How to Remove and Install the Engine Opel Meriva A

Warning: When working on the Common Rail System, please wait for one minute after switching the engine off. The system relieves the pressure automatically.

Important: When working with fuel systems, cleanliness must be ensured at all times since even the smallest dirt particles can lead to disruptions of engine operation or in the fuel system. Plug open fuel fittings with suitable sealing plugs. 1) Sealing plugs are intended for single use only.

Remove

1. 1. Open bonnet
2. 2. Disconnect battery • Detach ground clamp from ground terminal – Undo nut
3. 3. Detach steering intermediate shaft (1) • Remove lower clamp pin (2) – Unscrew nut (3) • Steering in straight ahead position • Engage steering lock • Remove steering intermediate shaft

Important. Do not alter steering wheel position

4. 4. For vehicles with air conditioning: drain air conditioning
5. 5. Loosen 2x front wheels • Undo 8x bolts
6. 6. Raise vehicle by half its height
7. 7. Detach 2x front wheels • Unscrew 8 bolts
8. 8. Remove front panelling
9. 9. Unfasten 2x axle shafts • Remove 2x split pin retainers (1) • Unscrew 2x nuts (2) – Counterhold with KM-468-B (3) – Remove washer

10. 10. Detach 2x tie rods from steering knuckle • Unscrew 2x nut • Push off 2x tie rods with KM-507-C (1)

11. 11. Detach 2x swing arms • From spring strut support tube • Unscrew 2x nut

Note. Counterhold with open-ended wrench

12. 12. Detach 2x guide joints • Remove 2x bolted connections (1) • Spread steering knuckle with KM-915

13. 13. Remove 2x axle shafts from wheel hub
14. 14. Raise vehicle by half its height
15. 15. Detach lower engine compartment cover / spray guard
16. 16. Place collecting basin underneath
17. 17. Drain coolant • Undo drain bolt (1) • Tighten drain bolt

18. 18. Remove rear silencer (4) • Release clamp (3) – Unscrew nut • Disconnect rear silencer from front exhaust pipe • Remove 3x damper rings (1) and (2)

Note. Plug and socket connection

19. 19. Remove front exhaust pipe (1) • Detach from catalytic converter – Undo screw connection (3) • Detach 2x damper rings (2)

Note. Plug and socket connection

20. 20. Disconnect shift linkage • Undo bolt (1)

21. 21. Attach KM-6394 • Place KM-6394 onto front axle body at front left • Place 2x brackets (3) onto right side of front axle body – Tighten 6 bolts

Note. Guide bolts (1) and (2) must sit in holes in front axle body

22. 22. Adjust supports at KM-6394 • Adjust bracket (2) for support • Screw on nut (1) • Transmission side • Engine timing side – Insert journal of the support in the bore of the cylinder block without play (arrow) – Tighten nuts (1)

Note. Turn spindles until mounts (3) are positioned at the guide journals free of play

23. 23. In vehicles with air conditioning system: detach compressor wiring harness • Disconnect wiring harness plug (1) • Cut cable ties

24. 24. Lower vehicle all the way
25. 25. Remove engine cover.
26. 26. Remove air cleaner housing
27. 27. In vehicles with air conditioning system: disconnect refrigeration line (2) • Unscrew bolt (1)

28. 28. Remove battery • Detach positive connection from positive terminal – Undo nut • Remove bracket – Unscrew nut
29. 29. Place collecting basin underneath
30. 30. 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

31. 31. 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
32. 32. Remove coolant compensation tank (1) • Detach 3x coolant hoses (4) • Remove body-bound rivet (2) • Unscrew bolt (3) • Unclip from upper front

33. 33. Detach 2x coolant hoses (1) and (2) from heater core • Unlock 2x quick release fittings

34. 34. Detach clutch pressure line (1) from pressure line connecting piece • Release clamp with screwdriver in direction of arrow and remove • Bend clip together a little and insert back into connecting piece

35. 35. Detach fuel return line (1) from accumulator • Disconnect quick-release fitting with KM-796-A • Seal fuel line and accumulator connection with KM-807

36. 36. Detach brake servo vacuum line (1) from vacuum pump • Disconnect quick-release fitting

37. 37. Disconnect engine management wiring harness • Disconnect 2x wiring harness plugs (3 and 4) • Detach positive cable (2) from positive terminal – Unscrew bolt • Detach ground cable (1) from ground terminal • Unscrew bolt • Cut cable ties

38. 38. Disconnect reversing lamps wiring harness plug
39. 39. Expose engine control unit wiring harness • Disconnect 2x cable tie
40. 40. In vehicles with air conditioning system: disconnect cooling module wiring harness • Disconnect 2x wiring harness plugs (1 and 2) • Unclip 2 wiring harnesses from auxiliary fan housing

41. 41. Detach right engine damping block from adapter • Unscrew 2x bolt (1)

42. 42. Detach left engine damping block from adapter • Unscrew 2x bolt (1)

43. 43. Raise vehicle all the way
44. 44. Detach engine control unit wiring harness • Disconnect 2x cable ties (1) • Disconnect wiring harness connector (2)

45. 45. Insert hydraulic jack • Place KM-6168 (2) onto KM-904 (1) – Lower body positioning pins (3) • Position KM-6168 beneath front axle body without play – Pay attention to centring points (arrows)

Note. Note that the centring bolts have different diameters

46. 46. Detach front axle body • Unscrew 4x bolts (arrows)

Important. The use of impact screwdrivers is strictly prohibited

Important. Carefully move front axle body with engine, transmission and cooling module out of engine compartment from below - do not damage attached parts

47. 47. Pull out drive unit

Note. Use a second person

Install

Important. Carefully move front axle body with engine, transmission and cooling module into engine compartment from below. Insert body positioning pins into body positioning holes. Do not damage attached parts.

48. 48. Push in drive unit

Note. Use a second person

49. 49. Attach front axle body • Tighten 4x new bolts 90 Nm + 45° + 15°

Important. The use of impact screwdrivers is strictly prohibited

50. 50. Remove hydraulic jack • Lower hydraulic jack
51. 51. Connect shift guide

Note. Do not tighten bolt of clamping piece yet

52. 52. Lower vehicle all the way
53. 53. Attach left engine damping block to adapter • Tighten 2x bolt 55 Nm
54. 54. Attach right engine damping block to adapter • Tighten 2x bolt 55 Nm
55. 55. In vehicles with air conditioning system; attach cooling module wiring harness • Connect 2x wiring harness plug • Clip on 2x wiring harnesses to auxiliary fan housing
56. 56. Attach engine control unit wiring harness • Fasten 2x cable ties
57. 57. Connect reversing lamp wiring harness plug
58. 58. Connect wiring harness for engine management • Connect 2x wiring harness plug • Attach positive cable to positive terminal – Tighten bolt • Attach ground cable to ground terminal • Tighten bolt
59. 59. Connect brake servo vacuum line to vacuum pump • Connect quick release fitting

Note. Quick-release fastening must audibly engage

60. 60. Attach fuel return line to accumulator • Connect quick release fitting – Remove KM-807
61. 61. Attach clutch pressure line to pressure line connecting piece
62. 62. Attach 2x coolant hoses to heater core

Note. Catches must audibly engage

63. 63. Install coolant compensation tank • Clip in to front at top • Tighten bolt • Install body-bound rivet • Attach 3x coolant hoses – Secure 3x clamp
64. 64. Bleed clutch
65. 65. Lock gearshift control lever in position • Unclip manual shift lever cover • Insert KM-527-A (1)

66. 66. Engage transmission locking pin • Engage locking pin (1) in shift cover plate (in direction of arrow) – Twist shifter rod to the left (direction of 3rd gear) to do this

67. 67. 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
68. 68. 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
69. 69. Install battery • Install bracket – Tighten nut • Attach positive clamp to positive terminal – Tighten nut
70. 70. In vehicles with air conditioning system: connect refrigerant line • Insert 2x new gaskets • Tighten bolt 20 Nm
71. 71. Install air cleaner housing
72. 72. Raise vehicle all the way
73. 73. Detach KM-6394
74. 74. Attach shift guide clamp • Tighten new bolt 12 Nm + 180° - 225°
75. 75. Attach engine control unit wiring harness • Connect wiring harness plug • Fasten 2x cable ties

Important. Prevent exhaust system from uncontrolled sagging. Bending of the flexible pipe by 5 - 10 degrees from the intended installation position can cause damage resulting in total failure of the flexible pipe.

76. 76. Install front exhaust pipe with middle silencer • Attach to catalytic converter – Attach 2x damping rings
77. 77. Attach rear silencer • Insert silencer • Attach 3x damping rings • Tighten bolted connection • Attach retaining ring
78. 78. In vehicles with air conditioning: fit compressor wiring harness • Connect wiring harness plug • Fasten cable tie
79. 79. Attach lower engine compartment cover / spray guard
80. 80. Lower vehicle by half its height
81. 81. Install 2x axle shafts in wheel hub
82. 82. Attach 2x guide joints • Renew 2x nuts • Tighten 2x bolts 60 Nm
83. 83. Attach 2x swing arms • Tighten 2x new nut 65 Nm

Note. Counterhold with open-ended wrench

84. 84. Attach 2x tie rods • Tighten 2x new nuts 35 Nm
85. 85. Attach 2x axle shafts • Insert 2x washers • Attach KM-468-B • Tighten 2x new nuts 120 Nm – Counterhold KM-468-B • Unfasten 2x nuts • Tighten 2x new nut 20 Nm + 90° • Install 2x new securing split pins

Note. If required, turn back nut until a pin hole is aligned with the following castellated nut

86. 86. Install front panelling
87. 87. Attach 2x front wheels • Screw in 8x bolts
88. 88. Lower vehicle by half its height
89. 89. Fasten 2x front wheels • Tighten 8x bolts 110 Nm
90. 90. In vehicles with air conditioning: top up air conditioning system
91. 91. Install engine cover.
92. 92. Connect battery • Attach ground clamp to ground terminal – Tighten nut
93. 93. Install steering intermediate shaft • Fix steering shaft in position with KM-6181 (1) • Fit intermediate steering shaft to steering gear • Tighten new nuts (2) 22 Nm • Detach KM-6181

Note. Steering wheel and front wheels must be in the straight-ahead position

Important. Move steering only slightly

Note. Steering can be unlocked to make it easier

94. 94. Test transmission shift linkage • Remove KM-527-A • Shift through gears • Clip in manual shift lever cover

Note. Locking pin in shift cover plate disengages after shifting in direction "R"

95. 95. Top up coolant • Observe specified coolant quantity
96. 96. Calibrate steering angle sensor • Switch ignition on

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

97. 97. Program volatile memory
98. 98. Close bonnet

1

) Protective caps can be ordered from the parts catalogue