vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Replace air cleaner housing > < Manual transmission from engine, remove and install

Corsa D

Repair engine using a short block engine

  Remove

1.   Remove engine
2.   Remove manual transmission from engine LUREF_1.gif
3.   Detach thrust plate and clutch disk LUREF_1.gif
4.   Remove flywheel (3)
•   Lock with KM-652 (1)
•   Unscrew 6x bolt (2)
Object Number: 13408788 Size: DEFAULT


5.   Attach engine to suitable engine overhaul stand
•   Attach KM-2358 to 3x engine transport shackle
•   Raise using engine crane
•   Attach engine to engine overhaul stand
•   Detach KM-2358 from 3x engine transport shackle
6.   Drain engine oil
•   Place collecting basin underneath.
•   Remove oil drain bolt
•   Remove oil filter housing cover
•   Remove oil filter element
7.   Detach right engine damping block bracket (1)
•   Unscrew 3x bolts
8.   Screw in oil drain bolt
•   Replace sealing ring
•   Tighten bolt 10 Nm
Object Number: 2411044 Size: DEFAULT


9.   Detach ribbed V-belt
•   Mark direction of rotation
•   Tension the ribbed V-belt tensioner using KM-6131 (1) in the direction of the arrow
•   Insert KM-955-2 (2)
•   Release ribbed V-belt tensioner
Object Number: 10678417 Size: DEFAULT


10.   Remove ribbed V-belt tensioner
•   Tension the ribbed V-belt tensioner using KM-6131 in the direction of the arrow
•   Remove KM-955-2 (1)
•   Release ribbed V-belt tensioner
•   Unscrew 2 bolts (arrows)
•   Remove ribbed V-belt tensioner
Object Number: 2410378 Size: DEFAULT


11.   Detach coolant pump ribbed V-belt pulley
•   Unscrew 3x bolts
Note:   Counterhold with open-end wrench
12.   Detach alternator
•   Release alternator wiring harness (1)
– Unscrew 2x nuts
•   Remove cable ties
•   Detach 2x bolted connections
Object Number: 2410438 Size: DEFAULT


13.   Detach starter
•   Detach starter wiring harness
– Unscrew 2x nuts (1)
•   Unscrew 2 bolts (arrows)
Object Number: 2410463 Size: DEFAULT


Object Number: 2411043 Size: DEFAULT

14.   Detach engine management wiring harness
•   Detach fuel rail cover
– Unscrew 2x bolts
•   Separate 11x wiring harness for engine management
– Oil pressure switch (6), coolant temperature sensor (8), camshaft sensor (9), throttle valve module (2). engine control unit (12), exhaust gas recirculation valve (4), ignition module (3), knock sensor (10), crankshaft sensor (11), injectors (1)
•   Detach engine control unit earth cable (13)
•   Unclip wiring trough (7)
•   Unclip wiring harness
– 4x bracket (14)

15.   Detach 3x coolant hoses from coolant pump
16.   Detach coolant hose from coolant flange exhaust gas recirculation valve
•   Release clamp
17.   Detach coolant pump (1) together with thermostat housing
Note:   When removing guide sleeves, please note
•   Place collecting basin underneath.
•   Unscrew 9x bolts
Note:   Note differing bolt lengths (arrows = short bolts)
Object Number: 2410459 Size: DEFAULT


18.   Loosen oil dipstick guide tube
•   Unscrew bolt (arrow)
19.   Remove oil dipstick guide tube
•   Rotate oil dipstick guide tube forward
Object Number: 2410604 Size: DEFAULT


20.   Remove exhaust manifold heat shield
•   Unclip oxygen sensor mixture regulator wiring harness plug
•   Unscrew 2x bolts
21.   Remove exhaust manifold
•   Unscrew 7x nut
•   Undo 2x bolt from catalytic converter bracket
Object Number: 2410543 Size: DEFAULT


22.   Remove intake manifold
•   Detach vent hose from cylinder head cover
•   Detach EGR pipe from exhaust gas recirculation valve
– Unscrew 2x bolts (1)
– Remove seal
•   Unscrew 5x bolt (2)
•   Remove 3x intake manifold seal
Object Number: 13408824 Size: DEFAULT


23.   Detach EGR valve
•   Note seal
•   Unscrew 4x bolts
24.   Detach ignition module
•   Detach ignition module cover
– Push to the right
•   Unscrew 2x bolts
•   Pull out using KM-6009 (1)
Note:   Do not tilt
25.   Remove cylinder head cover
•   Unscrew 17x bolts
Object Number: 2410586 Size: DEFAULT


Object Number: 13408798 Size: DEFAULT

26.   Set engine to TDC of combustion stroke of cylinder 1
•   Unscrew crankshaft closure bolt
– Take out seal ring
•   Rotate crankshaft in direction of engine rotation to the marking (4) on the torsional vibration damper and align with marking (3) on timing case
Important:   It must be possible to insert EN-953 smoothly and without major effort into the camshaft grooves.
•   Lock camshafts with EN-953 (2)
Important:   It must be possible to insert KM-952 smoothly and without major effort into the crankshaft recess.
•   Fix crankshaft with KM-952 (1)

27.   Detach torsional vibration damper (3)
•   Counterhold it with EN-49979 (1) together with KM-956-1 (2)
•   Unscrew bolt (4)
Object Number: 13408794 Size: DEFAULT


28.   Rotate engine on engine overhaul stand through 180°
29.   Remove oil pan
•   Unscrew 16x bolts
Important:   Do not damage oil pan and base place seal surfaces when prising off
•   Detach oil pan by carefully prising out to position (1)
Object Number: 13408799 Size: DEFAULT


30.   Detach oil baffle plate
•   Unscrew 6x bolts
31.   Rotate engine on engine overhaul stand through 180°
Object Number: 2410461 Size: DEFAULT

32.   Remove timing case
•   Unscrew 15x bolts (arrows)
– Note bolt lengths
– Do not damage camshaft sensor (1)
•   Prise out timing case seal ring
Note:   Do not damage sealing surface

Object Number: 2398446 Size: DEFAULT

33.   Detach chain drive
•   Slacken bolts, camshaft sprockets
– Counterhold the camshafts on the hexagon
•   Lock chain tensioner (1)
– Insert KM-955-1 (2)
•   Detach sliding rail (3), guide rail (5), tension rail (7), camshaft sprockets
•   Take out timing chain (4) with drive gear (6)
•   Take out timing case gasket

34.   Remove cylinder head
•   Turn engine (90°)
•   Detach KM-953
•   Unscrew 10x cylinder head bolt
Note:   Undo cylinder head bolts in the order shown (1-10)
– Release cylinder head bolts (90°)
– Release cylinder head bolts (180°)
– Remove cylinder head bolts
•   Place cylinder head on wooden blocks
•   Remove cylinder head gasket
Object Number: 2410566 Size: DEFAULT


35.   Remove KM-952
36.   Detach oil filter housing
•   Unscrew 3x bolts
37.   Detach catalytic converter bracket
•   Unscrew 2x bolts
38.   Detach knock sensor
•   Unscrew bolt
39.   Detach crankshaft sensor
Note:   Note seal ring
•   Unscrew bolt
40.   Detach cylinder block from engine overhaul stand
•   Attach KM-2358
– Attach 2x engine transport shackle to cylinder block
– Tighten 2x bolts
•   Hitch cylinder block up to workshop crane.
•   Lower cylinder block onto wooden pallet
•   Remove KM-2358
•   Remove 2x engine transport shackle from cylinder block

  Install

41.   Attach cylinder block to suitable engine overhaul stand
•   Attach KM-2358
– Attach 2x engine transport shackle to cylinder block
– Tighten 2x bolts
•   Hitch cylinder block up to workshop crane.
•   Attach cylinder block to suitable engine overhaul stand
•   Remove KM-2358
•   Detach 2x engine transport shackle
– Unscrew 2x bolts
42.   Input engine number, if required
43.   Input 6x guide sleeve in cylinder block, if required
44.   Clean all sealing surfaces
•   Cylinder block, cylinder head, cylinder head cover, oil filter housing, crankshaft bearing bridge, timing case, oil pan, coolant pump, exhaust manifold, intake manifold, cooling water connector
45.   Visually check components
•   Cylinder block, cylinder head, cylinder head cover, oil filter housing, crankshaft bearing bridge, chain drive, timing case, oil pan, coolant pump, exhaust manifold, intake manifold, cooling water connecting piece
46.   If testing and overhauling the cylinder head: Detach all attachments from cylinder head LUREF_1.gif
47.   Using a straightedge, check cylinder block lengthways and widthways for bend and in the diagonal for distortion.
Note:   Before carrying out the check, carefully clean the cylinder head sealing surface of any old gasket residues. Do not use any metal, sharp-edged tools when cleaning. Ensure that the cylinder head sealing surface is not damaged.
Object Number: 10680473 Size: DEFAULT


Object Number: 13408806 Size: DEFAULT

48.   Lock crankshaft
•   Unscrew crankshaft closure bolt
– Take out seal ring
Important:   It must be possible to insert KM-952 smoothly and without major effort into the crankshaft recess.
•   Insert KM-952 (1)
– Rotate smoothly on crankshaft dihedral (2) in direction of engine rotation until KM-952 engages

49.   Fit knock sensor
•   Tighten bolt 20 Nm
50.   Attach crankshaft sensor
•   Use new seal ring
•   Tighten bolt 8 Nm
51.   Attach catalytic converter bracket
•   Tighten 2x bolt 22 Nm
52.   Attach oil filter housing
•   Replace seal
•   Tighten 3x bolt 20 Nm
•   Replace oil filter element
•   Attach oil filter housing cover
– Replace sealing ring
– Tighten cover 10 Nm
53.   Adjust the camshafts
•   Insert KM-953-A (1)
– Turn the camshafts by the hexagon
•   Remove KM-953-A
54.   Adjust the camshafts
•   Insert KM-953-A
– Turn the camshafts by the hexagon
•   Remove KM-953-A
55.   Attach cylinder head
•   Replace seal
Note:   Marking TOP/OBEN must point up
•   Replace cylinder head bolts
•   Align cylinder head to cylinder block with straightedge
•   Tighten 10x bolt 25 Nm+ 60° + 60° + 60°
Note:   Note correct tightening sequence (1-10)
Object Number: 2411041 Size: DEFAULT


Object Number: 2410447 Size: DEFAULT

56.   Replace timing case gasket
•   Apply 2x sealing bead as shown (2 mm)
Note:   After application of the sealant, the chain drive and timing case must be fitted within 10 minutes
•   Place new gasket in position
Note:   Note guide bushings (arrows)
57.   Attach timing chain
•   Insert KM-953-A in camshafts
Note:   If necessary, gently adjust camshafts by the hex
•   Apply timing chain (3) together with drive gear (5)
58.   Attach timing chain tension rail (6)
•   Tighten bolt 20 Nm
Note:   Ensure correct seat of timing chain
59.   Attach timing chain guide rail (4)
•   Tighten 2x bolt 8 Nm
Note:   Ensure correct seat of timing chain
60.   Attach timing chain sliding rail (2)
•   Tighten 2x bolt 8 Nm
61.   Relieve tension on chain tensioner
•   Remove KM-955 (1)

Object Number: 13408825 Size: DEFAULT

62.   Attach timing case.
Note:   Note guide bushings and camshaft sensor
•   Screw in all bolts
•   Tighten 13x bolt M6 (1) 8 Nm
•   Tighten 2x M10 bolt (3) 35 Nm
63.   Replace front crankshaft sealing ring (2)
•   Push onto KM-960 (4)
•   Drive in flush using KM-960

Object Number: 13408812 Size: DEFAULT

64.   Fit torsional vibration damper (6)
•   Insert torsional vibration damper in oil pump rotor hex head (2) and crankshaft dihedral (1)
Note:   Marking on the torsional vibration damper must align with the marking on the timing case
•   Check for correct torsional vibration damper seating
– Measure distance between torsional vibration damper and edge of timing case (dimension a = 5,5 mm)
•   Screw in torsional vibration damper bolt (7)
•   Tighten torsional vibration damper bolt 150 Nm
– Counterhold it with EN-49979 (4) together with KM-956-1 (5)

65.   Fix 2x camshaft sprocket
•   Attach EN-49977-200 (3)
Note:   Press EN-49977-200 in direction of arrow so that the teeth (4) engage in the teeth of the intake camshaft sprocket without play
– Tighten 2x fastening bolt (1)
– Tighten adjusting bolt (2)
Note:   Press EN-49977-200 in direction of arrow when tightening
66.   Adjust and fix phase sensor disc
•   Rotate phase sensor disc until EN-49978 (5) can be inserted
Note:   EN-49978 must rest on the surfaces shown (arrows) without play
•   Tighten 2x fastening bolt (6)
67.   Tighten 2x camshaft sprocket 50 Nm + 60°
•   Counterhold with open-end wrench against the hexagon of the camshafts
68.   Remove all special tools: KM-952 , EN-953 , EN-49977-200 , EN-49978
Object Number: 13408826 Size: DEFAULT


69.   Timing, Check
•   Turn crankshaft (720°)
•   Insert KM-952
•   Insert KM-953-A
•   Attach EN-49978
70.   Repeat adjustment procedure if necessary
71.   Remove locking tool
•   KM-952 , KM-953-A , EN-49978
72.   Insert crankshaft sealing plug and tighten 50 Nm
Note:   Use new seal ring
73.   Attach coolant pump together with thermostat housing
•   Insert new gasket
•   Insert 9x bolt 8 Nm
Note:   Note different bolt lengths
74.   Attach coolant pump belt pulley
•   Insert 3x bolt and tighten 22 Nm
Note:   Counterhold with open-end wrench on flange
75.   Rotate engine on engine overhaul stand through 180°
76.   Attach oil baffle plate
•   Tighten 6x bolt 8 Nm
Object Number: 13408815 Size: DEFAULT

77.   67. Install oil pan
•   Apply sealant (dimension I = 2 mm)
Note:   Oil pan installation must take place within 10 minutes
– Inner oil pan edge
– Timing case groove
– For the bolt hole shown
•   Rotate 2x EN-49980 (1) into the positions shown
Important:   When positioning the oil pan, it is necessary to ensure that the sealing bead is not wiped away.
•   Carefully apply the oil pan
Note:   Pass EN-49980 through corresponding bolt holes
•   Insert 4x bolt, offset diagonally
•   Remove EN-49980
•   Screw in 12 bolts
•   Adjust oil pan with rubber mallet and straightedge
Note:   Straightedge must rest on the oil pan and cylinder block without play
•   Tighten 16x bolt 10 Nm

78.   Rotate engine on engine overhaul stand through 180°
79.   Attach cylinder head cover (1)
•   Replace gasket (2), seal rings
•   Apply sealant (dimension I = 2 mm)
Note:   Complete assembly work within 10 minutes
•   Tighten 17x bolts 8 Nm
•   Attach engine vent hose
– Fasten clamp
80.   Attach ignition module
•   Tighten 2x bolt 8 Nm
Object Number: 2410387 Size: DEFAULT


81.   Install EGR valve
Note:   Use new seal
•   Tighten 4x bolt 8 Nm
82.   Attach coolant hoses
•   to coolant pump
– Fasten clamp
•   to exhaust gas recirculation valve
– Fasten clamp
83.   Attach intake manifold
•   Insert 3x new gasket
•   Tighten 5 bolts 10 Nm
•   Attach EGR pipe to EGR valve
Note:   Use new seal
– Tighten 2x bolt 8 Nm
•   Attach engine vent hose to cylinder head cover
– Fasten clamp
84.   Install exhaust manifold
•   Insert new gasket
•   Screw 7 new nuts on
•   Attach 2x bolt to catalytic converter bracket
•   Tighten 7x exhaust manifold nut 22 Nm
•   Tighten 2x catalytic converter bracket bolt 10 Nm
85.   Install heat shield
•   Screw in 2x bolts
•   Clip in oxygen sensor mixture regulator wiring harness plug
86.   Install dipstick guide tube
•   Tighten bolt 8 Nm
•   Insert oil dipstick
87.   Fasten heat shield
•   Tighten 2x bolt 8 Nm
88.   Attach engine management wiring harness
•   Lay wiring harness
•   Connect 11x wiring harness plugs
•   Attach earth cable, engine control unit
– Tighten nut
•   Clip in wiring trough
•   Attach wiring harness
•   Attach fuel rail cover
– Tighten 2x bolts
89.   Fit starter
•   Tighten 2x bolt 25 Nm
90.   Install alternator
•   Tighten 2x screwed joint 35 Nm
91.   Attach engine wiring harness
•   Attach alternator wiring harness
– Tighten 2x nuts
•   Fasten starter wiring harness
– Tighten 2x nuts
92.   Attach ribbed V-belt tensioner -
•   Tighten bolt (M8) 20 Nm
•   Tighten bolt (M10) 55 Nm
93.   Insert ribbed V-belt
Note:   Ensure correct running direction and installation position
•   Release ribbed V-belt tensioner
•   Remove KM-955-2
94.   Attach engine bracket right
•   Tighten 2x bolt 60 Nm
95.   Top up engine oil.
•   Observe specified engine oil quantity
96.   Detach engine from engine overhaul stand
•   Attach KM-2358 to 3x engine transport shackle
•   Hitch engine up to workshop crane.
•   Lower engine onto wooden pallet
•   Detach KM-2358 from 3x engine transport shackle
97.   Fit flywheel
•   Clean 6x thread in crankshaft
•   Tighten 6x new bolt 35 Nm +60 °
– Lock with KM-652
98.   Attach thrust plate and clutch disk LUREF_1.gif
99.   Attach manual transmission to engine LUREF_1.gif
100.   Install engine

Replace air cleaner housing > < Manual transmission from engine, remove and install