1993-2000 Opel Corsa B Service & Repair Manual

Vauxhall Corsa Service and Repair Manual John S. Mead MlsTc Models covered Corsa models with petral engines, including special/limited editions Hatchback, Corsavan & Combo Van 1.0 litre (973cc) 3-cyl petral 1.2 litre (1196cc & 1199cc), 1.4 litre (1389cc) & 1.6 litre (1598cc) 4-cyl petral Does NOT cover diese! engine models Does NOT cover new Corsa range introduced October 2000 C Haynes Publishing 2002 A book In the Haynes Service and Repair Manual Series � Printed in the USA Haynes Publlshing Ali righʦ reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder. ISBN 1 85960 921 X British Llbrary Cataloguing in Publication Data A talogue record for this book is available from the British Libra. Sparkford, Yeovil, Somerset BA22 7JJ, England Haynes North Americe, lnc 861 Lawrence Orive, Newbury Park, California 91320, USP Editions Haynes 4, Ruede l'Abreuvoir 92415 COURBEVOIE CEDEX, France Haynes Publishing Nordiska AB Box 1504, 751 45 UPPSALA, Sweden (3921 - 384)

0•4 Advanced driving Many people see the words 'advanced driving' and believe that it won't interest them or that it is a style of driving beyond their own abilities. Nothing could be further from the truth. Advanced driving Is straightforward safe, sensible driving - the sort of drivlng we should all do every time we get behind the wheel. An average of 1 O people are killed every day on UK roads and 870 more are injured, soe seriousty. Uves are ruined daily, usualty because somebody did something stupid. Something like 95% of all accidents are due to human error, mostly driver failure. Sometimes we make genuina mistakes everyone does. Sometimes we have lapses of concentration. Sometimes we deliberately take risks. For many ple,   of 'leaming to drive' doesn't    an leamlng how to pass the drivlllQ tt bause of a common lief t   are made by 'experience'. Learning to drive by 'exפnence' teaches three driving  O Quick r  that was elosen O Good handli . , swve, brake, h). O AetiMCe   t. (Great stuff this ABS, st   Ce even In the wet...) Drivers whose skills are 'experience basad' generally have a lot of near misses and the odd accident. T ה can  sn every day in our courts and our hospital casualty departments. Advanced drivers have leamt to control the sks by controlling the sition and speed of their vehicle. They avoid accidents and near misses, even if the drivers around them make mistak. The key skitls of advanced driving are concentration, effective all�round observation, anticipation and planning. When good vehicle handling is added to these skills, all driving situations can be approached and negotiated in a safe, methodical way, leaving nothing to chance. Concentration means applying your mind to safe driving, completely exctuding anythlng that's not relevant. Driving is usually the most dangerous activity that most of us undertake in our daily routines. lt deserves our fuU attention. Observation means not just looking, but seeing and seeking out the information found in the driving envlronment. Anticipation means asking yourself what Is happening, what you can reasonably expect to happen and what could happen unexpecteclly. (One of the commonest words used in compiling accident reports Is 'suddenty'.) Planning is the link between seeing something and taking the appropriate action. Far many drivers, planning is the missing link. lf you want to become a safer and more skilful driver and you want to enjoy your drlving more, contact the lnstitute of Advanced Motorists on 0208 994 4403 ar write to IAM House, Chiswick High Road, London W4 4HS far an information pack.

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 Scalding • Don't remove the radiator or expansion tank cap while the engine is hot. • Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running. Burning • Beware of burns from the exhaust system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use. Crushing • 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. is only supported by a jack. • Take care if loosening or tightening high- torque nuts when the vehicle is on stands, nitial 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 Tcluding pilot lights) anywhere near a . 5- cle being worked on. Also beware of seating sparks electrically or by use of tools). • - jel vapour is heavier than air, so don't лчэгк on the fuel system with the vehicle over ал nspection pit. • Another cause of fire is an electrical :. eioad or short-circuit. Take care when 'spajring or modifying the vehicle wiring. • Keep a fire extinguisher handy, of a type s-. -arte for use on fuel and electrical fires. 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 400°C. 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/or facia. 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. • When working under or near a raised vehicle, ^ always ^ L ®"- . . ^ supplement the / / ^ jack with axle stands, or use ^^ ^ venture " under a car which Fume or gas intoxication • Exhaust fumes are poisonous; they often 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. Electric shock ^ • Ignition HT . --.age can be dangerous, especially to people with heart "j- nrcolems or a j- pacemaker. Don't ^r on or near the аглюп system with 5те engine running or Tie ignition switched on.

о.б Introduction to the Vauxhall Corsa Vauxhall Corsavan The original Corsa models were first introduced to the European market in Spring 1993 and are covered in the companion publication to this manual - SRM 1985. The models covered in this publication are the April 1997 onward models, which were the subject of a model facelift together with extensive mechanical revisions. This manual covers models fitted with petrol engines, but other models in the range are available with diesel engines. A variety of petrol engines are available in the Corsa range, of 1.0. 1.2, 1.4 and 1.6 litre capacity and with single overhead camshaft (SOHC) or double overhead camshaft (DOHC) configuration. All engines are of the four-cylinder, in-line type, with the exception of the 1.0 litre engine which is a three-cylinder unit. The engines all have fuel injection, and are fitted with a range of emission control systems. The Corsa is available in 3- and 5-door Hatchback, Corsavan (3-door Van based on Hatchback), and Combo Van body styles, with a wide range of fittings and interior trim depending on the mode; specification. Fully-independent front suspension is fitted; the rear suspension is semi-independent, with a torsion beam and trailing arms. The manual gearbox is of the five-speed all synchromesh type, and a four-speed electronically-controlled transmission is available as an option on certain models. A wide range of standard and optional equipment is available within the Corsa range to suit most tastes, including 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. Vauxhall Corsa GLS Vauxhall Combo Van Your Vauxhall 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. Hcv.ever. 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 -nportant. 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. Tasks are described and photographed in a clear step-by-step sequence. Acknowledgements Certain ustrations are the copyright of Vauxhall Motors Limited, and are used with their permission. Thanks are due to Draper Tools Limited, who provided some of the workshop tools, and to al those people at Sparkford who helped in the production of this Manual. We take great pride in the accuracy of information given in this manual, but 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 errors in, or omissions from, the information given. Vauxhall Corsa 16V

Roadside repairs 0.7 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 the P or N position. • 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 are trying to start, the battery is probably flat. Try 'jump starting' (see next page), using another 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, as applicable. that electrical connections are secure (with the ignition switched off) and spray with p Check that the coil's wiring plug is =rer cSspersant if you suspect a problem due to damp. С secure and spray with water-dispersant if necessary. A Check that the spark plug HT leads (where applicable) are connected firmly. В The fuel injection system wiring plug may cause problems if not connected securely. С Check all multi-plugs and wiring connectors for security, with the ignition switched off. D Check the security and condition of the battery connections.

0*8 Roadside repairs 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. • 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). Jump starting will get 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). 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 the jump leads in the reverse order of connection. Turn off the lights etc.

Roadside repairs o-s Wheel changing Л Some of the details shown here will vary according to model. Warning: Do not change a wheel in a situation where you risk being injured by other traffic. On busy roads, try to stop in a lay-by or gateway. Be wary 01 passing traffic while changing the wheel. It is easy to become distracted by the job in hand. Preparation • When a puncture occurs, stop when it is safe to do so. Z Park on firm level ground, if possible, and well out of the way of other traffic. • 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. • 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 or paving to spread the load under the foot of the jack. Changing the wheel Remove the wheel trim (where fitted) anc slacken each wheel bolt by half a turn. 6 Position the spare wheel and fit the bolts Hand tighten with the wheel brace anc lower the car to the ground. Tighten thf wheel bolts in the sequence shown, fit ths wheel trim and secure the punctured wheel ir the boot. 1 Remove the tool holder and unscrew the spare wheel clamp. 4 Raise the jack whilst locating below the jacking point (ensure that the jack is on firm ground and located on the car correctly). 2 For safety, place the spare wheel under the car near the jacking point. 5 Turn the handle clockwise until the wheel is raised clear of the ground. Remove the bolts and lift the wheel clear. Finally... Z =>c--iove the wheel chocks. Stow the jack and tools in the appropriate locations in the car. Z -~«ck the tyre pressure on the wheel just fitted. If it is low, or if you don't have a pressure :a_ge with you, drive slowly to the nearest garage and inflate the tyre to the correct oressure. Z -=.e the damaged tyre or wheel repaired or replaced, as soon as possible.

о.ю Roadside repairs The smell of a fluid leaking from the car may provide a clue to what's leaking. Some fluids are distinctively coloured. It may help to clean the car carefully and to park it over some clean paper overnight as an aid to locating the source of the leak. Remember that some leaks may only occur while the engine is running. HilYT Leaking antifreeze often leaves a crystalline deposit like this. Warning: Most automotive oils and fluids are poisonous. Wash them off skin, and charge out of contaminated clothing, without delay. Oil from filter ...or from the base of the oil filter. Brake fluid A leak occurring at a wheel is almost certainly brake fluid. Power steering fluid may leak from the pipe connectors on the steering rack. Identifying leaks Puddles on the garage floor or drive, or obvious wetness under the bonnet or underneath the car, suggest a leak that needs investigating. It can sometimes be difficult to decide where the leak is coming from, especially if the engine bay is very dirty already. Leaking oil or fluid can also be blown rearwards by the passage of air under the car, giving a false impression of where the problem lies. Gearbox oil Gearbox oil can leak from the seals at the inboard ends of the driveshafts. Power steering fluid Sump oil Engine oil may leak from the drain plug... Antifreeze Towing When all else fails, you may find yourself having to get a tow home - or of course you may be helping somebody else. Long- distance recovery should only be done by a garage or breakdown service. For shorter distances, DIY towing using another car is easy enough, but observe the following points: • Use a proper tow-rope - they are not expensive. The vehicle being towed must display an ON TOW sign in its rear window. • Always turn the ignition key to the 'on' position when the vehicle is being towed, so that the steering lock is released, and that the direction indicator and brake lights work. • Only attach the tow-rope to the towing eyes provided. • Before being towed, release the handbrake and select neutral on the transmission. • Never tow an automatic model backwards. If the automatic transmission appears to be in working order, the vehicle can be towed for a maximum distance of 62 miles (100 km), at no more than 50 mph (80 km/h). The vehicle can be towed greater distances with the front wheels raised. • Note that greater-than-usual pedal pressure will be required to operate the brakes, since the vacuum servo unit is only operational with the engine running. • On models with power steering, greater- than-usual steering effort will also be required. П Make sure that both drivers know the route before setting off. П The driver of the car being towed must keep the tow-rope taut at all times to avoid snatching. • Only drive at moderate speeds and keep the distance towed to a minimum. Drive smoothly and allow plenty of time for slowing down at junctions. A Warning: To prevent damage to the catalytic converter, a vehicle must not be push-started, or started by towing, when the engine is at operating temperature; use jump leads (see 'Jump starting').

Weekly checks 0 .11 Introduction There are some very simple checks that need only take a few minutes to carry out, but that could save you much inconvenience and expense. These Weekly checks require no great skill or special tools and the small amount of time they take to perform could prove to be very well spent, for example. • Keeping an eye on tyre condition and pressures, will not only help to stop them wearing out prematurely but could also save your life. • Many breakdowns are caused by electrical problems. Battery related faults are particularly common and a quick check on a regular basis will often prevent the majority of these. • If your car develops a brake fluid leak, the first time you might know about it is when your brakes don't work properly. Checking the level regularly will give warning of this kind of problem. • If the oil or coolant levels run low, the cost of repairing any engine damage will be far greater than fixing the leak, for example. Underbonnet check points SOHC engine Д Engine oil level dipstick В Engine oil filler cap С Coolant expansion cap D Brake fluid reservoir E Screen washer fluid reservoir F Battery

o.i2 Weekly checks Engine oil level Before you start • Make sure that your car is level ground. • Check the oil level before the car is driven or at least 5 minutes after the engine has been switched off. If the oil is checked immediately after driving the vehicle, some of the oil will remain in the upper engine components, resulting in an inaccurate reading in the dipstick. The correct oil Modem engines place great demands on their oil. It is very important that the correct oil for your car is used (See 'Lubricants and Fluids'). Car Care • If you have to add oil frequently, you should check whether you have any oil leaks. Place some clean paper under the car overnight, and check for stains in the morning. If there are no leaks, the engine may be burning oil. • Always maintain the level between the upper and lower dipstick marks (see photo 3). If the level is too low severe damage may occur. Oil seal failure may result if the engine is overfilled by adding too much oil. ЖШ HilUT I The dipstick is often brightly coloured for easy identification (see Underbonnet check points on page 0.11 for exact location). Withdraw the dipstick. 3 Note the level on the end of the dipstick, which should be between the upper (MAX) mark (B) and lower (MIN) mark (A). 2 Using a clean rag or paper towel remove all oil from the dipstick. Insert the clean dipstick into the tube as far as it will go, then withdraw it again. 4 Oil is added through the filler cap. Unscrew the cap and top-up the level. A funnel may help to reduce spillage. Add the oil slowly, checking the level on the dipstick frequently. Avoid overfilling (see Car Care). Coolant level Warning: DO NOT attempt to remove the expansion tank pressure cap when the engine is hot, as there is a very great risk of scalding. Do not leave open containers of coolant about, as it is poisonous. The coolant level varies with the temperature of the engine. When the engine is cold, the coolant level should be near the COLD (or KALT) mark. Car Care • Adding coolant should not be necessary on a regular basis. If frequent topping-up is required, it is likely there is a leak. Check the radiator, all hoses and joint faces for signs of staining or wetness and rectify as necessary. 2 If topping-up is necessary, wait until the engine is cold. Slowly unscrew the cap to release any pressure present in the cooling system and remove it. • It is important that antifreeze is used in the cooling system all year round, not just during the winter months. This is due to it's cooling and anti-corrosion properties. Do not top-up with water alone, as the antifreeze will become too diluted. 3 Add a mixture of water and antifreeze to the expansion tank until the coolant level is up to the COLD/KALT mark.

1993-2000 Opel Corsa B Service & Repair Manual

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