Replace Radiator (Without Air Conditioning) Opel Meriva A

Remove

1. 1. Open bonnet

Important. In vehicles with ESP - the steering angle sensor loses its basic settings every time the battery is disconnected and has to be recalibrated.

2. 2. Disconnect battery • Detach ground cable
3. 3. Drain coolant Warning: The cooling system is under pressure. Open the cover of the coolant compensation tank with care. • Place collecting basin underneath. • Open drain bolt (arrow) • Open coolant expansion tank cover

4. 4. Detach upper part of radiator hose • From radiator • Release clamp
5. 5. Detach overflow hose • From radiator • Release clamp
6. 6. Release upper front panelling • Remove 2x bolts (arrow) • Remove cover of radiator/condenser (1)

7. 7. Raise vehicle
8. 8. Detach wiring harness plug for fan motor (1) • Unclip from bracket

9. 9. Release lower front panelling • Remove 3x clips (1) • Disconnect wiring harness plug (2)
10. 10. Lower vehicle
11. 11. Detach front side panelling • Unscrew 4x bolts (arrows)

12. 12. Remove front panelling

Note. 2nd mechanic is required.

13. 13. Detach lower part of radiator hose • From radiator • Release clamp
14. 14. Remove horn • Disconnect wiring harness plug (3) • Remove bolt • Unclip wiring harness
15. 15. Remove resonator • Remove bolt • Remove resonator from guide
16. 16. Remove bracket block threaded connector • Remove bolt (arrow) • Detach radiator bracket at top (1) – Remove bolt • Remove bracket (2)

Note. The air conditioning system remains closed.

17. 17. Detach condenser • Unclip from radiator bracket (1, 2) in direction of arrow • Suspend condenser

Note. Keep an eye on guides (3, 4)

18. 18. Release receiver-dryer • Detach rubber belt (1)

19. 19. Detach 2x lower radiator brackets • Unscrew 4x bolts (1, 2)

20. 20. Remove radiator

Note. 2nd fitter required. Remove radiator carefully downwards.

21. 21. Detach fan housing

Note. Unclip fan housing carefully from radiator.

Install

22. 22. Attach fan housing • To radiator • 4x clips
23. 23. Insert radiator • 2nd fitter required

Note. Carefully insert radiator from below.

24. 24. Attach 2 lower radiator brackets • Tighten 4x bolts – Tightening torque 15 Nm
25. 25. Connect lower part of radiator hose • Fasten clamp
26. 26. Fasten condenser • Release condenser • Attach drier tank – Attach rubber belt
27. 27. Attach bracket block threaded connector • Tighten bolt – Attach upper radiator bracket – Tighten bolt – Tightening torque 15 Nm
28. 28. Install resonator • Tighten bolt
29. 29. Install horn • Tighten bolt – Tightening torque 25 Nm • Connect wiring harness plug. • Attach wiring harness
30. 30. Attach overflow hose • Fasten clamp
31. 31. Install upper radiator hose • Fasten clamp
32. 32. Position front panelling

Note. 2nd mechanic is required.

33. 33. Fasten upper front panelling • Position radiator cover • Tighten 2 bolts
34. 34. Raise vehicle
35. 35. Fasten lower front panelling • Install 3x clips • Connect wiring harness plug.
36. 36. Clamp radiator wiring harness in place • Connect 2 wiring harness plugs – Fan motor, multiplier • Fasten cable harness
37. 37. Lower vehicle
38. 38. Attach side front panelling • Tighten 4x bolts
39. 39. Lower vehicle
40. 40. Attach engine cover • Unscrew oil filling nozzle cover • Tighten 2 bolts – Tightening torque 8 Nm • Screw in the oil filler nozzle cover • Clip in coolant hose.
41. 41. Connect battery
42. 42. Calibrate steering angle sensor • Turn on ignition

Note. Turn the steering wheel once from the right stop to left stop.

43. 43. Fill and bleed cooling system
44. 44. Program volatile memory
45. 45. Close bonnet