel filter housing
26. 26. Disconnect harness connector from sensor for water ingress (if installed)
27. 27. Remove protection cover (1) from fuel filter housing • Rotate locking ring anti-clockwise, then lift off
28. 28. Disconnect fuel feed pipe (3) for high pressure pump from fuel filter housing • Release clip • Install 2x new blanking plug

29. 29. Disconnect fuel pipe from engine and high pressure pump • Release 5x integral clip (1) • Install 10x new blanking plug
30. 30. Remove fuel pipe from engine compartment • Release from 8x clip

31. 31. Release high pressure pipe from engine • Remove bolt (2) • Remove bolt (arrowed)
32. 32. Release high pressure fuel pipe from high pressure pump • Disconnect pipe union (3) – Use Pipe Spanner KM-812 • Install 2x new blanking plug
33. 33. Remove high pressure fuel pipe from engine • Disconnect pipe union (1) – Use suitable tool • Install 2x new blanking plug

34. 34. Disconnect harness connector from fuel pressure regulator
35. 35. Remove high pressure pump from cylinder head • Remove 3x bolt

36. 36. Install high pressure pump to soft jawed vice • Secure gear in soft jawed vice
37. 37. Remove gear from high pressure pump • Release gear from high pressure pump, do not remove at this stage – Release nut (1) • Reposition high pressure pump to soft jawed vice • Remove nut and gear (2) from high pressure pump – Use commercially available puller

38. 38. Remove high pressure pump from soft jawed vice

Install

39. 39. Install gear to new high pressure pump • Secure gear in soft jawed vice • Degrease mating surface of pump shaft and gear • Position high pressure pump to gear • Secure high pressure pump to gear – Install new nut 90 Nm

40. 40. Prime high pressure pump • Connect suitable hose to high pressure pump inlet port – Remove blanking plug from inlet port • Position collecting container below • Fill hose with diesel fuel • Install Pressure and Vacuum Pump MKM-667 – Use suitable adaptor • Remove blanking plug from high pressure pump outlet port Warning: Maximum pressure must not exceed 1.5 bar . • Apply pressure until diesel fuel flows from outlet port and is clear and free from bubbles • Install blanking plug to high pressure pump outlet port • Remove Pressure and Vacuum Pump MKM-667 and adaptor from hose • Remove hose from high pressure pump inlet port • Install blanking plug to high pressure pump inlet port

41. 41. Remove high pressure pump from soft jawed vice
42. 42. Install new seal (1) to high pressure pump

43. 43. Install high pressure pump to cylinder head

Note. Ensure correct alignment of 3x bolt hole at rear of high pressure pump.

44. 44. Secure high pressure pump to cylinder head • Install 3x new bolt 5 Nm , then 25 Nm in sequence shown – Apply locking compound to thread of 3x bolt – see “Sealants, Lubricants and Locking Compounds”

45. 45. Connect harness connector to fuel pressure regulator
46. 46. Release common rail from cylinder head • Release 3x bolt (1)

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

47. 47. Install high pressure pipe to common rail and high pressure pump • Remove 4x blanking plug • Connect 2x pipe union; do not tighten at this stage
48. 48. Secure common rail to cylinder head • Secure 3x bolt 25 Nm
49. 49. Secure high pressure fuel pipe to high pressure pump • Secure pipe union (3) 32 Nm – Use Pipe Spanner KM-812
50. 50. Secure high pressure fuel pipe to common rail • Secure pipe union (1) 32 Nm – Use suitable tool
51. 51. Secure high pressure fuel pipe to engine • Install bolt (2) 10 Nm • Install bolt (arrowed) 10 Nm

52. 52. Install fuel pipe to engine compartment • Secure to 8x clip
53. 53. Connect fuel pipe to engine and high pressure pump • Remove 10x blanking plug • Secure 5x integral clip (1)

54. 54. For vehicles without protection cover, connect fuel feed pipe for high pressure pump to fuel filter housing • Remove 2x blanking plug • Secure integral clip (1)

55. 55. For vehicles with protection cover, connect fuel feed pipe (3) for high pressure pump to fuel filter housing • Remove 2x blanking plug • Secure clip
56. 56. Install protection cover (1) to fuel filter housing • Push on, then rotate locking ring clockwise
57. 57. Connect harness connector (2) to fuel filter housing
58. 58. Connect harness connector to sensor for water ingress (if installed)

59. 59. For vehicles with protection cover, secure fuel filter housing to support bracket • Secure to clip
60. 60. Connect fuel pipe (1) to fuel filter housing • Remove 2x blanking plug • Secure clip

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

62. 62. Connect harness connector to fuel temperature sensor

63. 63. Install fuel rail cover (1) to engine • Install 6x bolt (2) • Secure harness to clip (3)

64. 64. Install turbocharger intake hose (1) to engine compartment • Secure 2x clip • Connect breather hose – Push in • Secure vacuum pipe to hose – Secure to 3x retainer

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

65. 65. Install duct assembly (2) to engine compartment • Install new O ring to intercooler pipe – Apply suitable lubricant to 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

66. 66. Install intercooler outlet hose to engine compartment • Secure 3x clip • Connect harness connector

67. 67. Install support frame (1) to engine compartment • Install 2x bolt (3), 2x nut (2)
68. 68. Secure coolant preheater (1) (if installed) to support frame • Install bolt (3) • Secure clip (2)

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

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

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

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

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

75. 75. Install air intake duct (1) to air cleaner assembly (2) • Secure 2x clip

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

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

79. 79. Connect battery negative lead
80. 80. Program all volatile memories