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Power Steering Pump Replace (With Air Conditioning) Opel Vivaro A

Power Steering 31 illustrations ~959 words

Remove

  1. 1. Disconnect battery negative lead
  2. 2. Remove air cleaner assembly (1) from engine compartment • Disconnect harness connector (3) from mass air flow meter • Disconnect hose (2) from mass air flow meter – Release clamp • Disconnect air intake duct (4) from air cleaner assembly – Remove cable tie, then pull off • Remove air cleaner assembly from engine cover – Lift right side from 2x grommet, then slide to right to release from locating peg • Disconnect breather hose assembly (5) from air cleaner assembly – Pull off
  1. 3. Release turbocharger intercooler hose from intercooler, then move to one side • Release clip
  2. 4. Remove oil level dipstick
  3. 5. Remove engine cover (1) • Release coolant hose (2) from engine cover – Release from clip • Release fuel pipe (3) from engine cover – Release from 5x clip • Release breather hose from engine cover – Release from clip • Remove nut (4) • Release locater of engine cover from grommet
  1. 6. Release air intake manifold intercooler hose from intercooler • Release clip
  2. 7. Remove intercooler from reinforcement panel • Remove 2x bolt (1) • Release 2x locating pin of intercooler from 2x rubber guide – Pull upwards
  1. 8. Remove front grille from vehicle • Remove 5x screw
  2. 9. Disconnect 3x harness connector (1) from right headlamp
  1. 10. Remove right headlamp from front panel • Remove 2x bolt (1), then release locating pin from grommet
  1. 11. Remove bracket (1) from exhaust gas recirculation (EGR) housing and power steering pump • Release 2x bolt

Note. Engine shown removed for clarity.

  1. 12. Remove guide tube for oil level dipstick from engine compartment • Remove 2x bolt
  2. 13. Raise vehicle
  3. 14. Remove engine and transmission undershield from vehicle
  4. 15. Remove right splash panel • Release washer hose from 2x clip • Remove 2x bolt, screw
  1. 16. Remove ribbed V-belt from engine • Rotate tension roller clockwise, then lock using Locating Pin KM-6130 (1)
  1. 17. Lower vehicle
  2. 18. Disconnect harness connector from fuel temperature sensor
  3. 19. Disconnect harness connector (1) from camshaft sensor
  1. 20. Release power steering fluid reservoir from support bracket, then move to one side • Release clip
  1. 21. Remove pulley (2) from power steering pump • Remove 3x bolt (1) – Prevent shaft of pump from turning, using suitable tool (3) inserted into hexagonal opening
  1. 22. Release feed hose (1) from power steering pump • Install hose clamp (2) (commercially available) • Release clip (3)
  1. 23. Remove pressure hose assembly (1) from power steering pump (2) • Disconnect union (3) • Install 2x new blanking plug
  1. 24. Remove power steering pump from auxiliary housing • Remove 3x bolt (1) • Install new blanking plugs
  1. 25. Install power steering pump (1) to Press Plate KM-6281-1 (3) • Release pump hub (2) from shaft using hydraulic press (4)
  2. 26. Remove pump hub from Press Plate KM-6281-1 (3)

Install

  1. 27. Install pump hub (2) to new pump (1) shaft using KM-6281-3 (3)
  1. 28. Check installation height of hub using KM-6281-4 (2)
  1. 29. Remove hub installer from pump KM-6281-3
  2. 30. Install power steering pump to auxiliary housing • Install 3x bolt (1) 21 Nm
  1. 31. Install bracket (1) to EGR housing and power steering pump • Install 2x bolt 10 Nm

Note. Engine shown removed for clarity.

  1. 32. Install pulley (2) to power steering pump • Install 3x bolt (1) 10 Nm – Prevent shaft of pump from turning, using suitable tool (3) inserted into hexagonal opening
  1. 33. Install pressure hose assembly (1) to power steering pump (2) • Remove 2x blanking plug • Connect union (3) 24 Nm
  1. 34. Install fluid reservoir for power steering to support bracket • Secure clip
  1. 35. Connect supply hose (1) to power steering pump • Remove 2x blanking plug • Secure clip (3) • Remove hose clamp (2)
  1. 36. Connect harness connector (1) to camshaft sensor
  1. 37. Connect harness connector (1) to fuel temperature sensor
  2. 38. Install guide tube for oil level dipstick to engine compartment • Install upper bolt 25 Nm , lower bolt 10 Nm
  3. 39. Install intercooler to reinforcement panel • Install 2x bolt (1) 8 Nm
  1. 40. Connect air intake manifold intercooler hose to intercooler • Secure clip
  2. 41. Install right headlamp to front panel • Secure locating pin to grommet, then install 2x bolt (1)
  1. 42. Connect 3x harness connector (1) to right headlamp
  1. 43. Install front grille to vehicle • Install 5x screw
  2. 44. Install engine cover (1) • Secure locater of engine cover to grommet • Install nut (4) • Secure fuel pipe (3) to engine cover – Secure to 5x clip • Secure breather hose to engine cover – Secure to clip • Secure coolant hose (2) to engine cover – Secure to clip
  1. 45. Install oil level dipstick
  2. 46. Secure turbocharger intercooler hose to intercooler • Secure clip
  3. 47. Install air cleaner assembly (1) to engine compartment • Connect breather hose assembly (5) to air cleaner assembly • Install air cleaner assembly to engine cover – Push on – Install to locating peg, then push right side into 2x grommet • Connect air intake duct (4) to air cleaner assembly – Push on, then install new cable tie • Connect hose (2) to mass air flow meter – Secure clamp • Connect harness connector (3) to mass air flow meter
  1. 48. Raise vehicle
  2. 49. Install ribbed V-belt to engine • Rotate tension roller clockwise, then remove Locating Pin KM-6130 (1)
  1. 50. Install right splash panel • Install washer hose 2x clip • Install 2x bolt 8 Nm
  1. 51. Install engine and transmission undershield to vehicle
  2. 52. Lower vehicle
  3. 53. Connect battery negative lead
  4. 54. Bleed hydraulic system – see operation “Hydraulic System, Bleed”
  5. 55. Program all volatile memories

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