Replace Coolant Pipe (Upper) Opel Meriva A

Remove

1. 1. Remove air intake manifold • Unscrew 2x bolt • Unclip 3x wiring harnesses • Detach engine vent hose – Disconnect quick-release fitting • Detach from air intake manifold – Release clamp • Detach from turbocharger – Release clamp
2. 2. Remove battery • Detach positive connection from positive terminal – Undo nut • Remove bracket – Unscrew nut
3. 3. Place collecting basin underneath
4. 4. Remove fuel filter (2) • Disconnect 2x wiring harness plugs (1 and 4) – Filter heater – Water level sensor • Disconnect 3x fuel lines (3) • Seal fuel lines and fuel filters with KM-615 and KM-807

5. 5. Remove battery support. • Unclip and remove relay carrier from battery carrier • Disconnect preheating system control unit wiring harness plug • Disconnect 2x cable tie • Unscrew 2x bolt • Unscrew 2x nut
6. 6. Remove charge air pipe (1) • Release clamp • Unscrew 4x bolts (arrows)

7. 7. Remove turbocharger charge air hose at charge air pipe • Release 2x clamp
8. 8. Raise vehicle all the way
9. 9. Place collecting basin underneath
10. 10. Drain coolant • Undo drain bolt (1) • Tighten drain bolt

11. 11. Lower vehicle all the way
12. 12. Remove oil filter housing heat shield • Unscrew 2x bolt • Unscrew nut

13. 13. Remove coolant supply pipe (1) • Detach from heat exchanger – Unscrew 2x bolt • Detach from cylinder block – Unscrew bolt • Unclip 2x wiring harness brackets • Detach coolant hose – Release clamp

14. 14. Clean sealing surface • On oil filter housing
15. 15. Install coolant supply pipe • Attach to heat exchanger – Replace seal – Tighten 2x bolt 9 Nm • Attach to cylinder block – Tighten bolt 9 Nm • Attach coolant hose – Fasten clamp • Clip 2x wiring harness brackets into position
16. 16. Install oil filter housing heat shield • Tighten bolt 9 Nm • Tighten nut 9 Nm
17. 17. Fit turbocharger charge air hose to charge air pipe • Tighten 2x clamp 3.5 Nm
18. 18. Install charge air pipe • Tighten clamp 3.5 Nm • Tighten 4 bolts 8 Nm
19. 19. Install battery carrier • Tighten 2x bolts 15 Nm • Tighten 2x nuts 15 Nm • Fasten 2x cable ties • Connect preheating system control unit wiring harness plug • Clip relay carrier to battery carrier
20. 20. Install fuel filter • Insert in bracket • Connect 2x wiring harness plug – Filter heater – Water level sensor • Connect 3x fuel lines – Remove KM-615 and KM-807
21. 21. Install battery • Install bracket – Tighten nut • Attach positive clamp to positive terminal – Tighten nut
22. 22. Install air intake manifold • Attach to turbocharger – Tighten clamp 3.5 Nm • Attach to air intake manifold – Tighten clamp 3.5 Nm • Tighten 2 bolts • Attach engine vent hose – Fasten clamp • Clip in 3x wiring harnesses
23. 23. Top up coolant