vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Oil Return Line from Turbocharger, Replace > < Oil Return Line from Turbocharger, Replace

Corsa C

Turbocharger Oil Feed Line, Replace (Z 17 DTH, without AC, LHD)

1.   Open bonnet
Important:   On vehicles 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.   Detach coolant compensation tank hose from fan housing
4.   Release upper front panelling (1)
•   Unscrew 2x bolt (arrows)
Object Number: 2406228 Size: DEFAULT


5.   Raise vehicle
6.   Release lower front panelling
•   Disconnect wiring harness plug (2)
•   Remove 3 clips (1)
•   Unscrew 4 bolts (arrows)
Object Number: 2406229 Size: DEFAULT


7.   Remove ribbed V-belt cover
•   Unscrew 3 bolts (1)
•   Remove clip (arrow)
Object Number: 2410600 Size: DEFAULT


Important:   When removing the centre muffler, a catalytic converter, an exhaust manifold or an exhaust manifold with catalytic converter, the exhaust system piece remaining in the vehicle must be prevented from swinging uncontrollably. 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.
8.   Remove exhaust system
•   Remove front exhaust pipe
– Unscrew 3x nut (1)
Object Number: 2413387 Size: DEFAULT


9.   Attach exhaust system
Note:   Second person required
•   Detach exhaust system
– 7x damper ring
•   Attach exhaust system
10.   Remove ribbed V-belt
Note:   Mark running direction.
•   Tension ribbed V-belt tensioner in direction of arrow
•   Use KM-913-A
Object Number: 2411073 Size: DEFAULT


11.   Lower vehicle
•   Half-way up
12.   Detach front panelling
Note:   Second person required
13.   Drain coolant
•   Place collecting basin underneath.
•   Open coolant drain bolt
14.   Disconnect 2 fan motor wiring harness plugs
15.   Detach 2 charge air hoses
•   From intercooler
•   Release 2x clamp
16.   Detach 3 coolant hoses
•   From radiator
•   Release 3x clamp
17.   Release lower radiator bracket
•   Unscrew 2 bolts (1)
•   Loosen 2 bolts (2)
Object Number: 2410721 Size: DEFAULT


18.   Remove cooling module
Note:   2nd person required. Carefully remove cooling module from below
19.   Detach connection hose (1) from turbocharger to charge air pipe
•   Release clamp
Object Number: 2408329 Size: DEFAULT


20.   Detach coolant hose, coolant connection (1)
•   Release clamp
Note:   Set coolant hose to one side
Object Number: 2408330 Size: DEFAULT


21.   Detach 2 vacuum lines of vacuum pump (3)
•   Unscrew nut
•   Detach hose
22.   Detach oil dipstick guide tube
•   Unscrew 4 bolts
23.   Release alternator
•   Disconnect wiring harness plug (1)
•   Detach wiring harness
– Unscrew nut (2)
•   Remove nut
•   Remove bolt
Note:   Oil feed line (4) remains connected. Hinge alternator forwards
Object Number: 2411119 Size: DEFAULT


24.   Remove heat shield of pre-catalytic converter
•   Unscrew 3 bolts
25.   Remove pre-catalytic converter (1)
•   Unscrew 5 bolts
•   Remove gasket.
Object Number: 2408331 Size: DEFAULT


26.   Detach turbocharger oil feed line (1)
•   Unscrew 2 banjo bolts
•   Remove 4x seal ring
Object Number: 2412717 Size: DEFAULT


  Install

27.   Attach turbocharger oil feed line
•   Replace 4x seal ring
•   Tighten 2 banjo bolts
– Tighten at cylinder block 27.5 Nm
– Tighten at turbocharger 20.6 Nm
28.   Remove oil dipstick guide tube
29.   Clean sealing surfaces
30.   Insert dipstick guide tube
•   Replace seal ring
31.   Install pre-catalytic converter
•   Replace gasket
•   Tighten 3 bolts at turbocharger 45 Nm
•   Tighten 2 lower bolts
32.   Install heat shield of pre-catalytic converter
•   Tighten 3 bolts 11.8 Nm
33.   Attach alternator
•   Tighten M8 bolt 18.6 Nm
•   Tighten M10 bolt 46.1 Nm
•   Connect wiring harness plug
•   Attach wiring harness
– Tighten nuts
34.   Fasten oil dipstick guide tube
•   Tighten 4 bolts 9.8 Nm
•   Insert oil dipstick.
35.   Attach 2 vacuum lines of vacuum pump
•   Tighten nuts
•   Attach hose
36.   Attach coolant hose, coolant connection
•   Fasten clamp
37.   Attach connection hose from turbocharger to charge air pipe
•   Tighten clamp 5 Nm
38.   Install cooling module
Note:   Second person required
39.   Fasten lower radiator bracket
•   Tighten 4 bolts 15 Nm
40.   Attach 3 coolant hoses
•   Secure 3x clamp
41.   Attach 2x charge air hose
•   Fasten 2 clamps 5 Nm
42.   Connect 2 wiring harness plugs for fan motors
43.   Close coolant drain bolt
44.   Position front panelling
Note:   Second person required
45.   Raise vehicle
46.   Fasten lower front panelling
•   Connect wiring harness plug
•   Fasten 3 clips
•   Tighten 4 bolts
47.   Install ribbed V-belt
Note:   Observe running direction and installation position
•   Release ribbed V-belt tensioner
•   Use KM-913-A
48.   Attach exhaust system
Note:   2.

person required
49.   Attach exhaust system
•   Replace gasket
•   Tighten 3 new nuts 25 Nm
50.   Install ribbed V-belt cover
•   Tighten 3 bolts
•   Fasten clip
51.   Lower vehicle
52.   Fasten upper front panelling
•   Tighten 2 bolts
53.   Fasten coolant compensation tank hose to fan housing
54.   Connect battery
•   Ground cable
55.   Check and correct engine oil level
•   Observe specified engine oil quantity
56.   Top up and bleed cooling system LUREF_1.gif
57.   Program volatile memory
58.   Close bonnet

Oil Return Line from Turbocharger, Replace > < Oil Return Line from Turbocharger, Replace