2006-2011 Opel Corsa D Service & Repair Manual

VAUXHALL/OPEL CORSA Sept 2006 to 2010 (56 to 10 reg) Petrol & Diesel Owners Workshop Manual step-by-step maintenance and repair expert22 fl/ia http://rutracker.org The best selling car manuals in the world

VauxhalI/Opel Corsa Owners Workshop Manual John S. Mead Models covered (4886 - 304) Hatchback & Corsavan Petrol: 1.0 litre (998cc) 3-cylinder, 1.2 litre (1229cc) & 1.4 litre (1364cc) 4-cylinder Turbo-diesel: 1.3 litre (1248cc) CDTi Does NOT cover models with 1.6 litre petrol engine or 1.7 litre diesel engine, or Combo van ©Haynes Publishing 2010 KLMNO A book in the Haynes Owners Workshop Manual Series All rights reserved. No part of this book may be reproduced or Printed in the USA transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or Haynes Publishing retrieval system, without permission in writing from the copyright Sparkford, Yeovil, Somerset BA22 7JJ, England holder. ISBN 978 1 84425 886 4 Haynes North America, Inc 861 Lawrence Drive, Newbury Park, California 91320, USA British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library. Haynes Publishing Nordiska AB Box 1504, 751 45 UPPSALA, Sverfo*

Contents LIVING WITH YOUR VAUXHALL/OPEL CORSA Introduction to the Vauxhall/Opel Corsa Page 0*4 Safety first! Page 0*5 Roadside Repairs If your car won’t start Page 0*6 Jump starting Page 0*7 Wheel changing Page 0*8 Using the puncture repair kit Page 0*9 Identifying leaks Page 0*10 Towing Page 0*10 Weekly checks Introduction Page 0»11 Underbonnet check points Page 0*11 Engine oil level Page 0*12 Coolant level Page 0*12 Brake and clutch fluid level Page 0*13 Screen washer fluid level Page 0*13 Tyre condition and pressure Page 0*14 Wiper blades Page 0*15 Battery Page 0*15 Electrical systems Page 0*16 Lubricants and fluids Page 0*17 Tyre pressures Page 0*17 MAINTENANCE Routine Maintenance and Servicing Vauxhall/Opel Corsa petrol models Page 1A*1 Servicing specifications Page 1A»2 Maintenance schedule Page 1A«3 Maintenance procedures Page 1A*5 Vauxhall/Opel Corsa diesel models Page 1B-1 Servicing specifications Page 1B*2 Maintenance schedule Page 1B*3 Maintenance procedures Page 1B*5 Illegal Copying It is the policy of Haynes Publishing to actively protect its Copyrights and Trade Marks. Legal action will be taken against anyone who unlawfully copies the cover or contents of this Manual. This includes all forms o f unauthorised copying including digital, mechanical, and electronic in any form. Authorisation from Haynes Publishing will only be provided expressly and in writing. Illegal copying will also be reported to the appropriate statutory authorities. _____________________ expert22 nnn http://rutracker.org

Contents REPAIRS AND OVERHAUL Engine and Associated Systems Petrol engine in-car repair procedures Page 2A»1 Diesel engine in-car repair procedures Page 2B*1 Engine removal and overhaul procedures Page 2C*1 Cooling, heating and ventilation systems Page 3*1 Fuel and exhaust systems - petrol engines Page 4A«1 Fuel and exhaust systems - diesel engines Page 4B«1 Emissions control systems Page 4C*1 Starting and charging systems Page 5A»1 Ignition system - petrol engines Page 5B«1 Transmission Clutch Page 6*1 Manual transmission Page 7A»1 Automatic transmission Page 7B*1 Easytronic transmission Page 7 0 1 Driveshafts Page 8«1 Brakes and suspension Braking system Page 9»1 Suspension and steering Page 10*1 Body equipment Bodywork and fittings Page 11*1 Body electrical system Page 12*1 Wiring diagrams Page 12*17 REFERENCE Dimensions and weights Page REF»1 Fuel economy Page REF*2 Conversion factors Page REF»6 Buying spare parts Page REF»7 Vehicle identification Page REF»7 General repair procedures Page REF*8 Jacking and vehicle support Page REF«9 Disconnecting the battery Page REF«9 Tools and working facilities Page REF*10 MOT test checks Page REF*12 Fault finding Page REF»16 Index Page REF»24 expert2'2 fl/ia fTttp:77rutracker.org

o .4 Introduction The Vauxhall/Opel Corsa-D model was introduced in the UK in September 2006 as a replacement for the previous Corsa, the ‘C’ model. It is available in 3- and 5-door Hatch back, and 3-door Van versions with 1.0 litre, 1.2 litre and 1.4 litre petrol engines, and a 1.4 litre diesel engine. The engines are of the four-cylinder double overhead camshaft (DOHC) configuration, in-line type, with the exception of the 1.0 litre petrol engine which is a three-cylinder unit. The engines all have fuel injection and are fitted with a range of emission control systems. 1.6 litre petrol and 1.7 litre diesel engines are also available, but are not covered in this manual. According to engine type, the manual gearbox is of the five- or six-speed all synchromesh type, with a four-speed electronically-controlled automatic transmission optionally available on 1.4 litre petrol engine models. An ‘Easytronic’ manual/ automatic transmission is also available on both petrol and diesel engine models. All models have front-wheel-drive with fully-independent front suspension, and semi independent rear suspension with a torsion beam and trailing arms. A wide range of standard and optional equipment is available within the Corsa range to suit most tastes, including electric power steering, air conditioning, remote central locking, electric windows, electric sunroof, anti-lock braking system, electronic alarm system and supplemental restraint systems. For the home mechanic, the Corsa is a relatively straightforward vehicle to maintain, and most of the items requiring frequent attention are easily accessible. Your Vauxhall/ Opel Corsa manual The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs, it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components, so that their layout can be understood. Then the tasks are described and photographed in a clear step-by-step sequence. References to the ‘left’ or 'right' are in the sense of a person in the driver’s seat, facing forward. Project vehicles The main vehicle used in the preparation of this manual, and which appears in many ol the photographic sequences, was a Vauxhal Corsa Hatchback with a 1.3 litre diesel engine. Additional work was carried out on a Corsa Hatchback with a 1.4 litre petrol engine. Acknowledgements Certain illustrations are the copyright ol Vauxhall Motors Limited, and are used with their permission. Thanks are also due tc Draper Tools Limited, who provided some 01 the workshop tools, and to all those people at Sparkford who helped in the production ol this manual. We take great pride in the accuracv of information given in this manual, bul vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Safety First! 0.5 Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude. General hazards Scaiding • Don't remove the radiator or expansion lank cap while the engine is hot. • Engine oil, transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running. Burning • Beware of bums from the exhaust system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use. Crushing • When working under or near a raised vehicle, always supplement the jack with axle stands, or use drive-on ramps. Never venture under a car which is only supported by a jack. • Take care if loosening or tightening high- Uxque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground. Fire • Fuel Is highly flammable; fuel vapour is explosive. • Don't let fuel spill onto a hot engine. • Do not smoke or allow naked lights (including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (electrically or by use of tools). • Fuel vapour is heavier than air, so don't work on the fuel system with the vehicle over an Inspection pit. • Another cause of fire is an electrical overload or short-circuit. Take care when repairing or modifying the vehicle wiring. • Keep a fire extinguisher handy, of a type suitable for use on fuel and electrical fires. Electric shock • Ignition HT and Xenon headlight voltages can be dangerous, especially to people with heart problems or a pacemaker. Don’t ^ work on or near these systems with the engine running or the ignition switched on. • Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker. Fume or gas intoxication • Exhaust fumes are poisonous; they can contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine in a confined space such as a garage with the doors shut. • Fuel vapour is also poisonous, as are the vapours from some cleaning solvents and paint thinners. Poisonous or irritant substances • Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Don’t syphon them by mouth. If such a substance is swallowed or gets into the eyes, seek medical advice. • Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream if necessary. Change out of oil-soaked clothes and do not keep oily rags in your pocket. • Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame (including a cigarette). It can also cause skin burns on contact. Asbestos • Asbestos dust can cause cancer if inhaled or swallowed. Asbestos may be found in gaskets and in brake and clutch linings. When dealing with such components it is safest to assume that they contain asbestos. Special hazards Hydrofluoric acid • This extremely corrosive acid is formed when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses etc, are exposed to temperatures above 4000C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned. • When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use. The battery • Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care when topping-up or carrying the battery. • The hydrogen gas given off by the battery is highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads. Air bags • Air bags can cause injury if they go off accidentally. Take care when removing the steering wheel and trim panels. Special storage instructions may apply. Diesel injection equipment • Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes. A Warning: Never expose the hands, face or any other part of the body to injector spray; the fuel can penetrate the skin with potentially fatal results. Remember... DO • Do use eye protection when using power tools, and when working under the vehicle. • Do wear gloves or use barrier cream to protect your hands when necessary. • Do get someone to check periodically that all is well when working alone on the vehicle. • Do keep loose clothing and long hair well out of the way of moving mechanical parts. • Do remove rings, wristwatch etc, before working on the vehicle - especially the electrical system. • Do ensure that any lifting or jacking equipment has a safe working load rating adequate for the job. DON’T • Don’t attempt to lift a heavy component which may be beyond your capability - get assistance. • Don't rush to finish a job, or take unverified short cuts. • Don’t use ill-fitting tools which may slip and cause injury. • Don’t leave tools or parts lying around where someone can trip over them. Mop up oil and fuel spills at once. • Don’t allow children or pets to play in or near a vehicle being worked on.

o .6 Roadside repairs The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair information in the main chapters. If your car won’t start and the starter motor doesn’t turn □ If it’s a model with automatic transmission, make sure the selector is in P or N. □ Open the bonnet and make sure that the battery terminals are clean and tight. □ Switch on the headlights and try to start the engine. If the headlights go very dim when you’re trying to start, the battery is probably flat. Get out of trouble by jump starting (see next page) using a friend’s car. If your car won’t start even though the starter motor turns as normal □ Is there fuel in the tank? □ Is there moisture on electrical components under the bonnet? Switch off the ignition, then wipe off any obvious dampness with a dry cloth. Spray a water-repellent aerosol product (WD-40 or equivalent) on ignition and fuel system electrical connectors like those shown in the photos. Pay special attention to the ignition coil wiring connector and HT leads. I On petrol engines, check that the wiring to Check that the airflow meter or air tempera- o Check the security and condition of the the ignition module is connected firmly. ^ ture sensor wiring is connected securely. O battery connections. Check all multiplugs and wiring ' connectors for security. Check that electrical connections are secure (with the ignition switched off) and spray with water dispersant if you suspect a problem due to damp. Check that all fuses are still In good condition fina none have blowr

Roadside repairs 0.7 Jump starting When jump-starting a car using a booster battery, observe the following precautions: ✓ Before connecting the booster battery, make sure that the ignition is switched off. Caution: Remove the key in case the central locking engages when the jump leads are connected ✓ Ensure that all electrical equipment (lights, heater, wipers, etc) is switched off. ✓ Take note of any special precautions printed on the battery case. ✓ Make sure that the booster battery is the same voltage as the discharged one in the vehicle. ✓ If the battery is being jump-started from the battery in another vehicle, the two vehicles MUST NOT TOUCH each other. ✓ Make sure that the transmission is in neutral (or PARK, in the case of automatic transmission). era Jump starting will got you out of trouble, but you must correct whatever made the battery go flat in the first place. There are three possibilities: T The battery has been drained by repeated attempts to start, or by leaving the lights on. 2 The charging system is not working properly (alternator drivebelt slack or broken, alternator wiring fault or alternator itself faulty). 3 The battery itself is at fault (electrolyte low, or battery worn out). Connect one end of the black jump lead to the negative (-) terminal of the booster battery I Connect the other end of the black jump lead to a bolt or bracket on the engine block, well away from the battery, on the vehicle to be started. I Make sure that the jump leads will not come into contact with the fan, drive-belts or other moving parts of the engine. Start the engine using the booster battery and run it at idle speed. Switch on the lights, rear window demister and heater blower motor, then disconnect ttmjump leads in the reverse order of

o .8 Roadside repairs Wheel changing Note: Certain Corsa models are equipped with a puncture repair kit and do not have a spare wheel and jack. If your car has a puncture repair kit, refer to the information contained on the next page. Warning: Do not change a wheel in a situation where you risk being hit by other traffic. On busy roads, try to stop in a lay-by or a gateway. Be wary of passing traffic while changing the wheel - it is easy to become distracted by the job in hand. A Preparation □ When a puncture occurs, stop as soon as □ If you have one, use a warning triangle to it is safe to do so. □ Park on firm level ground, if possible, and well out of the way of other traffic. □ Use hazard warning lights if necessary. Changing the wheel alert other drivers of your presence. □ Apply the handbrake and engage first or reverse gear (or Park on models with automatic transmission). □ Chock the wheel diagonally opposite the one being removed - a couple of large stones will do for this. If the ground is soft, use a flat piece of wood to spread the load under the jack. I Lift the floor covering and unscrew the spare wheel clamp nut. Lift out the spare wheel. 2 The jack and tools are located in the storage compartment on the right-hand side of the luggage compartment. Open the cover and lift out the tools. 3 Use the special tool or screwdriver provided to pull the wheel trim from the wheel or wheel bolts, then slacken each wheel bolt by half a turn. 4 Locate the jack head below the jacking point nearest the wheel to be changed; the jacking point is indicated by an arrow in the sill. Turn the handle until the base of the jack touches the ground ensuring that the jack is vertical. Raise the vehicle until the wheel is clear of the ground. If the tyre is flat make sure that the vehicle is raised sufficiently to allow the spare wheel to be fitted. 5 Remove the bolts and lift the wheel from the vehicle. Place it beneath the sill as a precaution against the jack failing. 7 Lower the vehicle to the ground, then finally tighten the wheel bolts in a diagonal sequence. Refit the wheel trim. Note that the wheel bolts should be tightened to the specified torque at the earliest opportunity. 6 Fit the spare wheel and tighten the bolts moderately with the wheel brace. Finally... □ Remove the wheel chocks. □ Stow the jack and tools in the correct locations in the car. □ Check the tyre pressure on the wheel just fitted. If it is low, or if you don’t have a pressure gauge with you, drive slowly to the next garage and inflate the tyre to the correct pressure. □ Have the damaged tyre or wheel repaired as soorv.flf»|DOssible. or another puncture stranded.

Roadside repairs 0.9 Using the puncture repair kit A Warning: Do not attempt to repair a punctured tyre in a situation where you risk being hit by other traffic. On busy roads, try to stop in a lay-by or a gateway. Be wary of passing traffic while using the kit - it is easy to become distracted by the job in hand. A Warning: Repair of a tyre using the puncture repair kit must be regarded as a ‘get you home’ emergency repair only. A new tyre must be fitted as soon as possible. Preparation □ When a puncture occurs, stop as soon as it is safe to do so. □ Park on firm level ground, if possible, and well out of the way of other traffic. Repairing the puncture C Use hazard warning lights if necessary. □ If you have one, use a warning triangle to alert other drivers of your presence. □ Apply the handbrake and engage first or reverse gear (or Park on models with automatic transmission). I Open the storage compartment cover on the right-hand side of the luggage compartment. Take out the sealant bottle and bracket together with the air hose. 2 Detach the air hose from the bracket and screw it onto the sealant bottle connection. 3 Slide the sealant bottle onto the bracket making sure it is fully located and will not fall over. 4 Unscrew the dust cap from the punctured tyre, and screw the sealant bottle short air hose onto the tyre valve. Important notes 5 Take the long air hose into the car and screw it onto the connection on the electric pump. To avoid discharging the battery when the electric pump is running, it is advisable to start the engine. 6 Press the '+’ button on the electric pump to start the pump. The pump will initially pump the sealant into the tyre which will take approximately 30 seconds, and then start to inflate the tyre. During the initial 30 second period the pressure gauge on the pump will indicate up to 6 bar (87 psi) and then drop. The correct tyre pressure (see end of Weekly checks) should be obtained within 10 minutes. The electric pump can then be switched off by pressing the '+' button again. □ If the correct tyre pressure is not obtained within 10 minutes, it is likely that the tyre is too badly damagedtobe repaired with the kit. □ If it is necessary to release the pressure in the tyre, press the button on the electric pump. □ The maximum speed sticker attached to the sealant bottle should be placed in the driver’s field of view. Do not exceed the permitted maximum speed until an undamaged wheel and tyre have been fitted. □ On completion, disconnect the sealant bottle, tyre repair kit and long air hose, and connect the end of the short air hose to the free connection on the sealant bottle. This will prevent any remaining sealant from leaking out. □ Continue driving immediately so that the sealant is evenly distributed around the inside of the tyre. □ After driving approximately 6 miles (but no more than 10 minutes) stop and check the tyre pressure by connecting the longair hose directly to the tyre valve. As long as the pressure indicated on the gauge is more than 1.3 bar (19 psi) it may be adjusted to the correct value using the electric pump. If the pressure has fallen below 1.3 bar (19 psi) the repair has not been siiccessjHhapd the car should not be driven. It will therefore be necessary to seek roadside assistance.

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2006-2011 Opel Corsa D Service & Repair Manual

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