How to Replace the Throttle Valve Module Opel Vivaro A

Remove

1. 1. Disconnect hose (1) from oil filler on air cleaner assembly, then move to one side • Release clip (2)

2. 2. Disconnect hose (2) from mass air flow meter (1) • Release clip
3. 3. Disconnect harness connector (3) from mass air flow meter

4. 4. Remove air intake duct (1) from air cleaner assembly (2) and front panel • Release 2x clip

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

6. 6. Release fuel pipe (2) from support frame (1) • Release 2x clip

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

8. 8. Release harness for coolant heater assembly (if installed) from support frame • Release clip (2)
9. 9. Release bracket with coolant heater assembly (1) (if installed) from support frame • Remove bolt (3)

10. 10. Remove support frame (1) from engine compartment • Remove 2x bolt (3), 2x nut (2)
11. 11. Disconnect turbocharger outlet pipe from intercooler • Release clip
12. 12. Remove intercooler pipe (1) from vehicle • Release 2x clip (2)

13. 13. Remove radiator grille from vehicle • Remove 5x bolt (1) • Release from 10x retaining clip

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

15. 15. Remove dipstick with guide tube assembly from engine • Remove bolt (1) • Remove O ring • Install new blanking plug to engine

16. 16. Remove throttle valve assembly with adaptor from exhaust gas recirculation (EGR) valve • Disconnect harness connector (1) from throttle valve • Disconnect harness connector (2) from charge pressure sensor • Release harness from clip (3) • Remove 6x bolt, bracket • Remove 2x gasket

Install

17. 17. Install adaptor with new throttle valve assembly to EGR valve • Clean mating surfaces • Install 2x new gasket • Install bracket, 6x bolt 10 Nm • Connect harness connector (1) to throttle valve • Connect harness connector (2) to charge pressure sensor • Secure harness to clip (3)

18. 18. Install dipstick with guide tube assembly to engine • Remove blanking plug • Apply lubricant to new O ring – see “Sealants, Lubricants and Locking Compounds” • Install new O ring • Install bolt (1) 10 Nm
19. 19. Install intercooler to upper front panel • Secure 2x locating pin of intercooler to 2x rubber guide – Push downwards • Install 2x bolt (1) 8 Nm

20. 20. Install radiator grille to vehicle • Secure to 10x retaining clip • Install 5x bolt (1) 4 Nm

21. 21. Install intercooler pipe (1) to vehicle • Secure 2x clip (2)

22. 22. Connect turbocharger outlet pipe to intercooler • Secure clip

23. 23. Install support frame (1) to engine compartment • Install 2x nut (2), 2x bolt (3) 8 Nm
24. 24. Secure bracket with coolant heater assembly (1) (if installed) to support frame • Install bolt (3)
25. 25. Secure harness for coolant heater assembly (if installed) to support frame • Secure clip (2)

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

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

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

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

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

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

33. 33. Programming with Tech 2 is required after replacing the throttle valve module