How to Remove and Install the Engine Opel Corsa D

Warning: When working on the Common Rail system, wait for one minute after switching off the engine. The system reduces the pressure automatically.

Important: When working on the fuel system, pay strict attention to cleanliness as even the smallest particle of dirt may lead to malfunctions in engine operation or the fuel system. Seal opened fuel connections with suitable closure plugs 1) . Closure plugs are intended for single use.

Remove

1. 1. Open bonnet
2. 2. Secure radiator from above
3. 3. Detach earth cable (1) from earth terminal • Unscrew bolt

4. 4. Remove battery tray
5. 5. Release engine compartment electronics module • Unclip lug (1)

6. 6. Remove engine compartment electronics module (1) • Rotate the fuse box clockwise and release

Important. Cooling system is under pressure. Cautiously open coolant expansion tank closure cap

7. 7. Unscrew coolant expansion tank closure cap
8. 8. Undo 2x front wheels • Slacken 8x bolt
9. 9. Raise vehicle by half its height
10. 10. Detach 2 front wheels • Unscrew 8x bolts
11. 11. Remove front part of the inner left wing protective panelling • Remove 3x body-bound rivets (1) • Unscrew 2x bolts (2)

12. 12. Remove front part of the inner right wing protective panelling • Unscrew 2x bolts • Remove 3x body-bound rivets
13. 13. Raise vehicle by half its height
14. 14. Drain coolant • Place collecting pan underneath. • Push on suitable hose (2) • Open drain cock (1) in the direction of the arrow • Collect coolant • Close drain cock

15. 15. Remove crossmember (1) • Unscrew 2x bolts (2)

Note. Observe installation direction -- the marking "LH" is located on the left side seen in the direction of travel.

16. 16. Detach front exhaust pipe
17. 17. Expose wiring harness temperature sensor (3) • Separate retaining clip (1) from front axle body • Separate 3x cable ties (4) from hose, differential pressure line (2)
18. 18. Detach hose, differential pressure line, from pipe, differential pressure line • Release clamp

19. 19. Disconnect compressor wiring harness plug (1)

Note. For vehicles with climate control system

20. 20. Unclip wiring harness compressor from bracket (2)

Note. For vehicles with climate control system

21. 21. Detach charge air hose, intercooler to turbocharger (3) • Release clamp • Detach from radiator crossbrace – Unscrew 2x bolt (arrow)

22. 22. Detach thermostat housing coolant hose (1) from radiator • Disconnect quick-release fitting
23. 23. Detach charge air hose, intake manifold to intercooler (2) • Release clamp (3)

24. 24. Detach radiator crossbrace • Detach 2x bracket clamp (1) and (3) – Unscrew 2x nuts • Unscrew 3x bolt (4), lower front panelling • Unscrew 2x bolts (2) crossbrace
25. 25. Separate coupling line (1) • Release quick-release fitting

26. 26. Detach ribbed V-belt
27. 27. Detach compressor (1) from compressor support • Unscrew 3x bolts (2) • Fasten the compressor to the chassis using wire

28. 28. Detach selector linkage • Detach fastening clamp (2) • Undo bolt (1)

Note. On vehicles with F17+ transmission

29. 29. Lower vehicle by half its height
30. 30. Release 2x axle shaft • Attach KM-6610 (1) in conjunction with KM-956-1 (2) to wheel hub • Unscrew 2x nuts with DT-48489 – Bend open 2 stakes

Note. Use holes marked "4"

31. 31. Loosen 2 tie rods • Attach 2 CH-47658 (1) to tie rod (3) – Centre using hexagon socket (5) – Use suitable sleeve (4) – Tighten spindle (2) – Slacken 2x nut • Detach 2 CH-47658 from tie rod

32. 32. Detach 2 tie rods • Press off 2 tie rods (1) using 161-B in conjunction with KM-161-2 (2)

33. 33. Loosen 2 axle knuckles (1) • Remove 2 bolted connections (2) • Spread steering knuckle with KM-915 (2)

Note. Then remove tool KM-915 (2)

34. 34. Press out 2 axle shafts using KM-6282 (1)

35. 35. Lower vehicle by half its height

36. 36. Detach 2 gearshift cables (1) from transmission • Detach 2x gearshift cable from shift linkage lever • Detach 2 shift cables from retainer

Note. On vehicles with M20-6 transmission

37. 37. Separate wiring harness plug from MTA control unit

Note. On vehicles with MTA transmission

38. 38. Remove engine cover
39. 39. Remove air cleaner housing with air intake pipe
40. 40. Detach wiring harness bracket (2) battery support • Unscrew nut (1) • Unclip 2 wiring harnesses (3)

41. 41. Detach wiring harness engine control unit (1) from bulkhead • Detach 2x cable ties • Disconnect wiring harness plug (2) – Unlatch fuse • Disconnect wiring harness connector (3) – Unlatch fuse

42. 42. Detach fuel supply line (1) from fuel filter • Undo quick-release fitting (5) with KM-796-A – Seal fuel line with KM-807 • Unclip from bracket (2)
43. 43. Detach fuel return line (3) from front fuel return line • Undo quick-release fitting (4) with KM-796-A – Seal fuel line with KM-6015 • Unclip from bracket (2)

44. 44. Remove brake force amplifier vacuum line (1) • Disconnect quick-release fitting • Lay brake servo vacuum line aside

45. 45. Detach reduced pressure control valve (1) • Unclip 2x wiring harness from bracket (2) • Unscrew bolt (3)

Important. Apply colour marks for assignment

46. 46. Detach 2 heating hoses (1) from the heating element • Unlatch 2 quick-release fittings (2) using a screwdriver

47. 47. Detach coolant return hose (1) from coolant expansion tank • Release clamp

48. 48. Set CH-48373-2 onto right motor damping block • Unfold support (1)

49. 49. Set CH-48373-3 onto left motor damping block • Unfold support (1)
50. 50. Raise vehicle by its full height
51. 51. Attach adapter (1) to transmission For F17 transmission, use adapter CH-48373-4 For M20 transmission, use adapter CH-48373-6 • Tighten 2 bolts (2)

52. 52. Place KM-904 (2) and CH-48373 (3) onto hydraulic jack (4) • Attach 2 retaining pins (1) – Attach 2 cotter pins • Attach CH-48373-11 (5) – Tighten 2x bolts • Place probes (arrows) downward – Detach 2 cotter pins

53. 53. Support the engine and transmission with the hydraulic lift, CH-48373 and CH-48373-11 • Fasten CH-48373-2 (1) and CH-48373-3 (1) to CH-48373 – Tighten 4x bolted connections (arrows) • Screw support (2) upward until it makes light contact with the rear reaction member bracket • Screw support (3) up until it is pressing gently against CH-48373-4 or CH-48373-6 • Screw support (4) upward until it seats with light pressure in the intended hole in the cylinder block
54. 54. Remove rear reaction member (1) • Unscrew 2 bolts (2) and (3)

55. 55. Disconnect CH-48373 from KM-904 • Remove 2 cotter pins
56. 56. Extend hydraulic jack with KM-904
57. 57. Lower vehicle by its full height
58. 58. Detach right-hand engine damping block (1) from engine damping block support • Unscrew 3x bolts (2)

59. 59. Detach left engine damping block (1) from engine damping block support • Unscrew 3x bolts (2)

60. 60. Raise vehicle by its full height
61. 61. Attach hydraulic jack with CH-48373 • Connect CH-48373 with KM-904 – Attach 2 cotter pins
62. 62. Detach CH-48373-2 and CH-48373-3 from CH-48373 • Remove 4 bolted connections • Unfold 2 supports from CH-48373-2 and CH-48373-3
63. 63. Extend front axle body with engine and transmission carefully down out of the engine compartment

Note. Use a second person

Install

64. 64. Carefully bring engine and transmission upwards into engine compartment.

Note. Use a second person

65. 65. Attach CH-48373-2 and CH-48373-3 to KM-282-0 in 2 places • Tighten 4 bolted connections
66. 66. Disconnect CH-48373 from KM-904 • Remove 2 cotter pins
67. 67. Extend hydraulic jack with KM-904
68. 68. Lower vehicle by its full height
69. 69. Attach left engine damping block • Tighten 3 new bolts 80 Nm + 45°

Note. Use new bolts!

70. 70. Attach engine damping block, right hand side • Tighten 3 new bolts 80 Nm + 45°

Note. Use new bolts!

71. 71. Raise vehicle by its full height
72. 72. Detach CH-48373 • Screw 3 supports down • Retract hydraulic jack with KM-904 • Detach CH-48373-2 and CH-48373-3 from CH-48373 – Detach 4 bolted connections – Unfold supports
73. 73. Install rear reaction member • Tighten 2x new bolt 80 Nm + 45°

Note. Use new bolts!

74. 74. Detach CH-48373-4 and CH-48373-6 from transmission • Unscrew 2x bolts
75. 75. Lower vehicle by its full height
76. 76. Remove 2x supports CH-48373-2 and CH-48373-3
77. 77. Attach coolant hose to coolant expansion tank • Fasten clamp
78. 78. Attach coolant feed and return hoses to the heating element • Connect 2 quick release fitting

Note. Note the assignment.

79. 79. Attach reduced pressure control valve • Tighten bolt • Clip wiring harness into bracket in 2 places
80. 80. Attach vacuum line brake servo • Connect quick release fitting
81. 81. Attach fuel return line to front fuel return line • Connect quick release fitting – Remove sealing plug KM-6015 • Clip into bracket

Note. Quick-release coupling must audibly engage.

82. 82. Attach fuel supply line to fuel filter • Connect quick release fitting – Remove sealing plug KM-807 • Clip into bracket

Note. Quick-release coupling must audibly engage.

83. 83. Attach wiring harness engine control unit to bulkhead • Connect 2x wiring harness plugs – Lock 2x fuses • Connect 2 cable ties
84. 84. Attach 2 shift cables (2) to transmission • Suspend 2x shift cable in counterhold – Press 2x lock ring (1) towards back • Attach 2x shift cable to shift linkage lever

Note. On vehicles with M20-6 transmission.

85. 85. Connect wiring harness plug MTA transmission control unit

Note. On vehicles with M20-6 MTA transmission

86. 86. Attach wiring harness bracket battery support • Tighten nut • Clip in 2x wiring harnesses
87. 87. Attach fuse box to chassis • Insert into bracket and rotate anti-clockwise – Lug must latch
88. 88. Install battery holder
89. 89. Install air cleaner housing with air intake pipe
90. 90. Attach engine cover
91. 91. Lower vehicle by half its height
92. 92. Attach 2 axle shafts • Use new nuts • Screw in 2x nuts
93. 93. Attach 2x guide joint • Use new bolted connections • Tighten 2 bolted connections 60 Nm
94. 94. Attach 2 tie rod ball joints • Use new nuts • Tighten 2 nuts 35 Nm
95. 95. Secure 2x axle shaft • Counterhold with KM-6610 in conjunction with KM-956-1 on the wheel hub • Tighten 2x new nut 70 Nm + 60°+ 5° • Secure 2 nuts by hammer blows in the notch
96. 96. Raise vehicle by half its height
97. 97. Attach selector linkage • Tighten bolt • Attach fastening clamp

Note. On vehicles with F17+ transmission

98. 98. In the version with air conditioning: attach compressor • Loosen wire • Tighten 3 bolts 22 Nm
99. 99. In the version with air conditioning: connect compressor wiring harness plug
100. 100. In the version with air conditioning: position the ribbed V-belt
101. 101. Connect coupling line • Lock quick-release fitting
102. 102. Attach radiator crossbrace • Tighten 2x crossbrace • Tighten 3x bolt, lower front panelling • Attach 2x bracket clamp – Tighten 2x bolts
103. 103. Attach charge air hose, intake manifold to intercooler • Fasten clamp
104. 104. Detach thermostat housing coolant hose from radiator • Connect quick release fitting
105. 105. Attach charge air hose, intercooler to turbocharger • Attach to radiator crossbrace – Tighten 2x bolts • Fasten clamp
106. 106. On variants with air conditioning: clip wiring harness compressor into bracket
107. 107. Attach hose, differential pressure line, to pipe, differential pressure line • Fasten clamp
108. 108. Lay wiring harness, temperature sensor • Connect with 3x cable ties to hose, differential pressure line • Clip retaining clip to front axle
109. 109. Install front exhaust pipe
110. 110. Attach crossmember to front axle body • Tighten 2x bolt 60 Nm

Important. The mark "LH" must be on the left as seen in the direction of travel

111. 111. Raise vehicle by half its height
112. 112. Install front part of the inner left wing protective panelling • Tighten 2x bolts • Install 3 expanding rivets
113. 113. Install front part of the inner right wing protective panelling • Tighten 2x bolts • Install 3 expanding rivets
114. 114. Attach 2 front wheels • Screw in 8 bolts
115. 115. Lower vehicle by half its height
116. 116. Fasten 2 front wheels • Tighten 8x bolts 110 Nm
117. 117. Remove fuse, radiator
118. 118. Fill and bleed cooling system
119. 119. Connect battery • Attach earth connection to earth terminal – Tighten nut • Attach earth cable to earth terminal – Tighten bolt
120. 120. Attach earth cable to earth terminal • Tighten bolt
121. 121. Adjust transmission remote switch On F17+ transmission For M20-6 transmission
122. 122. Program volatile memories
123. 123. Close bonnet

1

) ; protective caps are available in the parts catalogue