How to Remove and Install the Engine Opel Meriva A

Remove

1. 1. Open bonnet
2. 2. Detach ground cable from ground terminal • Unscrew bolt
3. 3. Disconnect battery • Detach ground clamp from ground terminal – Undo nut
4. 4. Detach steering intermediate shaft (1) from steering gear • Disconnect bolted connection (2) • Steering in straight ahead position • Engage steering lock • Detach steering intermediate shaft from steering gear

Important. Cooling system is under pressure.

5. 5. Carefully open cover of coolant compensation tank
6. 6. Slacken front wheels • Undo 8x bolts
7. 7. Detach front panelling at the top • Unscrew 2x bolt (arrow) • Remove radiator cover (1)

8. 8. Raise vehicle by half of its height
9. 9. Remove front wheels • Unscrew 8 bolts
10. 10. Raise vehicle by half of its height
11. 11. Detach lower engine compartment cover / spray guard
12. 12. Expose catalytic converter control oxygen sensor wiring harness (1) • Cut cable tie (2) • Disconnect wiring harness connector (3)

13. 13. Remove rear silencer • Slacken bolted connection • Remove 3x from damper ring • Detach rear silencer from centre exhaust pipe
14. 14. Remove front exhaust pipe with front silencer • Unscrew 3x nut • Detach 2 rubber dampers • Remove front exhaust pipe with front silencer

15. 15. Attach KM-6394 (1) • Position KM-6394 on left on front axle body – Push brackets (2) and (3) inwards to the stop • Position KM-6394 on right on front axle body – Push bracket (4) from the inside outwards to the stop – Push bracket (5) from the outside inwards to the stop • Tighten 8 bolts
16. 16. Insert dowel pins (1) upwards into front axle body • Install 2x split pin retainers

17. 17. Attach support to KM-6394 • Adjust bracket (2) for support • Screw on nut (1)
18. 18. Install 3x supports • Transmission side • Engine timing side – Tighten nuts (1)

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

Note. Insert support journals in cylinder block hole free of play (arrow)

19. 19. Release lower front panelling • Remove 3x clips (3) • Disconnect wiring harness plug (2) • Unscrew 4x bolts (arrow)

20. 20. Lower vehicle by half of its height
21. 21. Place collecting basin underneath
22. 22. Detach front panelling • Disconnect hose for headlamp cleaning system – Quick-release fitting

Note. Use a second person

23. 23. Place collecting basin underneath
24. 24. Drain coolant • Open drain bolt (arrow) • Close drain bolt

25. 25. Lower vehicle by half of its height
26. 26. Remove battery • Detach positive cable from positive terminal – Unscrew bolt • Detach positive connection from positive terminal – Undo nut • Remove battery bracket – Unscrew bolt
27. 27. Unclip and remove relay carrier (1) from battery support (2)

28. 28. Remove battery support. • Unscrew 4x bolt (arrows)
29. 29. Remove air cleaner housing with air intake pipe • Detach air intake pipe (4) from throttle valve module – Release clamp • Disconnect wiring harness plug for intake air temperature sensor (3) – Unclip wiring harness • Unclip 2x fuel degassing pipes (1) • Unscrew bolt (2)

30. 30. Detach tank vent valve hose • Release connection for tank vent valve (1) in direction of arrow • Unclip hose

Important. Exiting fuel - observe safety regulations and national legislation

31. 31. Release fuel pressure • Release fuel pressure via test connection (1) with pressure tester KM-J-34730-91 (2) – Collect exiting fuel in a suitable container

32. 32. Detach fuel line (2) from fuel rail • Disconnect with KM-796-A (1) • Unclip from bracket

33. 33. Detach brake servo vacuum line (1) from intake manifold

34. 34. Detach 2x heater hoses (1) from heat exchanger • Release 2x quick-release fittings (2) with screwdriver

35. 35. Disconnect wiring harness plug of engine control unit (1) • Open lock • Unclip 2x wiring harnesses
36. 36. Disconnect wiring harness plug (2) • Unclip wiring harness

37. 37. Disconnect wiring harness plug (1)

38. 38. Detach coolant compensation tank • Unscrew bolt (2) • Remove body-bound rivet (1) • Unclip from front-end at top • Detach coolant hose (3) – Release clamp – Unclip 2x

39. 39. Disconnect wiring harness plug for MTA transmission (1) • Unclip 2x
40. 40. Release adapter for right engine damping block adapter • Unscrew 2x bolt (1)

41. 41. Release left-hand engine damping block adapter • Unscrew 2x bolt (arrows)

42. 42. Raise vehicle by half of its height
43. 43. Detach 2x tie rods • Unscrew 2x nut • Press out 2x tie rod ball joints with KM-507-C (1)

44. 44. Detach 2x swing arms from spring strut support tube • Unscrew 2x nut

Note. Counterhold with open-ended wrench

45. 45. Detach 2x guide joints from steering knuckle • Detach 2x bolted connections (1)

46. 46. Unfasten 2x axle shafts • Detach 2x split pin retainers (1) • Unscrew 2x nuts (2) – Counterhold at wheel hub with KM-468-B (3)

47. 47. Push out 2x axle shafts • Attach KM-6282 (1) with wheel bolts – Tighten 2 bolts • Press out 2x wheel hubs – Counterhold with open-ended wrench (2)

48. 48. Detach left radiator hose from radiator • Release clamp
49. 49. Remove right-hand radiator hose • Release 3x clamp • Unclip 2x
50. 50. Disconnect 2x cooling module wiring harness plugs (1)

51. 51. Disconnect wiring harness plug for coolant temperature sensor (1) • Unclip wiring harness

52. 52. Fasten cooling module to front-end at top • Attach 2x tension straps
53. 53. In vehicles with air conditioning system: detach ribbed V-belt • Note ribbed V-belt's direction of travel • Tension ribbed V-belt tensioner at lug (1) in direction of arrow • Remove ribbed V-belt

54. 54. In vehicles with air conditioning system: detach compressor • Detach wiring harness plugs for • Unscrew 3x bolt • Suspend compressor

Note. The air conditioning system remains closed

55. 55. Raise vehicle by half of its height

56. 56. Attach KM-6168 • Place KM-6168 (2) onto KM-904 • Position KM-6168

Note. Lower body positioning pins (3)

Note. Play-free below front axle body, note centring points in front axle body.

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

Important. Carefully lower front axle body with engine and transmission downwards out of engine compartment. Do not damage attaching parts

58. 58. Lower drive unit

Note. Use a second person

59. 59. Pull out drive unit

Install

60. 60. Check thread • Check 4x lock nuts
61. 61. Clean threads • Of steering clamping piece
62. 62. Push in drive unit

Note. Fix positioning pins for bodywork in upper position

63. 63. Raise drive unit • Insert body positioning pins into locating holes in body

Important. Carefully guide front axle body with engine and transmission upwards into the engine compartment. Do not damage attaching parts.

Note. Use a second person

64. 64. Attach front axle body • Replace 4x bolt • Tighten 4x bolts 90 Nm + 45° + 15°
65. 65. Remove hydraulic jack
66. 66. Lower vehicle by half of its height
67. 67. In vehicles with air conditioning system: attach air conditioning compressor • Tighten 3x bolts 20 Nm • Connect wiring harness plug
68. 68. In vehicles with air conditioning system: attach ribbed V-belt • Tension tensioning device anti-clockwise • Install ribbed V-belt

Note. Note running direction.

69. 69. Release radiator fastening • Detach 2x tension straps
70. 70. Connect wiring harness plug for coolant temperature sensor • Clip wiring harness into position
71. 71. Connect 2x wiring harness plugs for cooling module
72. 72. Attach left radiator hose • Fasten clamp
73. 73. Install right-hand radiator hose • Secure 3x clamp • Clip in 2x
74. 74. Pull in 2x axle shaft • Use new nuts – Insert 2x washers – Screw on 2x nuts
75. 75. Attach 2x guide joints • Use new bolted connection • Tighten 2x screw connections 60 Nm
76. 76. Attach 2x swing arms • Use new nuts • Tighten 2x nuts 65 Nm

Note. Counterhold with open-ended wrench

77. 77. Attach 2x tie rod ball joints • Use new nuts • Tighten 2x nuts 35 Nm
78. 78. Attach 2x axle shafts • Counterhold at wheel hub with KM-468-B • Tighten 2x nuts 20 Nm + 90° • Install 2x new securing split pins

Note. If necessary, turn nut far enough back for a split pin hole to be in line with the next castle nut groove

79. 79. Lower vehicle by half of its height
80. 80. Attach left hand engine damping block support • Tighten 2x bolts 55 Nm
81. 81. Attach engine damping block support, right hand side • Tighten 2x bolts 55 Nm
82. 82. Connect wiring harness plug for MTA transmission • Clip in 2x
83. 83. Attach engine control wiring harness • Connect 3 wiring harness plugs • Clip wiring harness into position • Install 2x wiring harnesses in bracket
84. 84. Attach coolant expansion tank • Attach coolant hose to radiator – Fasten clamp • Clip into front at top • Tighten bolt • Install body-bound rivet
85. 85. Attach 2x coolant hoses to heat exchanger • Connect 2x quick release fittings

Note. Catches must audibly engage

86. 86. Connect vacuum line for brake servo
87. 87. Attach fuel supply line to fuel rail • Clip into bracket • Connect quick release fitting
88. 88. Attach vent line to tank vent valve
89. 89. Install air cleaner housing with air intake pipe • Attach air intake manifold – Tighten clamp 3.5 Nm • Attach wiring harness of mass air flow meter – Connect wiring harness plug • Clip in 2x vent pipes • Tighten bolt
90. 90. Install battery carrier • Tighten 4x bolt • Clip in relay bracket
91. 91. Install battery • Attach battery bracket – Tighten bolt • Attach positive clamp to positive terminal – Tighten nut • Attach positive cable to positive terminal – Tighten bolt
92. 92. Raise vehicle all the way
93. 93. Detach KM-6394 • Remove support – Unscrew nut • Turn 2x supports downwards • Unscrew 4x bolt
94. 94. Attach front exhaust pipe with front silencer • Use new seal • Tighten 3x nuts 20 Nm – Use new nuts • Fit 2x rubber dampers
95. 95. Install rear silencer • Attach rear silencer to exhaust pipe • Insert 3x into rubber damper • Tighten screw connection 20 Nm
96. 96. Connect wiring harness plug for catalytic converter control oxygen sensor • Clip wiring harness into position
97. 97. Attach lower engine compartment cover / spray guard
98. 98. Lower vehicle by half of its height
99. 99. Attach front panelling • If fitted: connect hose for headlamp cleaning system – Quick-release fitting

Note. Use a second person

100. 100. Fasten front panelling • Install 3x body-bound rivets • Connect wiring harness plug • Tighten 4x bolt
101. 101. Attach 2x front wheel • Screw in 8x bolts
102. 102. Lower vehicle by half of its height
103. 103. Fasten 2x front wheel • Tighten 8x bolts 110 Nm
104. 104. Attach upper front panelling • Insert radiator cover • Tighten 2 bolts
105. 105. Connect battery • Ground clamp to ground terminal – Tighten nut
106. 106. Attach ground cable to ground terminal • Tighten bolt
107. 107. Install steering intermediate shaft • Open steering lock • Push on steering intermediate shaft • Insert clamping bolt • Replace nut • Adjust length compensation with KM-6181 – Tighten nut • Remove KM-6181

Note. Wheels in straight-ahead position

Note. Hole for clamping bolt must be at the flat side of the steering journal

108. 108. Fill and bleed cooling system
109. 109. Program volatile memory
110. 110. Close bonnet