vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Add-on Heater, Remove and Install > < Engine control unit, remove and install (with start/stop system)

Corsa D

Starter, remove and install (with start/stop system)

  Remove

1.   Open bonnet
2.   Remove battery
3.   Remove battery tray
4.   Remove gearbox neutral switch LUREF_1.gif
5.   Separate universal joint from shift rod
•   Press in locking spring (arrow) on hollow pin
•   Lever out hollow pin with KM-569-A
6.   Press adjustment pin (2) into adjustment bore
•   Twist shift rod to left (towards 3rd gear)
7.   Detach and remove selector cover (1) from gearbox
•   Unscrew 4x bolts
Note:   Cover opening in gearbox with a clean cloth.
•   Remove any gasket residue and clean sealing surfaces
Object Number: 2398561 Size: DEFAULT


8.   Remove starter at top on the transmission side
•   Unscrew bolt
9.   Raise vehicle by its full height
10.   Remove vacuum reservoir (2) with bracket
•   Detach 2x vacuum line
•   Unscrew 2x bolts (1)
Object Number: 23677001 Size: DEFAULT


11.   Remove starter (1)
•   Detach starter wiring harness (2)
– Unscrew 3x nut
•   Unscrew bolt
Object Number: 3446313 Size: DEFAULT


  Install

12.   Install starter
•   Screw in bolt
Note:   Do not tighten bolt completely yet!
13.   Lower vehicle by its full height
14.   Attach starter at top
•   Tighten bolt 25 Nm
15.   Raise vehicle by its full height
16.   Attach starter at bottom
•   Tighten bolt 25 Nm
•   Install starter wiring harness
– Tighten 3x nuts
17.   Install vacuum reservoir with bracket
•   Tighten 2x bolts
•   Attach 2x vacuum line
18.   Lower vehicle by its full height
19.   Attach selector housing cover
•   Measure play (I) between dowel pin (2) and 5th gear shift driver (1) with feeler gauge
•   Play must be minimum 0.3 mm and maximum 0.5 mm
Object Number: 2398562 Size: DEFAULT


20.   Install new gasket
•   Bond gasket to transmission housing with grease
21.   Position selector cover on gearbox
Note:   Ensure that the adjustment pin sits in the adjustment bore and locks the selector.
22.   Attach selector cover to gearbox
•   Tighten cover 15 Nm
•   Pull adjustment pin out of adjustment bore
23.   Push universal joint (2) into shift fork (3)
•   Coat new hollow pin with grease
•   Press hollow pin (1) in direction of arrow until locking spring engages
Object Number: 2398563 Size: DEFAULT


24.   Check transmission fluid level, correct if necessary LUREF_1.gif
25.   Check that gears can be selected easily
•   With vehicle stationary
•   With engine running
•   With clutch pressed
26.   Install gearbox neutral switch LUREF_1.gif
27.   Install battery holder
28.   Install battery
29.   Program volatile memories
30.   Close bonnet

Add-on Heater, Remove and Install > < Engine control unit, remove and install (with start/stop system)