vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Replace differential gear (F13/F13 MTA/F17/F17 new/F17+/F17+ MTA) > < Replace reversing lamp switch (F13/F17/F17 new/F17+)

Corsa C

Remove and install manual transmission (F13/F17/F17 new/F17+)

  Remove

1.   Align drive unit
Note:   In order to ensure that the drive unit is correctly aligned when the left engine damping block bolts are undone, the drive unit must be aligned with the front axle body using the KM-6169
Object Number: 2410004 Size: DEFAULT


2.   Remove crash box
•   Z 13 DT / Z 13 DTJ / Z 17 DTH LUREF_1.gif
•   Y 17 DT
3.   Remove charge air pipe (1)
Note:   Only required for Z 13 DT and Z 13 DTJ.
•   Remove 3x bolts
•   Loosen clamp (4)
•   Unscrew bolt (2)
•   Unclip wiring harness (3)
Object Number: 10678758 Size: DEFAULT


4.   Fill brake fluid reservoir to "MAX" mark and seal with MKM-558-10 .
5.   Remove upper engine cover
Note:   If present.
6.   Disconnect pressure line (4) from connector (2) for pressure line for central release from transmission housing
•   Release clamp (3) with screwdriver and remove
•   Detach pressure line
•   Bend clamp together a little and insert back into connector
Note:   Collect escaping brake fluid
7.   Detach wiring harness plug (1) from reversing lamp switch
8.   Disconnect wiring harness plug from coolant temperature sensor
Release wiring harness plug and disconnect.
Note:   Only required for Z 13 DT and Z 13 DTJ.
9.   Remove 3 transmission bolts (arrows)
Note:   If necessary pull coolant pipe upwards and secure with cable ties
Object Number: 2403344 Size: DEFAULT


10.   Remove front axle body
Note:   The tool KM-6169 remains on the front axle body and must not be adjusted.
11.   Remove engine damping block retaining bracket
•   Remove left engine damping block bolts (1)
•   Remove 2 bolts (2) for left engine damping block retaining bracket from transmission
12.   Lower engine with transmission on MKM-883-1 by approx. 5 cm
Note:   Ensure that the coolant hoses and wiring harnesses are not stretched.
13.   Detach shift linkage from shift guide
•   Undo shift guide clamp
Object Number: 2410001 Size: DEFAULT


Important:   Fluid escapes. Place collecting pan underneath and close off apertures with plug.
14.   Remove axle shafts from transmission LUREF_1.gif
Note:   Axle shafts remain in wheel hubs.
•   Attach axle shafts to vehicle underbody
15.   Detach front engine damping block (2) from transmission
Note:   If present.
•   Unscrew 2x bolt (arrows)
16.   Detach rear engine damping block bracket (3) from transmission
•   Unscrew 2x bolt (arrows)
Object Number: 10680356 Size: DEFAULT


Object Number: 10679390 Size: DEFAULT

17.   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.
18.   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

19.   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.
20.   Detach transmission from DT-47648
Note:   2nd person required
•   Unscrew 2x bolt
•   Carefully lay transmission down

  Install

21.   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
Object Number: 10679899 Size: DEFAULT

Important:   Ensure that no cables and brackets get trapped between the transmission and engine.
22.   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

23.   Detach transmission holder DT-47648 from transmission
•   Unscrew 2x bolt
•   Lower and extend hydraulic jack
24.   Attach front engine damping block (2) to transmission
•   Tighten 2x bolts 95 Nm
25.   Attach rear engine damping block bracket (3) to transmission
•   Tighten 2x new bolts 80 Nm + 45° – 60°
Object Number: 10680356 Size: DEFAULT


26.   Attach new retaining ring to axle shaft LUREF_1.gif
27.   Attach axle shafts to transmission
•   Detach axle shafts from vehicle underbody
28.   Attach left engine damping block retaining bracket
•   Tighten 2 bolts (2) 60 Nm
29.   Lift engine with KM-883-1 until installation position is reached
Note:   Ensure that there is some clearance between the left engine damping block and the engine damping block bracket.
30.   Loosely fit 2 new engine damping block brackets (1) to the engine damping block retaining bracket
Note:   Do not tighten bolts yet
Object Number: 2410001 Size: DEFAULT


Important:   When installing the front axle body, ensure that the support bearings (1) of the KM-6169 are correctly seated in the guide pins of the front engine damping block (2) and the rear engine damping block bracket (3). If necessary, correct installation position of engine and transmission using MKM-883-1 .
31.   Install front axle body
Object Number: 2409771 Size: DEFAULT


32.   Tighten 2 engine damping block brackets (1) at engine damping block retaining bracket 80 Nm + 60° – 75°
33.   Detach and remove KM-883-1
Object Number: 2403342 Size: DEFAULT


34.   Fasten transmission at the top
•   Tighten upper transmission bolts (arrows) 60 Nm
•   Tighten ground cable 60 Nm
•   Tighten wiring harness bracket 60 Nm
Note:   If present.
•   Tighten coolant pipe bracket at transmission 60 Nm
Note:   If present.
35.   Connect wiring harness plug for coolant temperature sensor and lock
Note:   Only required for Z 13 DT and Z 13 DTJ.
36.   Attach pressure line (4) to connecting piece (2) for pressure line for central release at clutch housing
Note:   Clamp (3) must audibly engage.
37.   Connect wiring harness plug (1) to reversing lamp switch
Object Number: 2403344 Size: DEFAULT


38.   Install charge air pipe (1)
Note:   Only required for Z 13 DT and Z 13 DTJ.
•   Tighten 3x bolts
•   Fasten clamp (4)
•   Tighten bolt (2)
•   Clip in wiring harness (3)
Object Number: 10678758 Size: DEFAULT


39.   Check transmission fluid level and correct if necessary LUREF_1.gif
40.   Slide shift guide onto shift rod
41.   Transmission Shift Linkage, Adjust LUREF_1.gif
•   Tighten clamping screw
42.   Install lower and upper engine compartment cover
Note:   If present.
43.   Detach MKM-558-10 from brake fluid reservoir
44.   Install crash box
•   Z 13 DT / Z 13 DTJ / Z 17 DTH LUREF_1.gif
•   Y 17 DT
45.   Bleed hydraulic clutch actuation LUREF_1.gif
•   Correct brake fluid reservoir to "MAX" mark
46.   Program volatile memory

Replace differential gear (F13/F13 MTA/F17/F17 new/F17+/F17+ MTA) > < Replace reversing lamp switch (F13/F17/F17 new/F17+)