Replace Steering Gear (Diesel Engine) Opel Meriva A

Note. When steering gear is replaced, the tie rod ends must be rebuilt – see procedure Tie Rod Ends, Remove and Install

Important: Before the front axle body can be detached, the engine damping blocks must be inspected to ensure that they are free of damage

Important: Before detaching the steering intermediate shaft from steering pinion or steering shaft, bring the steering into straight ahead position and lock it with the steering lock.

Remove

1. 1. Detach 2x front wheels • Remove 10x wheel bolts
2. 2. Remove the lower clamp bolt (1) of the steering intermediate shaft on the steering pinon • Detach the steering intermediate shaft from steering pinion

3. 3. Disconnect battery • Remove ground terminal from ground pole. – Loosen nut
4. 4. Secure cooling module • Secure 2 tension straps (1) to the upper brackets

5. 5. Secure retaining strap (1) to the top of the front assembly • Guide retaining strap (1) downward between engine and cooling module (arrow)

6. 6. Loosen front panelling from front axle body • Detach 3 body-bound rivets (arrow)

7. 7. Remove engine splash protection right • Unscrew 3 bolts (1) • Unclasp clip (arrow)

8. 8. Loosen exhaust system and securely attach to vehicle
9. 9. Release tie rod end (3) from steering knuckle • Attach CH-47658 (2) – Place CH-47658 (2) in position using a suitable sleeve (4) – Fasten CH-47658 (2) to hexagon (1) • Unscrew nut of tie rod end • Detach CH-47658 (2) – Release at hexagon (1)

Note. To centre CH-47658 (2), CH-47658 (2) must be used with the appropriate socket wrench socket (5).

10. 10. Detach tie rod end (1) from steering knuckle • press out with KM-507-C (2)

11. 11. Loosen front engine damping block (1) • Unscrew bolt connection • Secure with tension strap (2)

Note. For Diesel engines

12. 12. Remove engine damping block (2) along with bracket (1) • Remove bracket (1) – Unscrew bolt (3) • Detach engine damping block (2) – Unscrew 3 bolts (arrow)

13. 13. Detach crash bracket (1) from transmission • Unscrew 2x bolts

14. 14. Position hydraulic jack with KM-904 and KM-6168-A (2) below front axle body (1)

Note. It is not necessary to remove the front axle body. The steering gear can be loosened and removed by lowering the front axle body.

Note. To lower the front axle body, the positioning studs for the vehicle undercarriage must be lowered beforehand. Guide studs must rest in the guide holes of the front axle body on both sides

15. 15. Loosen front axle body • Unscrew 4 bolts (arrows) • Lower front axle body
16. 16. Remove steering gear • Unscrew 2 screwed connections (1) • Remove steering gear (arrow)

Note. Hold nuts, remove washers (2) and remove steering gear from front axle body.

Note. Two persons required

17. 17. Rebuild tie rods when replacing steering gear

Install

18. 18. Transfer steering pinion seal (1)

19. 19. Install steering gear • Tighten 2x bolts (4) 45 Nm + 45° + 15° • Assemble seal on steering pinion

Note. Counterhold 2x nuts.

20. 20. Attach front axle body • Move positioning studs out of KM-6168-A • Lift front axle body • Secure front axle body – Tighten 4 new bolts 90 Nm + 45° + 15°

Note. Check 4 clamping nut threads

21. 21. Attach crash bracket to transmission • Tighten 3x bolts
22. 22. Attach rear engine damping block along with bracket • Tighten 4 bolts 80 Nm
23. 23. Attach front engine damping block • Tighten screwed connection 80 Nm • Remove tension strap
24. 24. Attach exhaust system
25. 25. Secure front panelling to front axle body • Fit 3x body-bound rivet
26. 26. Attach tie rod end to steering knuckle • Attach CH-47658 – Place CH-47658 in position using a suitable sleeve – Fasten CH-47658 to hexagon • Tighten new tie rod end nut 35 Nm • Detach CH-47658 – Release at hexagon

Note. To centre CH-47658 , CH-47658 must be used with the appropriate socket wrench socket. Insert fastening nut of the tie rod end into the socket wrench socket

27. 27. Attach right side engine splash protection • Screw in 3 bolts • Install clip
28. 28. Remove retaining strap from front assembly
29. 29. Remove radiator retainers
30. 30. Attach the steering intermediate shaft to the steering pinion 24 Nm
31. 31. Check straight-ahead position
32. 32. Test track and adjust if necessary • Refer to brochure "Chassis Alignment Values" of the respective model year.