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Vauxhall Workshop Service and Repair Manuals

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MTA Manual Transmission from Engine, Detach and Attach > < Cooling System, Charge and Bleed

Corsa C

Engine with Transmission, Remove and Install

  Remove

1.   Open bonnet
Important:   On vehicles as of model year 04 with ESP - every time the battery is disconnected, the steering angle sensor loses its basic setting. It must be recalibrated.
2.   Disconnect battery
•   Detach ground cable
3.   Detach steering intermediate shaft (1)
•   Remove lower clamp bolt (2)
– Unscrew nut (3)
•   Steering in straight ahead position
•   Engage steering lock
Important:   Do not alter steering wheel position.
•   Remove steering intermediate shaft
Object Number: 2410520 Size: DEFAULT


4.   Loosen front wheels
•   Loosen 8 bolts
5.   Detach front panelling
Note:   On Tigra-B (Model R97): detach front panelling
6.   Raise vehicle
7.   Remove front wheels
8.   Remove lower engine compartment cover / splash protection
9.   Drain coolant
•   Place collecting basin underneath.
•   Open drain bolt
Object Number: 2411059 Size: DEFAULT


10.   Lower vehicle
11.   Remove air cleaner housing
12.   Remove coolant compensation tank
•   Undo retaining clip
•   Detach 3 coolant hoses
– Release 3x clamp
13.   Remove fuel filter (2)
•   Detach 4 lines (1...4)
– Use KM-796-A
•   Disconnect wiring harness plug (3)
•   Close 4 fuel lines
14.   Remove fuel filter crash box
•   Unscrew nut
•   Remove nut
15.   Detach brake servo vacuum line (5)
•   From vacuum pump
Object Number: 2406291 Size: DEFAULT


16.   Detach 2 coolant hoses
•   From heater core
17.   Disconnect fan motor wiring harness
•   Open relay box
•   Disconnect 2 wiring harness plugs (1)
•   Unclip relay box
18.   Disconnect wiring harness for engine management
•   Disconnect engine control unit wiring harness plug (2)
•   Disconnect wiring harness
– Release cable ties
19.   Detach ground cable
•   From side member
– Remove castellated nut (arrow)
Object Number: 2406292 Size: DEFAULT


20.   Disconnect starter/alternator wiring harness
•   Detach ground cable
•   Detach positive cable (1)
•   Disconnect central plug (2)
•   Unclip wiring harness from bracket (arrow)
•   Remove rubber seal (3)
Object Number: 2410519 Size: DEFAULT


21.   Drain air conditioning system LUREF_1.gif
22.   Disconnect refrigerant line of block connector (2)
•   Remove bolt (1)
Object Number: 2406293 Size: DEFAULT


23.   Raise vehicle
24.   Close coolant drain bolt
25.   Release 2x axle shaft
•   Remove 2 cotter pins (1)
•   Use KM-468-B (3)
•   Unscrew 2 nuts (2)
– Counterhold using KM-468-B
– Remove washer
Object Number: 2406234 Size: DEFAULT


26.   Detach 2x tie rod ball joints
•   From steering knuckle
•   Unscrew 2 nuts
•   Extract 2 tie rods
•   Use KM-507-C (1)
Object Number: 2409857 Size: DEFAULT


27.   Detach 2x swing arm
•   From spring strut support tube
•   Unscrew 2 nuts
Note:   Counterhold with open-ended wrench
Object Number: 2410521 Size: DEFAULT


28.   Detach 2 guide joints
•   From steering knuckle
•   Unscrew 2 nuts (1)
– Remove 2x bolt
Object Number: 2411020 Size: DEFAULT


29.   Press out 2x axle shaft
•   From wheel hub
30.   Raise vehicle
31.   Disconnect MTA transmission wiring harness plug (1)
•   Disconnect wiring harness
Object Number: 2406233 Size: DEFAULT


Important:   When removing the centre muffler, a catalytic converter, an exhaust manifold, or an exhaust manifold with catalytic converter, secure that portion of the exhaust system remaining on the vehicle against uncontrolled suspension. The exhaust system piece with the flex pipe inside can be secured for this purpose using suitable means, such as a wire on the vehicle underbody. Bends in the flex pipe with an angle as little as 5 – 10 degrees from the intended installation position may result in damage with subsequent total failure of the flex pipe.
32.   Remove exhaust system
•   Release clamp
33.   Remove exhaust system
•   Detach exhaust system
Note:   2nd mechanic required.
– Detach 5 damper rings
34.   Attach KM-6394
•   Position KM-6394 (1) at the front on the front axle body
Note:   Both locating pins (arrows) must be seated in the bores in the front axle body.
•   Push front bracket (2) in the direction of the arrow
•   Place rear bracket (4), right hand side, on front axle body
•   Attach rear bracket (3), left hand side
– Screw in 2x bolt
•   Tighten 6 bolts
Object Number: 2408346 Size: DEFAULT


Object Number: 2411021 Size: DEFAULT

35.   Install support
•   On KM-6394
– Adjust bracket (2) for support
•   Screw on nut (1)
36.   Adjust 3x support
•   Transmission side
Note:   Turn spindles until mounts (3) are positioned at the guide journals free of play.
•   Engine timing side
– Insert journal of the support in the bore of the cylinder block free of play (arrow)
– Tighten nuts (1)

37.   Lower vehicle
38.   Detach right engine damping block
•   Loosen right engine bracket
– Unscrew 2 bolts
Object Number: 2406283 Size: DEFAULT


39.   Detach left engine damping block
•   Loosen left engine bracket
– Unscrew 2 bolts
Object Number: 2411258 Size: DEFAULT


40.   Raise vehicle
Object Number: 2409773 Size: DEFAULT

41.   Insert hydraulic jack
•   Use KM-904
42.   Attach KM-6168 (2)
•   Position KM-6168
– On KM-904 (1)
Note:   Note differing centring bolt diameters
•   Position KM-6168
– Without play under front axle body
Note:   Pay attention to centring point in front axle body (arrows); lower body positioning pins (3)

Object Number: 2409774 Size: DEFAULT

43.   Release front axle body
Important:   The removal of the front axle body with an impulse or impact screwdriver is not permitted
•   Unscrew 4 bolts (arrows)

Important:   Carefully lower front axle body with engine and transmission downwards out of engine compartment. Do not damage attaching parts
44.   Lower drive unit
Note:   Second person required
45.   Remove drive unit
Important:   Before installing the front axle body, the lock nut threads must be checked for ease of movement. Replace lock nuts if necessary
46.   Check threads of 4 lock nuts

  Install

47.   Install drive unit
Important:   Carefully guide the front axle body with engine and transmission upwards into the engine compartment. Guide the body positioning pins into body the positioning holes. Do not damage attaching parts.
48.   Raise drive unit
Note:   Second person required
49.   Fasten front axle body
•   Replace 4x bolt
Important:   Installation of the front axle body with an impulse or impact screwdriver is not permitted
•   Tighten 4 bolts 90 Nm + 45° + 15°
50.   Remove hydraulic jack
•   Lower hydraulic jack
51.   Lower vehicle
52.   Fasten left engine damping block
•   Replace 2x bolt
•   Tighten 2 new bolts 80 Nm + 60° - 75°
53.   Fasten right engine damping block
•   Replace 2x bolt
•   Tighten 2 new bolts 60 Nm + 30° - 45°
54.   Raise vehicle
55.   Detach support
56.   Detach KM-6169-1
57.   Attach exhaust system
Note:   Second person required
•   Fit 5 damper rings
58.   Attach exhaust system
•   Fasten clamp
59.   Connect MTA transmission wiring harness plug
•   Fasten cable harness
60.   Install lower engine compartment cover / splash protection
61.   Lower vehicle
•   Half way up
62.   Attach front panelling
Note:   On Tigra-B (Model R97): attach front panelling
63.   Insert 2 axle shafts
64.   Attach 2x guide joint
•   Tighten 2 new bolts 60 Nm
65.   Attach 2x swing arm
•   Tighten 2 new nuts 65 Nm
Note:   Counterhold with open-ended wrench
66.   Attach 2 tie rods
•   Tighten 2 new nuts 35 Nm
67.   Secure 2x axle shaft
•   Screw in 2 new nuts
– Fit 2 washers
•   Attach KM-468-B
•   Tighten 2 nuts 120 Nm
– Counterhold using KM-468-B
•   Loosen 2 nuts
•   Tighten 2 nuts 20 Nm + 90°
– Counterhold using KM-468-B
•   Install 2 cotter pins
Note:   If necessary, unscrew the nut until a pin hole aligns with the next castle nut groove
68.   Fit front wheels
•   Screw in 8 nuts
69.   Lower vehicle
70.   Fasten front wheels
•   Tighten 8x bolts 110 Nm
71.   Connect refrigerant line block connector
•   Replace 2 gaskets
•   Tighten bolt 20 Nm
72.   Attach starter/alternator wiring harness
•   Route and secure wiring harness
•   Connect central plug
•   Attach positive cable
•   Connect ground cable.
•   Install rubber seal
73.   Attach engine management wiring harness
•   Connect engine management wiring harness
•   Fasten cable harness
– Attach cable ties
•   Connect ground cable.
74.   Connect fan motor wiring harness
•   Clip in relay box
•   Connect 2 wiring harness plugs
•   Close relay box
75.   Attach 2x coolant hose
•   To heater core
76.   Attach brake servo vacuum line
Note:   Connection must audibly engage
77.   Install fuel filter crash box
•   Tighten 2 nuts 25 Nm
78.   Install fuel filter
•   Connect 2 wiring harness plugs
•   Connect 4 lines
79.   Install coolant compensation tank
•   Attach 3 coolant hoses
– Secure 3x clamp
•   Fasten retaining clip
80.   Install air cleaner housing
81.   Install steering intermediate shaft
Note:   Wheels in straight-ahead position
•   Release steering lock
•   Push on steering intermediate shaft
Note:   The bore for the clamp bolt must be on the flat-milled side of the stub axle
•   Insert clamp pin
•   Replace nut (2)
•   Adjust length compensator
– Use KM-6181 (1)
•   Tighten nut 22 Nm
•   Remove KM-6181
Object Number: 2410159 Size: DEFAULT


82.   Fill air conditioning system
83.   Top up coolant
84.   Connect battery
85.   Program volatile memory
86.   Close bonnet

MTA Manual Transmission from Engine, Detach and Attach > < Cooling System, Charge and Bleed