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Vauxhall Workshop Service and Repair Manuals

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Repair engine using a short block engine > < Fit and remove engine bridge to engine

Corsa D

Manual transmission from engine, remove and install

  Remove

1.   Detach reversing lamp wiring harness (1)
•   Disconnect wiring harness plug (4)
•   Detach wiring harness bracket
– Unscrew bolt (3)
•   Unclip cable tie (2)
Object Number: 8125539 Size: DEFAULT


2.   Place collecting pan underneath.
3.   Detach right axle shaft (1) from intermediate shaft
Note:   Use a second person
•   Knock out axle shaft with KM-6003 and KM-313
Note:   Seal opening using closure plugs.
Object Number: 8125553 Size: DEFAULT


4.   Remove left axle shaft (1) from transmission
Note:   Use a second person
•   Knock out axle shaft with KM-6003-1 and KM-313
Note:   Seal opening using closure plugs.
Object Number: 8125552 Size: DEFAULT


5.   Remove intermediate shaft with bearing (1)
•   Detach intermediate shaft bearing from bearing support
– Unscrew 3 bolts
Object Number: 8125554 Size: DEFAULT


6.   Tie ropes to drive unit
•   Attach 3x KM-2358 to engine transport shackle
7.   Raise drive unit of CH-48373
•   Detach adapter for rear engine damping block from transmission
– Unscrew 3 bolts
Important:   The drive unit must be supported securely on a pallet for removal of the transmission.
8.   Place the drive unit down securely on a pallet
9.   Remove gearbox
•   Detach from transmission bracket
– Unscrew 2 bolts (2) and (3)
•   Detach from cylinder block
Note:   Note different bolt lengths!
– Unscrew 3x bolts (1)
Object Number: 8125923 Size: DEFAULT


10.   Remove transmission
Note:   Use a second person
•   Attach KM-2358

  Install

11.   Position transmission
Note:   Use a second person
12.   Install gearbox
•   Attach to cylinder block
– Tighten 3 bolts M12 60 Nm
•   Attach to transmission bracket
Note:   Note different bolt lengths!
– Tighten 2x bolt M10 40 Nm
•   Remove KM-2358
13.   Tie ropes to drive unit
•   Attach 3x KM-2358 to engine transport shackle
14.   Lower drive unit onto CH-48373
•   Attach adapter for rear engine damping block to transmission
– Tighten 3 new bolts 80 Nm + 45°
15.   Detach 3x KM-2358
16.   Install left axle shaft in the transmission
•   Attach new circlip (1) to axle body
– Remove closure cover
Object Number: 2417920 Size: DEFAULT


17.   Insert intermediate shaft in transmission
•   Remove closure cover
•   Insert DT-6332 in transmission
– Use DT-6332 to avoid damage
•   Tighten 3x bolts 18 Nm
18.   Attach right axle shaft to intermediate shaft
•   Attach new retaining ring to intermediate shaft
19.   Attach wiring harness for reversing light
•   Install wiring harness bracket
– Tighten bolt
•   Attach cable ties
•   Fix wiring harness plug

Repair engine using a short block engine > < Fit and remove engine bridge to engine