vauxhall Workshop Repair Guides

Vauxhall Corsa Workshop Service and Repair Manuals

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Replace exhaust gas recirculation valve > < Damage diagnosis, dual mass flywheel

Removing and Installing Attachments for Cylinder Head of DOHC Diesel Engine

Attaching Parts – Cylinder Head, Remove and Install

  Remove

1.   Detach exhaust manifold heat shield (2)
•   Detach engine transport shackle (3)
– Unscrew bolt (4)
•   Unscrew 2x nuts (5) from exhaust manifold (1)
2.   Remove 4x sheathed glow plug (1)
3.   Remove oil pressure switch (2)
4.   Detach exhaust manifold (3)
•   Unscrew 10x nut
•   Remove gasket
Object Number: 8063940 Size: DEFAULT


5.   Detach thermostat housing (2)
•   Unscrew 2x bolts (1)
Object Number: 10681680 Size: DEFAULT


6.   Detach throttle valve module bracket (1)
•   Unscrew 2x bolts (2)
Object Number: 10681672 Size: DEFAULT


7.   Detach metal pipe for exhaust gas recirculation (3)
•   Unscrew 2x bolts (1) from flange of exhaust gas recirculation valve
•   Unscrew 3x bolts (5) from intake manifold
•   Remove gasket (4)
•   Remove seal ring (2)
Object Number: 10681673 Size: DEFAULT


8.   Detach exhaust gas recirculation cooler (2)
•   Unscrew 3x bolts (3)
•   Remove gasket (1)
Object Number: 10681674 Size: DEFAULT


9.   Detach intake manifold (1)
•   Unscrew 9x bolt (2) and (3)
Note:   Note different bolt lengths!
•   Remove gasket
Object Number: 8125665 Size: DEFAULT


10.   Clean sealing surfaces.
11.   Transfer 6x stud bolt

  Install

12.   Install inlet manifold
•   Insert new gasket
•   Tighten 9x bolts 25 Nm
Note:   Note different bolt lengths!
13.   Attach exhaust manifold
•   Replace gasket
– Tighten 10x new nut 15 Nm + 30°
Note:   Coat thread with lubrication compound. Select suitable lubrication compound from the spare parts catalogue.
14.   Attach exhaust gas recirculation cooler
•   Insert new gasket
•   Tighten 3 bolts 22 Nm
•   Insert new gasket
15.   Attach metal pipe, exhaust gas recirculation
•   Check seal ring for damage
•   Insert new gasket
•   Tighten 2x bolts on flange of exhaust gas recirculation valve 9 Nm
•   Tighten 3x bolts on intake manifold 9 Nm
16.   Attach throttle valve module bracket
•   Tighten 2x bolt 9 Nm
17.   Attach thermostat housing
•   Insert new gasket
•   Tighten 2x bolt 25 Nm
18.   Attach exhaust manifold
•   Insert new gasket
•   Tighten 10x new nut 15 Nm + 30°
– Use new nuts
19.   Attach oil pressure switch
•   Tighten oil pressure switch 32 Nm
20.   Install 4x sheathed glow plug
•   Tighten 4x sheathed glow plug 10 Nm

Replace exhaust gas recirculation valve > < Damage diagnosis, dual mass flywheel