vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Synchromesh Body Assembly, Replace (F17 new) > < Shift Guide, Dismantle and Assemble (F13/F17/F17 new/ F17+)

Corsa C

Manual Transmission, Remove and Install (F17+ MTA - Z 13 DT / Z 13 DTJ)

  Remove

1.   Detach crash box
Note:   The fuel system remains closed.
•   Z 13 DT / Z 13 DTJ / Z 17 DTH LUREF_1.gif
•   Y 17 DT
2.   Remove charge air pipe (3)
•   Unscrew 3x bolt (arrows)
•   Loosen clamp (1)
•   Unscrew bolt (2)
Object Number: 2405989 Size: DEFAULT


Object Number: 2405990 Size: DEFAULT

3.   Release transmission at top
•   Unscrew 2x bolt (arrows)
Note:   Bolts with washers.

Object Number: 2405982 Size: DEFAULT

4.   Attach engine bridge MKM-883-1 (1).
Note:   Follow manufacturer's instructions. 2nd mechanic required.
•   Prevent from tilting with MKM-883-3 (2) and (3)
Important:   Follow manufacturer's instructions.
5.   Attach engine
•   Attach MKM-883-1 to 2 engine transport shackles (arrows)
•   Tension hoist chains but do not raise engine

6.   Attach KM-6169 . Insert KM-6169 into front axle body
Note:   The drive unit must be aligned to the front axle body using KM-6169 in order to ensure correct alignment of the drive unit after releasing the bolts for the right and left engine damping blocks.
•   Insert KM-6169
•   Pins must be seated in the guide holes of the front axle body
•   Tighten 2 bolts for adjustment rails
•   Twist up the rear support bearing until it rests against the guide pins of the rear engine damping block bracket
Note:   The guide pins must sit in the support bearing without play.
•   Twist up the front support bearing until it rests against the guide pins of the front engine damping block bracket
Note:   The guide pins must sit in the support bearing without play.
Object Number: 2410004 Size: DEFAULT


7.   Remove front axle body
8.   Detach front engine damping block (1)
•   Unscrew 2x bolt (2)
Object Number: 2405991 Size: DEFAULT


9.   Remove rear engine damping block bracket (1)
•   Unscrew 2x bolt (2)
Object Number: 2405992 Size: DEFAULT


10.   Remove wiring harness, transmission
•   Loosen cable ties (2)
•   Release wiring harness plug (1) and disconnect.
Object Number: 2405993 Size: DEFAULT


11.   Detach left axle shaft
Note:   Place collecting basin underneath - fluid escapes
Note:   Axle shaft remains in wheel hub.
•   Insert plug
•   Attach axle shaft to vehicle underbody
12.   Detach right axle shaft
Note:   Axle shaft remains in wheel hub.
•   Attach axle shaft to vehicle underbody
13.   Loosen left engine damping block (1)
•   Unscrew 2x bolt (2)
Object Number: 2405994 Size: DEFAULT


14.   Lower drive mechanism
Note:   Lower drive mechanism approx. 5 cm. Do not damage attaching parts.
Object Number: 10679390 Size: DEFAULT

15.   Position transmission holder DT-47648 on KM-904 and preinstall as shown in the illustration:

Component

Position on base plate

Designation

DT-47648-2

(4)

2

Clutch housing support

DT-47648-3

(2)

14

Transmission housing support

DT-47648-5 left

(1)

A

Support with rear transmission swivel arm

DT-47648-5 right

(3)

F

Support with front transmission swivel arm

Important:   It is important that the manufacturer's instructions for transmission holder DT-47648 are followed.
16.   Attach transmission holder DT-47648 to transmission
Note:   Before placing in position, slacken all bolt connections of the swivel arms and supports as far as the base plate. Adjust the supports using the spindles until they are as low as possible.
•   Position transmission holder DT-47648 and supports under the transmission
•   Tighten the bolt connections of the supports
•   Attach swivel arms (1) and (2) to transmission
•   Tighten bolt connections of swivel arms, starting from the transmission and going as far as the base plate
Note:   Align the swivel arms so that as little leverage as possible is created.
Object Number: 10679389 Size: DEFAULT


Object Number: 10679899 Size: DEFAULT

17.   Remove transmission
•   Unscrew 3x bolts (2), transmission to oil pan
•   Unscrew 3x bolts (1) and (3), transmission to cylinder block
Note:   Note different bolt lengths
•   Push transmission away from engine
Important:   Do not damage add-on parts.
•   Carefully lower the transmission with the hydraulic jack and extend the hydraulic jack

Important:   Do not damage attaching parts when laying transmission down.
18.   Detach transmission from DT-47648
Note:   2nd person required
•   Unscrew 2x bolt
•   Carefully lay transmission down

  Install

19.   Install transmission with DT-47648
•   Raise and align transmission
•   Place transmission so that it is in even contact with the engine
Note:   Ensure that it is properly seated
•   Insert intermediate plate between engine and transmission
Object Number: 10679899 Size: DEFAULT

Important:   Ensure that no cables and brackets get trapped between the transmission and engine.
20.   Install transmission
•   Insert wiring harness bracket with front bolt
•   Tighten 3x bolts (1) and (3), transmission to cylinder block 60 Nm
•   Tighten 3x bolts (2), transmission to oil pan 40 Nm

21.   Detach transmission holder DT-47648 from transmission
•   Unscrew 2x bolt
•   Lower and extend hydraulic jack
22.   Install left engine damping block (1)
•   Lift drive mechanism
Note:   Until in installation position.
•   Screw in 2 new bolts (2)
Note:   Do not tighten, there must be some play between the transmission holder and the engine damping block.
Object Number: 2405994 Size: DEFAULT


23.   Attach left axle shaft
Note:   Place collecting basin underneath - fluid escapes
•   Remove plug
24.   Attach right axle shaft
Note:   Place collecting basin underneath - fluid escapes
•   Remove plug
25.   Install transmission wiring harness
•   Connect and lock wiring harness plug (1)
•   Attach wiring harness with cable ties (2)
Object Number: 2405993 Size: DEFAULT


26.   Attach rear engine damping block (1)
•   Tighten 2 new bolts (2) 80 Nm + 45° – 60°
Object Number: 2405992 Size: DEFAULT


27.   Attach front engine damping block (1)
•   Tighten 2 bolts (2) 95 Nm
Object Number: 2405991 Size: DEFAULT


28.   Install front axle body
Note:   The drive unit must be aligned to the front axle body using KM-6169 in order to ensure correct alignment of the drive unit after releasing the bolts for the right and left engine damping blocks.
Note:   Ensure that guide pins of bracket for rear engine damping block and front engine damping block are seated in the support bearings (2,3) of KM-6169 (1). Support bearings must not be moved.
Object Number: 2403408 Size: DEFAULT


29.   Detach MKM-883-1
•   Lower engine/transmission using MKM-883-1
Note:   Guide pins of front engine damping block and rear engine damping block bracket must be seated in support bearing of KM-6169 .
•   Detach hoist chains from engine
•   Remove MKM-883-3
30.   Fasten left engine damping block (1)
•   Tighten 2 new bolts (2) 80 Nm +60° – 75°
Object Number: 2405994 Size: DEFAULT


Object Number: 2405990 Size: DEFAULT

31.   Fasten transmission at the top
•   Tighten 2 bolts (arrows) 60 Nm

32.   Attach rear engine damping block
•   Tighten bolt 80 Nm
33.   Attach front engine damping block
•   Fit bolt with vibration absorber
•   Tighten bolt to front axle body using new nut 60 Nm
34.   Remove KM-6169
35.   Transmission Fluid Level, Check and Correct LUREF_1.gif
36.   Install charge air pipe (3)
•   Fit charge air pipe with new gasket
•   Tighten 3 bolts (arrows)
•   Tighten clamp (1) 3.5 Nm
•   Tighten bolt (2)
Object Number: 2405989 Size: DEFAULT


37.   Attach crash box
•   Z 13 DT / Z 13 DTJ / Z 17 DTH LUREF_1.gif
•   Y 17 DT
38.   Program volatile memory
39.   Comply with the start-up routines required LUREF_1.gif

Synchromesh Body Assembly, Replace (F17 new) > < Shift Guide, Dismantle and Assemble (F13/F17/F17 new/ F17+)