vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
J470300 Gasket - Exhaust Manifold, Replace (Y 17 DTL, without AC, LHD) > < Flexible maintenance intervals

Corsa C

J471300 Gasket – Intake Manifold, Replace (Y 17 DTL, without AC, LHD)

1. Open bonnet

 Object Number: 2411064 Size: DEFAULT

Caution!

On vehicles from model year 04 with ESP - the steering angle sensor loses its basic adjustment each time the battery is disconnected. It must be recalibrated.

2. Disconnect battery

  • Detach ground cable

3. Remove air cleaner housing (1)

  • Remove wiring harness plug for hot film mass air flow meter (3)
    • Release in direction of arrow
  • Remove air intake hose (4)
    • Loosen clamp (5)
  • Remove bolt (2)
 Object Number: 2411078 Size: DEFAULT

4. Remove wiring harness plug for engine control unit

  • 3 off
    • Release 2 wiring harness plugs in direction of arrow
  • Unclip wiring harness

5. Remove air intake pipe

  • Remove 3 bolts
  • Remove vent hose (1)
    • From cylinder head cover
  • Detach air intake pipe from turbocharger
 Object Number: 2411065 Size: DEFAULT

6. Remove engine control unit

  • Remove wiring harness plug bracket
    • Remove 2 bolts (1)
  • Unscrew 2 bolts (2), 2 nuts (3)
 Object Number: 2411079 Size: DEFAULT

7. Remove engine control unit bracket

  • Unscrew 2 bolts (2), nut (1)
  • Unclip wiring harness (arrows)
 Object Number: 2411080 Size: DEFAULT

8. Detach starter/alternator wiring harness bracket

  • From exhaust recirculation valve
  • Remove 2 nuts

9. Remove charge air hose

  • From turbocharger, centre charge air pipe
    • Release clamps
 Object Number: 2411081 Size: DEFAULT

10. Remove centre charge air pipe (1)

  • Unscrew studs (2), 2 bolts

11. Detach sheathed glow plug wiring harness plugs

  • 4 off

12. Remove exhaust recirculation valve (1)

  • Remove exhaust recirculation pipe
    • Remove 2 bolts
  • Unscrew studs (3), 2 bolts (arrows)
  • Detach vacuum hose (2)
  • Remove gaskets
 Object Number: 2411082 Size: DEFAULT

13. Remove exhaust recirculation solenoid valve

  • Detach vacuum hose (1)
  • Detach wiring harness plug (2).
  • Remove 2 bolts
 Object Number: 2411095 Size: DEFAULT

14. Remove right rear engine transport shackle

  • Remove bolt

15. Remove charge pressure sensor (2)

  • Disconnect wiring harness plug (1)
  • Remove bolt
 Object Number: 2411096 Size: DEFAULT

16. Remove oil filter element

  • Place collecting basin underneath.
  • Unscrew oil filter housing cover

17. Detach oil filter housing cover return hose

  • Release clamp
 Object Number: 2411083 Size: DEFAULT

18. Remove injection line spacers

  • Remove 3 bolts

19. Remove injection lines

  • 4 off
  • With KM-6098

20. Detach outer oil leak line

  • Unscrew banjo bolt (3), bolt (2)
  • Remove hose (1)
 Object Number: 2411097 Size: DEFAULT

21. Disconnect wiring harness plug

  • From diesel injection pump
    • 3 off
 Object Number: 2416084 Size: DEFAULT

22. Remove two-part intake manifold (3)

  • Remove 7 bolts (1), 2 nuts (2)
  • Remove gaskets

23. Clean sealing surfaces

24. Install two piece intake manifold

  • Replace gaskets
  • Tighten bolts, nuts (24.5 Nm/18.7 lbf. ft.)

25. Connect wiring harness plug

  • To diesel injection pump

26. Install outer oil leak line

  • Renew seal rings
  • Tighten bolt, banjo bolt (14.7 Nm / 10.8 lbf. ft.)
  • Install hose

27. Install injection lines

  • Caution! Injection lines must be installed without tension. Hand-tighten at injector nozzles and injection pump.
  • Tighten union nuts (22.5 Nm/16.6 lbf. ft.)

28. Install injection line spacers

  • Note! Note spacer positions
  • 3 off

29. Install oil filter housing cover return hose

  • Fasten clamp

30. Install oil filter insert

  • Tighten oil filter housing cover (25 Nm/18.5 lbf. ft.)

31. Install charge control sensor

  • Tighten bolt (9.8 Nm / 7.2 lbf. ft.)
  • Connect wiring harness plug.

32. Install exhaust recirculation solenoid valve

  • Clean thread.
  • Install 2 bolts
    • Note! Insert bolts with locking compound
  • Connect wiring harness plug.
  • Connect vacuum hose.

33. Install right rear engine transport shackle

34. Install exhaust recirculation valve

  • Clean sealing surfaces.
  • Insert exhaust recirculation valve
    • Tighten studs, 2 bolts (24.5 Nm/18.1 lbf. ft.)
  • Replace gaskets
  • Connect vacuum hose.
  • Attach exhaust gas recirculation pipe
    • Tighten 2 bolts (28.4 Nm / 21 lbf. ft.)
    • Replace gasket

35. Install centre charge air pipe

  • Clean sealing surface
  • Tighten studs, 2 bolts
  • Replace gasket

36. Install starter/alternator wiring harness bracket

  • Screw in 2 nuts

37. Install sheathed glow plug wiring harness plugs

  • 4 off

38. Install engine control unit bracket

  • Tighten 2 bolts, 1 nut
  • Attach wiring harness

39. Install engine control unit

  • Tighten 2 bolts, 2 nuts (5.9 Nm/4.4 lbf. ft.)
  • Install wiring harness plug bracket
    • Tighten 2 bolts

40. Install air intake pipe

  • Install 3 bolts
  • Fasten clamp
  • Attach engine vent hose
    • Tighten clamps (3.5 Nm / 2.5 lbf. ft.)
  • Attach wiring harness

41. Attach charge air hose

  • Tighten clamps (3.5 Nm / 2.5 lbf. ft.)

42. Attach engine control unit wiring harness plug

  • Route wiring harness
  • Connect wiring harness plug.
    • 3 off
  • Attach wiring harness

43. Install air cleaner housing

  • Tighten bolt
  • Fasten air intake hose.
    • Tighten clamp (3.5 Nm / 2.6 lbf. ft.)
  • Connect wiring harness plug to hot film mass air flow meter

44. Check and correct engine oil level

  • Observe specified engine oil quantity

45. Connect battery

46. Calibrate steering angle sensor

  • Switch on ignition

Note:   Rotate the steering wheel one time from its right-hand to its left-hand stop.

47. Program volatile memories

48. Close bonnet

J470300 Gasket - Exhaust Manifold, Replace (Y 17 DTL, without AC, LHD) > < Flexible maintenance intervals