Replace Turbocharger Opel Meriva A

Remove

1. 1. Remove radiator
2. 2. Raise vehicle by half its height
3. 3. Remove engine compartment cover or right engine splash guard
4. 4. Remove ribbed V-belt • Tension ribbed V-belt tensioner in direction of arrow via bolt (1) • Fix ribbed V-belt tensioner to bore (2) with KM-6130 • Remove ribbed V-belt

5. 5. Lower vehicle all the way
6. 6. Remove resonator (2) • Unscrew bolt (1) • Slide resonator in direction of arrow and remove from front plate

7. 7. Detach compressor (1) • Unscrew 3x bolt (2) • Disconnect wiring harness connector. • Suspend compressor

Note. Note differing bolt lengths

8. 8. Remove compressor bracket (1) • Unscrew 3x bolt (2)

9. 9. Remove air intake hose (1) • Undo 2x clamps (arrows) • Unscrew 2x bolts (2)

10. 10. Release oil dipstick guide tube (2) • Remove oil dipstick (1) • Unscrew bolt (3)

11. 11. Remove charge air pipe (3) • Detach camshaft vent hose (1) from charge air pipe – Detach heat insulation – Release clamp • Unclip wastegate unit for bypass valve of exhaust gas recirculation cooler (2) • Unscrew bolt • Release clamp

12. 12. Raise vehicle all the way
13. 13. Place collecting basin underneath
14. 14. Drain engine oil
15. 15. Remove dipstick guide tube (1) • Unscrew 2x bolts (2)

16. 16. Detach exhaust system from rear silencer • Release clamp (1)

17. 17. Detach rear exhaust pipe temperature sensor (2) • Unscrew temperature sensor
18. 18. Detach oxygen sensor (1) • Unscrew oxygen sensor

19. 19. Detach particulate filter temperature sensor (1) • Unscrew temperature sensor

20. 20. Detach pressure connection of differential pressure sensor (1) • Unscrew pressure connection

21. 21. Detach particulate filter retaining bar (2) • Unscrew 2 nuts (1)

22. 22. Detach front exhaust pipe (1) from catalytic converter • Unscrew 3x nuts (2) • Remove seal

Important. Secure the flex pipe to prevent it from sagging

23. 23. Remove exhaust system • Second person required • Unhook 2x from rubber retainer
24. 24. Remove charge air pipe (1) from turbocharger • Unscrew 2x bolt • Remove seal

25. 25. Detach temperature sensor of pre-catalytic converter (1) • Unscrew temperature sensor

26. 26. Detach catalytic converter support (1) from catalytic converter • Unscrew 2x bolts (2)
27. 27. Pull off vacuum hose of turbocharger wastegate unit (1)

28. 28. Detach hose between turbocharger and cylinder block (1) from cylinder block • Release clamp

29. 29. Lower vehicle all the way
30. 30. Remove exhaust manifold heat shield for cylinders 1 and 2 (1) • Unscrew 3x bolt (2)

31. 31. Detach coolant hose between coolant pipe and exhaust gas recirculation cooler (1) • Release clamp • Place heat insulation to one side • Release clamp

32. 32. Remove exhaust gas recirculation cooler (5) • Pull off vacuum hose of wastegate unit for bypass valve • Detach pipe (2) from exhaust gas recirculation valve – Unscrew 2x bolt – Remove seal • Detach pipe (4) from thermostat housing – Unscrew bolt • Detach exhaust gas recirculation cooler retaining plate from cylinder head – Unscrew 2x bolts (1 and 3) • Detach bypass valve from exhaust manifold – Unscrew 2x bolts (6) – Remove seal

33. 33. Remove exhaust manifold heat shield for cylinders 3 and 4 (2) • Unscrew 2x bolt (1)

34. 34. Detach oil feed line from turbocharger (1) • Unscrew bolt (2) – Remove 2x seal ring

35. 35. Remove exhaust manifold with turbocharger (1) • Unscrew 2x bolt • Unscrew 7x nuts • Remove 2x gaskets

36. 36. Detach turbocharger (1) from exhaust manifold • Unscrew 3x nuts (arrows) • Remove seal

37. 37. Detach catalytic converter heat shield (2) • Undo 3x bolts (1)

38. 38. Detach catalytic converter (1) from turbocharger • Unscrew 3x bolt • Remove seal

39. 39. Detach hose between turbocharger and cylinder block (1) from turbocharger • Release clamp

Install

40. 40. Attach hose between turbocharger and cylinder block to turbocharger • Fasten clamp
41. 41. Attach catalytic converter to turbocharger • Replace seal • Tighten 3x bolts 45 Nm
42. 42. Attach catalytic converter heat shield • Tighten 3x bolts 5 Nm
43. 43. Attach turbocharger to exhaust manifold • Replace seal • Tighten 3x new nuts with MKM-6600-305 and KM-6600-12 – 1st tightening operation 24 Nm – 2nd tightening operation 48 Nm
44. 44. Install exhaust manifold with turbocharger • Replace 2x seals • Tighten 2x new bolts with 69 Nm • Tighten 7x new nuts 69 Nm

Note. Note correct tightening sequence (1-2-3-4-5-1-2-3-6-7-8-9)

45. 45. Attach oil feed line to turbocharger • Replace 2x seal rings – Tighten bolt 21 Nm
46. 46. Install exhaust manifold heat shield for cylinders 3 and 4 • Tighten 2x bolts 10 Nm
47. 47. Install exhaust gas recirculation cooler • Attach bypass valve to exhaust manifold – Replace seal – Tighten 2x bolts 29 Nm • Attach exhaust gas recirculation cooler retaining plate to cylinder head – Tighten 2x bolts 29 Nm • Attach pipe to thermostat housing. – Renew seal ring – Tighten bolt 10 Nm • Attach pipe to exhaust gas recirculation valve – Replace seal – Tighten 2x bolts 29 Nm • Attach vacuum hose of wastegate unit for bypass valve
48. 48. Install coolant hose between coolant pipe and exhaust gas recirculation cooler • Fasten clamp • Slide on the heat insulation • Fasten clamp
49. 49. Install exhaust manifold heat shield for cylinders 1 and 2 • Tighten 3x bolts 10 Nm
50. 50. Raise vehicle all the way
51. 51. Attach hose between turbocharger and cylinder block to cylinder block • Fasten clamp
52. 52. Attach vacuum hose of wastegate unit for turbocharger
53. 53. Attach catalytic converter support to catalytic converter • Tighten 2x bolt 25 Nm
54. 54. Attach temperature sensor of pre-catalytic converter • Tighten temperature sensor with MKM-6600-207 and MKM-6600-2
55. 55. Fit charge air pipe to turbocharger • Replace seal • Tighten 2 bolts
56. 56. Insert exhaust system • Second person required • Attach 2x to rubber retainer
57. 57. Attach front exhaust pipe to catalytic converter • Replace seal • Tighten 3x new nuts

Important. Secure the flex pipe to prevent it from sagging

58. 58. Clean 2 x threads
59. 59. Attach particulate filter retaining bar • Tighten 2x nuts

Note. Insert with locking compound

60. 60. Attach pressure connection of differential pressure sensor • Tighten pressure connection with MKM-6600-207 and MKM-6600-2
61. 61. Attach particulate filter temperature sensor • Tighten temperature sensor with MKM-6600-207 and MKM-6600-2
62. 62. Attach oxygen sensor • Tighten oxygen sensor with MKM-6600-211 and MKM-6600-2
63. 63. Attach rear exhaust pipe temperature sensor • Tighten temperature sensor with MKM-6600-207 and MKM-6600-2
64. 64. Attach rear silencer to exhaust pipe • Align rear silencer • Tighten clamp
65. 65. Install dipstick guide tube • Replace seal ring • Tighten 2x bolts 10 Nm
66. 66. Lower vehicle all the way
67. 67. Install charge air pipe • Tighten clamp 3.5 Nm • Tighten bolt 5 Nm • Clip in hose for wastegate unit of exhaust gas recirculation cooler bypass valve • Attach camshaft vent hose to charge air pipe – Fasten clamp – Attach heat insulation
68. 68. Fasten oil dipstick guide tube • Tighten bolt 10 Nm • Insert oil dipstick.
69. 69. Install air intake hose. • Attach 2x clamps • Tighten 2 bolts
70. 70. Install compressor bracket • Tighten 3x bolt 25 Nm
71. 71. Attach compressor • Release compressor • Tighten 3x bolts 43 Nm
72. 72. Install resonator • Tighten bolt
73. 73. Raise vehicle all the way
74. 74. Install ribbed V-belt • Install ribbed V-belt – I. Ribbed V-belt without AC – II. Ribbed V-belt with AC • Tension ribbed V-belt tensioner in direction of arrow via bolt (1) • Remove KM-6130 • Release ribbed V-belt tensioner

Note. Note ribbed V-belt's direction of travel

75. 75. Remove engine compartment cover or right engine splash guard
76. 76. Lower vehicle by half its height
77. 77. Install radiator
78. 78. Check engine oil level and correct if necessary.