How to Remove and Install the Engine Opel Corsa D

Warning: Exiting fuel - observe safety regulations and national legislation.

Note. The relevant fuel pressure is relieved only very slowly once the ignition is switched off. Before opening this pressurised part of the fuel system, therefore, the fuel pressure must be reduced via the test connection by means of a pressure gauge KM-J-34730-91 . Catch emerging fuel in a suitable container.

Remove

1. 1. Open bonnet
2. 2. Detach earth line from earth terminal connection • Unscrew bolt
3. 3. Detach positive line from positive terminal connection • Unscrew bolt
4. 4. Disconnect battery • Detach ground connection from ground terminal – Undo nut
5. 5. Remove air cleaner housing with air intake hose • Disconnect wiring harness plug of air-flow meter • Remove air intake hose from turbocharger – Release clamp • Detach resonator • Detach drainage line from air cleaner housing • Remove air cleaner housing
6. 6. Undo 2x front wheels • Undo 10 bolts
7. 7. Raise vehicle by half its height
8. 8. Detach 2x front wheels • Unscrew 10x bolt
9. 9. Remove front part of the inner right wing protective panelling • Remove 3x body-bound rivets (1)

10. 10. Remove front part of the inner left wing protective panelling • Unscrew 2x bolts • Remove 3x body-bound rivets
11. 11. Remove front panelling
12. 12. Drain coolant • Place collecting basin underneath. • Push hose (2) onto connection • Open drain bolt (1) • Collect coolant • Close drain bolt

13. 13. Raise vehicle by half its height
14. 14. Remove front axle crossmember (1) • Unscrew 2x bolts (2)

Note. Note correct installation direction

15. 15. Remove right engine splash guard • Unscrew 4x bolts
16. 16. Detach wiring harness for catalytic converter control oxygen sensor • Disconnect wiring harness connector. • Unclip 5x wiring harness plugs • Remove cable from cable bracket for power steering assistance
17. 17. Detach front exhaust pipe (1) from catalytic converter • Unscrew 3x nuts (2) • Remove seal

Important. Secure flex pipe against drooping

18. 18. Disconnect rear silencer from front exhaust pipe • Release clamping collar – Undo nut
19. 19. Remove front exhaust pipe • Remove rear damper ring • Detach damper ring bracket – Unscrew 2x bolts • Remove front exhaust pipe

Note. Use a second person.

20. 20. Loosen 2 tie rods (3) • Attach CH-47658 (1) in the correct position • Unscrew nut • Remove CH-47658 – Loosen on hexagon (2)

Note. Centre using spanner socket (5). Use suitable sleeve (4). Sleeve must lie flat on tie rod lever.

21. 21. Push off 2 tie rod ball-and-socket joints using KM-161-B (1) in conjunction with hook KM-161-2
22. 22. Loosen 2 steering knuckles • Remove 2 screw connections • Spread steering knuckle with KM-915 (2) • Pull guide joint (2) from steering knuckle

Note. Then remove tool KM-915 (2)

23. 23. Detach 2x stabiliser brace from spring strut • Unscrew 2x nuts
24. 24. Place collecting basin underneath.
25. 25. Remove 2x axle shaft from intermediate shaft and transmission • Catch escaping transmission fluid • Seal differential outlet with suitable object
26. 26. Detach 2 charge air hoses (1 and 2) from intercooler • Disconnect 2 quick-release fittings • Detach 2 hose clamps from radiator bracket – Unscrew 2 bolts (3 and 4)

27. 27. Detach lower radiator hose elbow (1) from radiator • Disconnect quick-release fitting (2)

28. 28. Detach upper radiator hose elbow from radiator • Undo quick-release fitting
29. 29. Detach coolant expansion tank (1) from front crossmember at top • Unscrew bolt (2)

30. 30. Detach condenser (1) from radiator • Unscrew 2 bolts (2 and 3) • Unclip condenser • Attach condenser to front crossmember at top with suitable object

31. 31. Detach cooling module wiring harness from front crossmember at top • Disconnect wiring harness plug (1) • Unclip 2x wiring harness plug from front crossmember • Detach earth connection – Unscrew nut

Note. Earth connection is on side member below coolant expansion tank.

32. 32. Detach coolant hose from coolant expansion tank • Release clamp
33. 33. Remove cooling module • Detach lower cross brace (1) – Unscrew 2x bolts (2) • Lower cooling module down and out

34. 34. Remove ribbed V-belt from compressor • Tension the ribbed V-belt tensioner using KM-6635 in the direction of the arrow • Insert KM-955-2 • Relieve tension on ribbed V-belt tensioner
35. 35. Disconnect compressor wiring harness plug
36. 36. Detach compressor from engine block and timing case • Unscrew 3x bolts • Fasten the compressor to the chassis using wire
37. 37. Lower vehicle by its full height
38. 38. Detach fuse holder from battery • Open cover • Detach bracket from positive terminal – Unscrew bolt (1) • Unclip fuse holder (arrows) and place aside

39. 39. Remove battery • Loosen battery bracket (1) – Loosen bolt (2)

40. 40. Remove battery tray
41. 41. Detach wiring harness bracket (2) • Unscrew nut (1) • Unclip 2 wiring harnesses (3)

42. 42. Remove fuse box (1) • Rotate the fuse box clockwise and release

43. 43. Remove wiring harness from engine control unit • Remove wiring harness plug (1) from engine control unit • Separate wiring harness plug for injectors (2) • Detach 2x cable ties (3)

44. 44. Disconnect reversing light switch wiring harness plug (3)
45. 45. Detach clutch pressure line (1) from connection piece • Release clamp (2) with screwdriver in direction of arrow and remove • Bend clip together a little and insert back into connecting piece • Seal line and connector with suitable object

46. 46. Detach engine wiring harness • Unclip wiring harnesses in 4 places
47. 47. Remove fuel supply line (2) • Undo quick-release fitting with KM-796-A • Seal fuel supply line
48. 48. Detach fuel return line (1) • Undo quick-release fitting with KM-796-A • Seal fuel supply line

49. 49. Separate line for fuel vapour separator • Undo quick-release fitting (1)
50. 50. Detach brake servo vacuum line from intake manifold • Disconnect quick-release fitting (2)

51. 51. Detach 2x shift cables from gearbox • Detach 2x shift cables (2) from selector unit with KM-6042 • Detach 2 shift cables (1) from transmission – Detach 2x quick-release fitting

Important. Apply colour marks for assignment.

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

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

54. 54. Set CH-48373-3 onto left motor damping block • Unfold support (1)
55. 55. Raise vehicle by its full height
56. 56. Unfold 2x support from CH-48373-3
57. 57. Attach CH-48373-7 (1) to transmission • Tighten 2 bolts (2)

58. 58. Place KM-904 (2) and CH-48373 (3) onto hydraulic jack (4) • Attach 2 retaining pins (1) – Attach 2 cotter pins • Attach CH-48373-10 (5) – Tighten 2x bolts • Place probes (arrows) downward – Detach 2 cotter pins

59. 59. 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) upward until it makes light contact with CH-48373-7 • Screw support (4) upward until it seats with light pressure in the intended hole in the cylinder block
60. 60. Remove rear reaction member (1) • Unscrew 2 bolts (2) and (3)

61. 61. Disconnect CH-48373 from KM-904 • Remove 2 cotter pins
62. 62. Extend hydraulic jack with KM-904
63. 63. Lower vehicle by its full height
64. 64. Detach right engine damping block (1) from engine damping block bracket • Unscrew 2x bolts (2)

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

66. 66. Raise vehicle by its full height
67. 67. Attach hydraulic jack with CH-48373 • Connect CH-48373 with KM-904 – Attach 2 cotter pins
68. 68. Detach 2 KM-280 from KM-282-0 • Remove 4 bolted connections • Fold out 2 supports from KM-280
69. 69. Extend front axle body with engine and transmission carefully down out of the engine compartment

Note. Use a second person

Install

Important. Carefully move front axle body with engine and transmission upward into engine compartment. Do not damage attaching parts.

70. 70. Install drive unit

Note. A second mechanic is necessary.

71. 71. Bolt 2 supports CH-48373-2 and CH-48373-3 to the frame • Fold in 2 supports • Tighten 4 bolted connections
72. 72. Remove hydraulic jack
73. 73. Lower vehicle by its full height
74. 74. Attach left engine damping block • Tighten 2x new bolt 80 Nm + 45°
75. 75. Attach engine damping block, right hand side • Tighten 2x new bolt 80 Nm + 45°
76. 76. Raise vehicle by its full height
77. 77. Install rear reaction member • Tighten 2x new bolt 80 Nm + 45°
78. 78. Remove frame CH-48373 • Screw 3 supports down • Insert hydraulic jack – Attach KM-904 to CH-48373 – Insert 2 retaining pins • Detach CH-48373-2 and CH-48373-3 from CH-48373 – Remove 4 bolted connections – Unfold supports • Extend hydraulic jack with KM-904 and CH-48373
79. 79. Detach CH-48373-7 from transmission • Unscrew 2x bolts
80. 80. Lower vehicle by its full height
81. 81. Remove support CH-48373-2 and CH-48373-3 upward
82. 82. Attach 2x axle shaft to intermediate shaft and transmission
83. 83. Attach 2x stabiliser brace to spring strut • Tighten 2x new nuts
84. 84. Attach guide joint • Use new bolted connections • Tighten 2 bolted connections 60 Nm
85. 85. Attach 2 tie rod ball joints • Use new nuts • Tighten 2 nuts 35 Nm
86. 86. Fit compressor • Loosen wire • Tighten 3 bolts 22 Nm
87. 87. Connect compressor wiring harness plug
88. 88. Install ribbed V-belt • Tension ribbed V-belt tensioner in direction of arrow using KM-6635 • Insert KM-955-2 (1) • Release ribbed V-belt tensioner
89. 89. Install cooling module • Insert cooling module • Insert lower cross brace – Tighten 2x bolts

Note. Use a second person, ensure correct seat of guide bearing at top.

90. 90. Attach charge air hose to intercooler • Lock 2x quick-release fitting • Tighten 2x bolts
91. 91. Attach lower radiator hose to radiator • Connect quick-release fitting
92. 92. Install front exhaust pipe • Attach rear damper ring • Attach damper ring bracket – Tighten 2x bolts

Note. Use a second person.

93. 93. Attach front exhaust pipe to catalytic converter • Use new seal • Tighten 3x nut 20 Nm
94. 94. Attach rear silencer to front exhaust pipe • Fasten clamp – Tighten nut
95. 95. Attach wiring harness for catalytic converter control oxygen sensor • Route cables • Clip in 5x wiring harness plugs • Insert cables in cable bracket for power steering assistance • Fix wiring harness plug
96. 96. Install cross-strut • Tighten 2x bolts

Note. Note correct installation direction

97. 97. Install right engine splash guard • Tighten 4x bolts
98. 98. Lower vehicle by its full height
99. 99. Attach condenser to radiator • Detach condenser from front crossmember at top • Clip in condenser • Tighten 2x bolts
100. 100. Attach upper radiator hose elbow to radiator • Connect quick-release fitting
101. 101. Attach cooling module wiring harness • Fix wiring harness plug • Clip in 2x wiring harness plug • Attach earth connection – Tighten nut
102. 102. Attach coolant hose to coolant expansion tank. • Fasten clamp
103. 103. Attach coolant return hose to coolant expansion tank • Attach clamp
104. 104. Attach coolant feed and return hoses to the heating element • Connect 2x quick-release fittings
105. 105. Attach clutch pressure line to connection piece • Retaining clamp must engage
106. 106. Attach 2x shift cable • Clip 2x on to bracket • Clip 2x shift cables to shifter
107. 107. Connect line for fuel vapour separator
108. 108. Attach brake servo vacuum line to intake manifold • Connect quick-release fitting
109. 109. Attach fuel supply lines to fuel rail • Remove 2 KM-807 • Connect 2x quick-release fittings • Unclip 2x from bracket
110. 110. Attach engine wiring harness • Attach wiring harness plug to engine control unit • Connect wiring harness plug for injectors • Connect wiring harness plug for reversing light switch • Clip wiring harness in 4 places
111. 111. Attach battery tray wiring harness bracket • Tighten nut
112. 112. Attach fuse box to chassis • Attach 3x wiring harness plug • Insert into bracket and rotate anti-clockwise
113. 113. Install battery holder • Tighten 3x bolts • Clip in 5x wiring harnesses
114. 114. Install battery • Install battery bracket – Tighten bolt • Attach positive connection to positive terminal – Attach positive cable to positive terminal – Tighten bolt • Attach fuse carrier to positive terminal – Tighten bolt • Close positive terminal cover
115. 115. Attach earth line to earth terminal connection • Tighten bolt
116. 116. Attach positive line to positive terminal connection • Tighten bolt
117. 117. Connect battery
118. 118. Install air cleaner housing with air intake hose • Attach resonator • Attach drainage line for air cleaner housing • Fasten clamp • Connect mass air flow meter wiring harness plug
119. 119. Raise vehicle by half its height
120. 120. Install front part of the inner left wing protective panelling • Tighten 2x bolts • Install 3 expanding rivets
121. 121. Install front part of the inner right wing protective panelling • Tighten 2x bolts • Install 3 expanding rivets
122. 122. Attach 2x front wheel • Screw in 10x bolt
123. 123. Lower vehicle by half its height
124. 124. Secure 2x front wheel • Tighten 10x bolt 110 Nm
125. 125. Attach front panelling
126. 126. Bleed hydraulic clutch actuation
127. 127. Fill and bleed cooling system
128. 128. Program volatile memories
129. 129. Close bonnet