vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Replace rear crankshaft seal ring > < Replacing oil pump seal ring

Corsa C

Checking engine pressure loss

  Remove

1.   Open bonnet
2.   Disconnect battery
•   Detach ground cable
3.   Remove air intake hose
•   Release 2x clamp
Object Number: 2408327 Size: DEFAULT

4.   Remove engine management wiring harness
•   Disconnect 3 wiring harness plugs (arrows)
•   Expose wiring harness

5.   Loosen air intake pipe (1)
•   Remove engine vent hose
•   Unscrew 2 bolts
•   Unclip wiring harness
Object Number: 2412653 Size: DEFAULT


6.   Remove engine control unit (1)
•   Release wiring harness plug in direction of arrow
•   Unscrew 2 bolts
•   Unscrew 2 nuts
Object Number: 2408319 Size: DEFAULT


7.   Disconnect 4 wiring harness plugs, injector (2)
8.   Detach engine control unit bracket (1)
•   Unscrew 4 bolts
Object Number: 2408321 Size: DEFAULT


9.   Disconnect 4x wiring harness plug, sheathed glow plug (1)
•   Use KM-717
10.   Remove 4x sheathed glow plug (2)
•   Use MKM-6104
Object Number: 2412655 Size: DEFAULT


11.   Raise vehicle all the way
12.   Remove right engine splash guard
•   Unscrew 3 bolts (1)
•   Remove body-bound rivet (arrow)
Object Number: 2410600 Size: DEFAULT


13.   Remove coolant compensation tank cap, oil filler port closure cap and oil dipstick

  Inspect

14.   Set crankshaft to "1st cylinder TDC" following direction of engine rotation
•   The markings (1) must align
Note:   The cams of 1st cylinder must face up - Cam position can be checked via the oil filler port. If 1st cylinder cams do not face up, turn the crankshaft one revolution to "1st cylinder TDC".
15.   Affix guide marking to torsional vibration damper
Note:   Guide marking must be exactly 180° across from TDC marking
16.   Attach pressure loss tester
•   Together with connector KM-6367
•   Calibrate pressure loss tester
Note:   Follow manufacturer's instructions
Object Number: 2415961 Size: DEFAULT


17.   Engage 4th gear; apply handbrake
18.   Check 1st cylinder pressure loss
•   Max. pressure difference between individual cylinders - approx. 10 %
•   Pressure loss per cylinder should not exceed 25 %
•   Check the following for air discharge to locate any damage:
– Intake ports
– Exhaust system
– Coolant compensation tank, dipstick guide tube
– Oil filler port
– Glow plug thread bores
19.   Detach pressure loss tester
•   Together with connector KM-6107
20.   Repeat pressure loss test for 3rd, 4th and 2nd cylinder
Note:   Turn crankshaft 180° to guide marking or TDC marking

  Install

21.   Fit coolant compensation tank cap, oil filler port closure cap and oil dipstick
22.   Install 4 sheathed glow plugs 17.5 Nm
•   Use MKM-6104
23.   Connect 4x injector wiring harness plug
24.   Attach engine control unit bracket
•   4 bolts
25.   Connect 4x injector wiring harness plug
26.   Fit engine control unit
•   Tighten 2 bolts 9.8 Nm
•   Tighten 2 nuts 9.8 Nm
•   Connect wiring harness plug
27.   Fasten air intake pipe
•   Tighten 2 bolts
•   Install vent hose
•   Attach wiring harness
28.   Attach engine management wiring harness
•   Route wiring harness
•   Connect 3 wiring harness plugs
29.   Install air intake hose.
•   Fasten 2 clamps 5 Nm
30.   Connect battery
•   Ground cable
31.   Close bonnet
32.   Calibrate steering angle sensor
•   Turn on ignition
Note:   Rotate the steering wheel one time from its right-hand to its left-hand stop.
33.   Program volatile memory

Replace rear crankshaft seal ring > < Replacing oil pump seal ring