How to Replace the Pressure Return Hose Opel Vivaro A

Remove

1. 1. Disconnect pressure return hose (2) from upper front panel • Release clip (1)

2. 2. Release fluid reservoir with support bracket from upper front panel, then move to one side • Release clip, then pull upwards

3. 3. Disconnect pressure return hose (1) from fluid reservoir • Release clip • Install new blanking plug to open connection of fluid reservoir and pressure return hose

4. 4. Support radiator at each side • Secure to upper front panel – Use 2x cable tie or 2x suitable strap

Note. This will prevent the radiator dropping when the radiator crossmember is removed at a later stage.

5. 5. Raise vehicle
6. 6. Remove engine and transmission undershield
7. 7. Remove radiator undershield • Remove 2x screw, bolt

8. 8. Remove engine splash panel, left side • Remove 2x bolt, screw
9. 9. Release radiator from crossmember • Remove 2x clip (1), 2x washer

10. 10. If clip is installed, release pressure return hose from pressure feed hose • Release clip

11. 11. Release pressure return hose from radiator crossmember • Remove bolt (1)

12. 12. Remove radiator crossmember • Remove 2x bolt • Release pressure return hose (1) from radiator crossmember – Slide off

13. 13. Release earth strap from transmission support bracket • Remove bolt (1)

14. 14. For left drive vehicles, disconnect pressure return hose (1) from steering gear • Release pressure feed hose (2) from steering gear, then release pressure return hose – Remove bolt • Secure pressure feed hose to steering gear • Install new blanking plug to open connection of pressure return hose and steering gear

15. 15. For right drive vehicles, disconnect pressure return hose from return line extension • Release integral clip • Install new blanking plug to open connection of pressure return hose and steering gear
16. 16. Release pressure return hose (1) from transmission support bracket and steering gear • Remove 2x bolt (2), nut (3) on steering gear

17. 17. Remove pressure return hose from vehicle

Install

18. 18. Position new pressure return hose to vehicle
19. 19. Secure pressure return hose (1) to transmission support bracket and steering gear • Install 2x bolt (2) 21 Nm , nut (3) 21 Nm

20. 20. Secure earth strap to transmission support bracket • Install bolt (1) 21 Nm

21. 21. For left drive vehicles, connect pressure return hose (1) to steering gear • Release pressure feed hose (2) from steering gear, then replace O ring • Secure pressure return hose and pressure feed hose to steering gear simultaneously – Remove blanking plug from steering gear – Install bolt 21 Nm

Note. Ensure correct location of 2x pressure hose (1, 2) to steering gear.

22. 22. For right drive vehicles, connect pressure return hose to return line extension • Remove blanking plug from open connection of pressure return hose and steering gear • Secure integral clip
23. 23. Secure pressure return hose (1) to radiator crossmember • Slide on

24. 24. Install bolt for pressure return hose to radiator crossmember; do not tighten at this stage

Note. Bolt is located below power steering pump.

25. 25. Position pressure return hose to fluid reservoir
26. 26. Install radiator crossmember • Install 2x bolt 44 Nm
27. 27. Secure pressure return hose to radiator crossmember • Secure bolt (1)

28. 28. Secure pressure return hose to pressure feed hose • Secure clip

Note. If a clip was not previously installed, install a new clip.

29. 29. Secure radiator to crossmember • Install 2x washer, 2x clip (1)

30. 30. Install radiator undershield • Install 2x screw, bolt 6 Nm

31. 31. Install engine splash panel, left side • Install 2x bolt 8 Nm , screw 6 Nm
32. 32. Install engine and transmission undershield
33. 33. Lower vehicle
34. 34. Connect pressure return hose (1) to fluid reservoir • Remove blanking plug from fluid reservoir • Secure clip

35. 35. Secure fluid reservoir with support bracket to upper front panel • Secure clip
36. 36. Connect pressure return hose (2) to upper front panel • Secure clip (1)

37. 37. Remove 2x cable tie or 2x strap from radiator
38. 38. Bleed hydraulic system – see operation “Hydraulic System, Bleed”