Remove and Install Manual Transmission on Engine (Engine Out) Opel Corsa D

Remove

1. 1. Detach charge air hose (1) from throttle valve housing (3) • Release clamp (2)

2. 2. Detach lower radiator hose elbow (1) from thermostat housing (2) • Release clamp (3)

3. 3. Detach upper radiator hose elbow (3) from coolant pump (1) • Release clamp (3)

4. 4. Detach charge air hose (3) from intercooler (1) • Release clamp (2)

5. 5. Detach coolant return hose (1) to coolant expansion tank. • Release clamp (2)

6. 6. Lever cooling module from front axle body

Note. Use a second person

7. 7. Detach air conditioning lines (1) from compressor • Unscrew 2x bolts (2)

8. 8. Place collecting basin underneath.
9. 9. Detach exhaust manifold heat shield • Unscrew 3x bolts (1)

10. 10. Detach turbocharger intake pipe (5) • Detach wiring harness – Undo cable tie – Disconnect charge-air control wiring harness plug (3) – Disconnect compressor wiring harness plug • Detach cylinder head cover vent line (1) – Undo quick-release fitting • Pull off vacuum control for recirculating air (4) • Remove vacuum pipe from turbocharger (2) – Release clamp • Unscrew 2x bolts (6)

11. 11. Remove oil dipstick guide tube (1) • Detach oil return hose from turbocharger – Unscrew 2x bolts (2) • Withdraw oil dipstick guide tube from oil pan (3)

12. 12. Remove exhaust manifold heat shield
13. 13. Remove extra catalytic converter (3) with oxygen sensor mixture control (2) and heat shield • Disconnect wiring harness plug of oxygen sensor mixture control (1) • Release clamp (4)

14. 14. Remove coolant supply line to turbocharger (1) • Release clamp (3) • Unscrew bolt (2) • Unscrew banjo bolt (4)

15. 15. Detach turbocharger coolant return line (1) from thermostat housing (3) • Undo quick-release fitting – Pull off retaining ring (2)

16. 16. Detach oil supply hose from turbocharger (2) • Unscrew banjo bolt (1)

17. 17. Detach exhaust manifold with turbocharger from cylinder head • Unscrew 9x nuts (arrows)

18. 18. Detach turbocharger oil feed line (1) • Twist turbocharger oil feed line forward by approx. 90° • Pull turbocharger oil feed line out of oil filter housing in direction of arrow

19. 19. Detach coolant pipe (1) from thermostat housing • Unscrew 2x bolts (2) • Push coolant pipe into oil filter housing (3)

20. 20. Detach coolant pipe (1) from coolant pump • Unscrew 2x bolts (2) • Push coolant pipe into oil filter housing

21. 21. Remove oil filter housing (3) • Detach coolant pipe (1) and push into oil filter housing – Unscrew bolt (2) • Unscrew 4x bolts (4)

22. 22. Detach ribbed V-belt (1) • Mark direction of rotation • Tighten ribbed V-belt tensioner (2) in direction of arrow and fix with KM-6130 (3) – Remove ribbed-V-belt

23. 23. Remove compressor • Disconnect compressor wiring harness plug • Unscrew 3x bolts
24. 24. Attach KM-412-31 (1)

25. 25. Detach intermediate shaft (1) with support (2) from engine/gearbox • Unscrew 3x bolts (3) • Pull intermediate shaft out of gearbox

26. 26. Attach KM-412-31 (1)

27. 27. Hitch engine up to workshop crane. • Attach suspension cable to engine transport shackle
28. 28. Detach front engine damping block • 1 bolt (1)
29. 29. Detach rear engine damping block • 1 bolt (2)

30. 30. Lever engine from front axle body
31. 31. Attach engine to engine overhaul stand KM-412 • Detach suspension cable from engine transport shackle

Note. 2 people

32. 32. Remove starter
33. 33. Detach transmission from engine • Unscrew 8x bolts

Note. One bolt remains screwed in for safety

34. 34. Remove gearbox • Attach suspension cable • Hitch gearbox up to workshop crane. • Unscrew bolt

Note. Ensure that the ancillaries and wiring harnesses are not damaged

Install

35. 35. Install gearbox • Hitch gearbox up to workshop crane. • Attach transmission to engine • Screw in bolt • Remove workshop crane • Remove suspension cable
36. 36. Attach transmission to engine • Tighten 9x bolts – 40 Nm (M10) – 60 Nm (M12)
37. 37. Install starter
38. 38. Hitch engine up to workshop crane. • Attach suspension cable to engine transport shackle
39. 39. Detach engine from engine overhaul stand KM-412 • Carefully lift engine

Note. Use a second person

40. 40. Attach engine damping block rear to front axle body • Attach bolted connection – Tighten new nut 55 Nm
41. 41. Attach front engine damping block to front axle body • Attach bolted connection – Tighten new nut 55 Nm
42. 42. Detach KM-412-31-1 and KM-412-31-2 from cylinder block • Unscrew 6x bolts
43. 43. Attach intermediate shaft with support to engine/gearbox • Tighten 3x bolt 55 Nm
44. 44. Fit compressor • Tighten 3x bolt
45. 45. Install ribbed V-belt
46. 46. Install oil filter housing • Tighten 4x bolt 25 Nm • Insert 3x new gaskets • O-rings with white silicone grease
47. 47. Attach coolant pipe to pump module • Pull coolant pipe from oil filter housing • Attach coolant pipe to oil filter housing – Tighten bolt 25 Nm
48. 48. Attach coolant pipe to pump module • Pull coolant pipe from oil pump housing • Tighten 2x bolts
49. 49. Attach coolant pipe oil filter housing to thermostat housing • Replace 2x seals • Push into oil filter housing • Attach to thermostat housing – Tighten 2x bolts
50. 50. Install turbocharger oil feed line
51. 51. Attach exhaust manifold with turbocharger to cylinder head • Tighten 9x nut 20 Nm

Note. Use new seal

52. 52. Attach turbocharger oil feed line to turbocharger • Tighten banjo bolt 30 Nm
53. 53. Attach turbocharger coolant return line to thermostat housing • Connect quick-release fitting – Attach retaining ring
54. 54. Install coolant supply line to turbocharger • Attach clamp • Tighten bolt • Tighten banjo bolt 35 Nm
55. 55. Install extra catalytic converter with oxygen sensor mixture control • Tighten clamp 7 Nm • Connect wiring harness plug of catalytic converter monitor oxygen sensor
56. 56. Insert exhaust manifold heat shield
57. 57. Attach dipstick guide tube • Insert oil dipstick guide tube in oil pan • Tighten bolt • Attach turbocharger oil return hose – Attach clamp – Tighten 2x bolt 8 Nm
58. 58. Install turbocharger intake pipe • Tighten 2x bolts • Attach wiring harness – Attach cable tie – Connect charge-air control wiring harness plug – Connect compressor wiring harness plug • Attach cylinder head cover vent line – Connect quick-release fitting • Push on vacuum control for recirculating air • Attach vacuum line to turbocharger – Attach clamp
59. 59. Attach exhaust manifold heat shield • Tighten 2x bolt 8 Nm
60. 60. Attach air conditioning lines to compressor • Tighten 2x bolt 20 Nm
61. 61. Place cooling module on front axle body

Note. Use a second person

62. 62. Attach lower radiator hose elbow to thermostat housing • Attach clamp
63. 63. Attach coolant return hose to coolant expansion tank • Attach clamp
64. 64. Attach charge air hose to intercooler • Tighten clamp 3.5 Nm
65. 65. Attach upper radiator hose elbow to coolant pump • Attach clamp
66. 66. Attach charge air hose to throttle valve housing • Release clamp