How to Replace the Intercooler 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 4x locating peg (1)

6. 6. For M9R 780, M9R 782, M9R 784, M9R 786 or M9R 788 engine, release charge pressure sensor and base adapter (2) from support frame (1) • Pull off
7. 7. For M9R 780, M9R 782, M9R 784, M9R 786 or M9R 788 engine, release harness for charge pressure sensor from support frame (1) • Release clip (3)

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

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

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

12. 12. Disconnect intake hose from intercooler • Release clip

13. 13. Remove support frame (1) from engine compartment • Remove 2x nut (2), 2x bolt (3)
14. 14. For M9R 630 engine, remove intercooler pipe (1) from vehicle • Release 2x clip (2)

15. 15. For M9R 780, M9R 782, M9R 784, M9R 786 or M9R 788 engine, remove intercooler pipe (1) from vehicle • Release 3x clip (2) • Disconnect harness connector (3)

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

17. 17. Remove air deflector (2) from intercooler • Remove 2x clip (1)

18. 18. Remove 2x rubber mount (1) from intercooler • Prise off using suitable tool

Install

19. 19. Install 2x rubber mount (1) to new intercooler

20. 20. Install air deflector (2) to intercooler • Install 2x clip (1)

21. 21. Install intercooler to upper front panel • Secure 2x locating pin of intercooler to 2x rubber guide – Push downwards • Install 2x bolt (1) 8 Nm

22. 22. For M9R 630 engine, install intercooler pipe (1) to vehicle • Secure 2x clip (2)

23. 23. For M9R 780, M9R 782, M9R 784, M9R 786 or M9R 788 engine, install intercooler pipe (1) to vehicle • Secure 3x clip (2) • Connect harness connector (3)

24. 24. Install support frame (1) to engine compartment • Install 2x nut (2), 2x bolt (3) 8 Nm
25. 25. Connect intake hose to intercooler • Secure clip

26. 26. Secure bracket with coolant heater assembly (1) (if installed) to support frame • Install bolt (3)
27. 27. Secure harness for coolant heater assembly (if installed) to support frame • Secure clip (2)

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

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

30. 30. For M9R 780, M9R 782, M9R 784, M9R 786 or M9R 788 engine, secure harness for charge pressure sensor to support frame (1) • Secure clip (3)
31. 31. For M9R 780, M9R 782, M9R 784, M9R 786 or M9R 788 engine, secure charge pressure sensor and base adapter (2) to support frame • Push on

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

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

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

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