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Vauxhall Workshop Service and Repair Manuals

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DOHC diesel engine|General > < Replace intercooler

Corsa D

Fit and remove engine bridge to engine

Note:   The following overview shows all special tools required for the procedure!

EN-47649 (1) in connection with EN-47649-100 (2)

Engine bridge (1) with special feet (2)

Hold/lower/raise engine

  

Object Number: 9008111 Size: DEFAULT

EN-47649-100 (1), (2)

2x special feet to convert engine bridge MKM-883-1-A

Object Number: 9008112 Size: DEFAULT

EN-47650-150 (1)

2x adapter for fitting carrier frame EN-47650 to Corsa-D

Object Number: 10678328 Size: DEFAULT

Object Number: 9008107 Size: DEFAULT

EN-47650

Carrier frame - engine bridge (assembly)

EN-47650-010 (2)

Crossbar

EN-47650-020 (1), (3)

2x longitudinal bar, 2x clamping support

EN-47650-040 (4), (5)

2x height spindle

EN-47650-030 (1), (2) not required on Corsa-D

2x extension to longitudinal bar EN-47650-020

Object Number: 9008109 Size: DEFAULT

EN-47650-50 (1), (2)

Holder rail for engine bridge EN-47649

Object Number: 9008613 Size: DEFAULT

  Install

1.   Support bonnet with EN-48375 (1)
•   Insert EN-48375 (1) at bottom in hole for bonnet catch
•   Place EN-48375 (1) at top on engine catch bolt
Object Number: 10678908 Size: DEFAULT


Important:   From MY 2008:
2.   When installing the engine bridge, the revised engine compartment electronics module (3) may in some circumstances make it difficult to release the Bowden cable (1). To prevent damaging the Bowden cable, it may be necessary to unclip the engine compartment electronics module on one side (2) and carefully push it to one side (arrow). The Bowden cable can then be placed to one side without damaging it.
Object Number: 10681034 Size: DEFAULT


3.   If fitted: pull alarm system switch (2) from guide and lay aside
4.   Remove bonnet support holder (3)
Note:   Release retaining lug with screwdriver. See diagram.
Important:   Do not kink bonnet release cable (4)!
•   Expose bonnet release cable (4)
•   Remove service flap right (1)
– Remove upwards
•   Clean grease and dirt from exposed service openings (arrows) on both sides, on top and bottom
Object Number: 10678909 Size: DEFAULT


Object Number: 10678910 Size: DEFAULT

Important:   Attach wing protectors! Risk of paint damage!
5.   Attach 2x adapter EN-47650-150 (1) and EN-47650-150 (6) at exposed service opening on both sides
Note:   Ensure that adapter EN-47650-150 (1) and EN-47650-150 (6) lie completely on the outer wing edge. Ensure that adapter EN-47650-150 (6) does not clamp the bonnet release cable (7).
•   Screw in 2x bolt (2), (5)
Note:   Do not tighten bolts! While screwing in, press retaining bracket (3), (4) on adapter EN-47650-150 (1) or EN-47650-150 (6) without play (arrows)

Object Number: 9008105 Size: DEFAULT

6.   Pre-set carrier frame EN-47650 to correct dimensions
Note:   Pre-set special tool assembly to table outside the vehicle!

Dimension I

1330 mm

Dimension II

435 mm

Dimension III

245 mm

Dimension IV

165 mm
Note:   The magnifying glass in the diagram shows a side view of EN-47650
•   Attach 2x clamping blocks EN-47650-020
– Tighten 2x hex heads (1), (6)
•   Set 2x height spindles EN-47650-040
– Tighten 2x hex heads (2), (5)
– Adjust 2x at hex heads (3), (4)

7.   Remove 2x bonnet buffers (2) left and right
Note:   Before removal, measure installation height (arrow) of bonnet buffers left and right, and record.
•   Twist catch (1) through 180°
– Remove 2x bonnet buffers (2)
Object Number: 10678911 Size: DEFAULT


8.   Remove coolant expansion tank (3) and lay aside
•   Unclip hose (2) from upper engine bay cover
•   Unscrew bolt (4)
9.   Detach wiring harness (1) from top front
•   Unclip 4x (5), (6)
Object Number: 10678912 Size: DEFAULT


Object Number: 10678913 Size: DEFAULT

10.   Fit pre-assembled carrier frame EN-47650
Note:   2nd person required!
•   Fit 2x pin (4) in bores on both sides
Note:   Ensure that the rubber feet of the height spindle sit at the marked points on the installation positions (6), (10) of the bonnet.
•   Attach 2x adapter EN-47650-150 both sides
•   Tighten 2 bolts (2)
Note:   During tightening, the retaining brackets (1) must be pressed play-free on the adapters EN-47650-150 (arrow)
•   If necessary: adjust position of rubber feet at knurled wheel (7) on both sides
11.   Fit carrier frame EN-47650
•   Tighten 4x bolt (3) both sides
•   Secure height spindle EN-47650-040 at top front
Note:   If necessary: adjust height of height spindle EN-47650-040 at both sides at hex head (5)
– Position 2x retaining hooks (9) under top front
– Twist 2x holders to position shown at knurled wheel (8) on both sides

12.   Place holder rails EN-47650-50 (1) on carrier frame EN-47650 at both sides
•   Secure with pins (2) at both sides
Note:   Check for correct position!
Object Number: 10678914 Size: DEFAULT


Object Number: 10678915 Size: DEFAULT

13.   Attach engine bridge EN-47649 (2)
Warning:   Only fit EN-47649 in secure state! Wind retaining chains (3) about chain box (2) and engine bridge foot EN-47647-100 and tighten chains at hex head on chain box.
14.   Insert engine bridge EN-47649 (2) in holder rail EN-47650-50
Note:   Insert engine bridge EN-47649 and position evenly!
Note:   2nd person required. Engine bridge must be perpendicular. Adjust at adjustment plates (1), (4)
•   Secure EN-47649 with pins (5) both sides
Note:   Check for even positioning of EN-47649

  Remove

Warning:   Only remove EN-47649 in secure state! Wind retaining chains about chain box and engine bridge foot and tighten chains at hex head on chain box.
15.   Remove engine bridge EN-47649
•   Remove 2x securing pins and release engine bridge foot EN-47649-100
•   Raise engine bridge EN-47649 from holder rail EN-47650-50
Note:   2nd person required!
•   Secure retaining chains of EN-47649 on both sides
16.   Remove holder rail EN-47650-50 from carrier frame EN-47650 on both sides
•   Release 2x safety pins
17.   Remove carrier frame EN-47650
•   Release 2x safety pins (arrow) on both sides and place in hole (1)
•   Unscrew 4x bolt (2)
Object Number: 10678329 Size: DEFAULT


18.   Remove carrier frame EN-47650 (continued)
•   Remove 2x retaining hooks (2) for height spindle EN-47650-040
•   Turn up 2x knurled screws (1)
•   Press 2x retaining hooks (2) down (arrow)
•   Fold out 2x retaining hooks from top front
Important:   Watch for paint damage!
19.   Remove carrier frame EN-47650
Note:   2nd person required!
Object Number: 9008119 Size: DEFAULT


20.   Remove 2x adapter EN-47650-150
•   Unscrew 2x bolts
– Remove adapter
21.   Lay bonnet release cable (1)
Note:   Check for correct installation position!
•   From MY 2008:
Clip in engine compartment electronics module
•   Fit bonnet support (arrow)
Note:   Check for correct installation position!
•   Where fitted: clip in alarm system switch
•   Install service flap right (2)
Note:   Check for correct installation position!
•   Remove bonnet support EN-48375
Object Number: 10678916 Size: DEFAULT


22.   Attach wiring harness to top front
•   Clip in 4x
23.   Fit coolant expansion tank
•   Tighten bolt
– Clip in hose
24.   Adjust bonnet
•   Insert 2x bonnet buffers to dimensions previously noted
– Twist catch clockwise through 180°
– Close bonnet and check for even lines to wings
– If necessary: readjust bonnet buffers

DOHC diesel engine|General > < Replace intercooler