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2000-2006 Opel Corsa Combo Service & Repair Manual
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Vauxhall/Opel Corsa
Service and· Repair Manual
A. K. Legg EM1M1and Peter T. Gi
Models covered
Hatchback, Corsavan & Combo Van models, including special/limited editions
Petrol engines: 1.0 litre (973cc) 3-cyl, 1.2 litre (1199cc) and 1.4 litre (1389cc) 4-cyl
Diesel engines: 1.7 litre (1686cc) turbo
Does NOT cover 1.8 litre (1796cc) petrol engines
Does NOT cover 'faceliſted' range introduced October 2006
Haynes Publishing 2006
book in the Haynes Service and Repair Manual Series
ABCDE
FGHIJ
KLMNO
PORST
All rights reseed. 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 25 079 2
British Library Cataloguing in Publication Data
catalogue record for this book is available from the British Library.
Printed in the USA
Haynes Publishing
Sparkford, Yeovil, Somerset BA22 7JJ, England
Haynes North America, Inc
861 Lawrence Drive, Newbury Park, California 91320, USA
Editions Haynes
4, Rue de l'Abreuvoir
92415 COURBEVOIE CEDEX, France
Haynes Publishing Nordiska AB
Box 1504, 751 45 UPPSALA, Sverige
(4079-384)

Contents
LIVING WITH YOUR VAUXHALL CORSA
Safety First! Page 0.5
Introduction to the Vauxhall Corsa Page 016
Roadside Repairs
Introduction Page 0.7
If your car won't start Page 0.7
Jump starting Page 0.8
Wheel changing 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
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 0.18
MAINTENANCE
Routine maintenance and servicing
Petrol engine '
Maintenance schedule Page 1A13
Maintenance procedures Page 1A.5
Diesel engine
Maintenance schedule Paae 1B.3
Maintenance procedures Page 1B.5

Contents
REWIRS & OVERHAUL
Engine and associated systems
1.0 and 1.2 litre petrol engine in-car repair procedures Page 2A.1
1.4 litre petrol engine in-car repair procedures Page 28.1
Diesel engine in-car repair procedures Page 2C.1
Engine removal and overhaul procedures Page 20.1
Cooling, heating and ventilation systems Page 3.1
Fuel and exhaust systems - 1.0 and 1.2 litre petrol-engines Page 4A.1
Fuel and exhaust systems - 1.4 litre petrol engine Page 48.1
Fuel and exhaust systems - diesel engine Page 4C.1
Emissions control systems Page 40.1
Starting and charging systems Page 5A.1
Ignition system - petrol engines Page 58.1
Pre/post-heating system - diesel engines Page 5C.1
Transmission
Clutch Page 6.1
Manual transmission Page 7A.1
Automatic transmission Page 78.1
Easytronic transmission Page 7C.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 systems Page 12.1
Wiring Diagrams Page 12.21
REFERENCE
Dimensions and weights Page REF.1
Conversion factors Page REF.2
Buying spare parts Page REF.3
Vehicle identification Page REF.4
General repair procedures Page REF.5
Jacking and vehicle support Page REF.6
Disconnecting the battery Page REF.7
Tools and working facilities Page REF.8
MOT test checks Page REF.10 .
Fault finding * Page REF.14
Glossary of technical terms Page REF.24
Index Page REF~~O

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 driving we
should all do every time we get behind the
wheel.
An average of 70 people are killed every day
on UK roads and 870 more are injured, some
seriously. Lives are ruined daily, usually
because somebody did something stupid.
Something like 95% of all accidents are due
to human error, mostly driver failure.
Sometimes we make genuine mistakes -
everyone does. Sometimes we have lapses of
concentration. Sometimes we deliberately
take risks.
Illegal Copying
For many people, the process of 'learning to
drive' doesn't go much further than learning
how to pass the driving test because of a
common belief that good drivers are made by
'experience'.
Learning to drive by 'experience' teaches
three driving skills:
Cl Quick reactions. (Whoops, that was
close!)
D Good handling skills. (Horn, swerve,
brake, horn).
U Reliance on vehicle technology. (Great
stuff this ABS, stop in no distance even in
the wet ...)
Drivers whose skills are 'experience based'
generally have a lot of near misses and the
odd accident. The results can be seen every
day in our courts and our hospital casualty
departments.
Advanced drivers have learnt to control the
risks by controlling the position and speed of
their vehicle. They avoid accidents and near
misses, even if the drivers around them make
mistakes.
The key skills 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 excluding anything
that's not relevant. Driving is usually the most
dangerous activity that most of us undertake
in our daily routines. It deserves our full
attention.
Observation means not just looking, but
seeing and seeking out the information found
in the driving environment.
Anticipation means asking yourself what is
happening, what you can reasonably expect
to happen and what could happen
unexpectedly. (One of the commonest words
used in compiling accident reports is
'suddenly'.)
Planning is the link between seeing
something and taking the appropriate
action. For many drivers, planning is the
missing link,
If you want to become a safer and more skilful
driver and you want to enjoy your driving more,
contact the Institute of Advanced Motorists at
www.iarn.0rg.uk, phone 0208 996 9600, or
write to IAM House, 510 Chiswick High Road,
London W4 5RG for an information pack. ~
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 of unauthorisedcopying including digital, mechanical, and electronic in any
form. Authorisation from Haynes Publishing will only be provided expressly and in writing. lllegal copying will also be reported to the appropriate
statutory authorities.

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
* When working under or near
&
a raised vehicle.
stands, or use
ventun,
under a car which
is only supported by a jack.
Take care if loosening or tightening high-
torque 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
explosive.
* Don't let fuel
* 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 often
contain carbon
monoxide, which 1s
rapidly fatal if inhaled.
Never run the
engine in a
conf~ned space
such as a garage
with the doors shut.
Fuel vapour is also
poisonous, as are the vapours from some
clean~ng solvents and paint thinners.
Poisonous or irritant substances
0 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.
0 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
Special hazards
Hydrofluoric acid
* This extremely corrosive acid is formed
when certain types of synthetic rubber, found
in some 0-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. I f it
gets onto the skin, it may be necessity to
amputate the limb concerned.
0 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.
l flammable; fuel vapour is Asbestos dust can cause cancer if inhaled Warning: Never expose the hands,
or swallowed. Asbestos may be found in
1
face or any other part of the body
spill onto a hot engine. gaskets and in brake and clutch linings. A to injector spray; the fuel can
* Do not smoke or allow naked lights When dealing with such components it is penetrate the skin with potentially fatal
(includingpilot lights) anywhere-near a safest to assume that they contain asbestos, results.
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 extinauisher handy, of a type
suitable for use o;fue l and electrical fires.
Electric shock ( ( 7
* Ignition HT
voltage can be
dangerous,
especially to
people with heart
problems or a
pacemaker. Don't
work on or near the
ignition svstem with
theengine running or ) j C I '
the ignition switched on.

0.6 Introduction
The original Corsa models were first
introduced to the European market in Spring
1993 and are covered in manual SRM 1985.
The Corsa then had a facelift from April 1997
onward models which was covered in manual
SRM 3921. This manual covers versions from
October 2000, which were the subject of
another model facelift, together with
mechanical revisions.
A variety of engines are available in the
Corsa range, of 1 .O, 1.2, and 1.4 litre petrol
engines and two versions of the 1.7 litre diesel
engines. All engines are of the four-cylinder
double overhead camshaft (DOHC)
configuration, 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 1.6 and 1.8 litre petrol engines
are not covered in this manual.
The Corsa is available in 3- and 5-door
Hatchback, Corsavan @-door Van based on
Hatchback), and Combo Van body styles,
with a wide range of fittings and interior trim
depending on the model 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. An
'Easytronic' rnanual/automatic transmission is
also available.
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.
Your Vauxhall Corsa Manual
The aim of this manual is to help you aet 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. Tasks are described and
photographed in a clear step-by-step
sequence.
References to the 'left' and 'right' of the
vehicle are in the sense of a person in the
driver's seat facing forward.
Acknowledgements
Certain illustrations 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 all 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.

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 If your car won't start
and the starter motor even though the starter
doesn't turn motor turns as normal
El If it's a model with automatic transmission, make sure the
selector is in the P or N position.
Cl Open the bonnet and make sure that the battery terminals
are clean and tight.
Cl 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. Try jump starting (see next page)
using another car.
0 Is there fuel in the tank?
U 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 @VD-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.
On petrol engines, check that the wiring Check that the air mass meter wiring is On diesel engines, check that the wiring
1 to the ignition DIS module is connected 2 connected securely. 3 to the engine ECU is connected
firmly. securely.
4 Check the security and condition of the
battery connections.
Check that electrical connections are secure (with the ignition switched off) and spray with Check all multi-plugs and wiring
\water dispersant if you suspect a problem due to damp. 5 connectors for security.

0.8 Roadside repairs
Jump starting
When jump-starting a car using a
booster battery, observe the following
precautions:
d Before connecting the booster
battery, make sure that the ignition is
switched off.
d Ensure that all electrical equipment
(lights, heater, wipers, etc) is
switched off.
d 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
l
of trouble, but you must correct /
whatever made the battery go
p: flat in the first place. There are
three possibilities:
1
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).
the positive (+) terminal of the flat positivs (+) terminal of the booster to the negative (-) terminal of the booster
battery W. battery
11).---.1--.1-.111--
l l I"----
I
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I
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,--, ' J
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Make sure that the jump leads wlil not
I
come into contact with the fan, dr~ve-
I belts or other movlng parts of the
I
I
I
I
I Start the englne uslng the booster
I
I
battery and run ~t at Idle speed. Switch
*-----------------------------J
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 0.9
Wheel changing
A
Waming: Do not change a wheel in a situation where you risk being hit by another vehicle. 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.
Preparation
1 When a puncture occurs, stop as soon as Ll If you have one, use a warning triangle to one being removed - a couple of large
~t is safe to do so. alert other drivers of your presence. stones will do for this.
(3 Park on firm level ground, if possible, Ll Apply the handbrake and engage first or Cl If the ground is soft, use a flat piece of
and well out of the way of other traffic. reverse gear. wood to spread the load under the foot of
9 Use hazard warning lights if necessary. Cl Chock the wheel diagonally opposite the the jack.
Changing the wheel C
Lift the floor covering and unscrew the
2
Remove the tools from the toolbag 3 Slacken each wheel bolt by half a turn.
1 spare wheel clamp nut. Note on Combo stored beneath the spare wheel. Use the
models, the spare wheel is stored in a special clip to 'pull off the wheel trim.
cradle beneath the floor; the cradle is lowered
by unscrewing the bolt in the rear floor, using
the wheelbrace. Lift out the spare wheel.
Make sure the jack is located on firm
5
Unscrew the wheel bolts and remove the . Securely tighten the wheel bolts in a
4 ground, and engage the jack head wheel. Fit the spare wheel and screw in 6 diagonal sequence then refit the wheel
correctly with the sill. Raise the jack until the bolts. Lightly tighten the bolts with trim. Stow the punctured wheel and tools
the wheel is clear of the ground. the wheelbrace then lower the car to the back in the luggage compartment or cradle
ground. (as applicable).
Finally. ..
0 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.
0 The wheel bolts should be slackened and retightened to the specifled torque at the earliest
possible opportunity.
O Have the damaged tyre or wheel repaired as soon as possible, or another puncture will
leave you stranded.

I
I
0.10 Roadside repairs
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
pr~blem lies.
Warning: Most automotive oils
and fluids are poisonous. Wash
them off skin, and change out
of contaminated clothing,
without delay.
-v:<mell from the car of a - L G 1 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.
Sump oil * Oil from filter Gearbox oil
Antifreeze Brake fluid
inboard ends of the driveshafts.
Power steerina fluid
. .
deposit like this. certainly brakehid. connectors on-the steering rack.
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:
E Use a proper tow-rope - they are not
expensive. The vehicle being towed must
display an ON TOW sign in its rear window.
E 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.
[Zi The towing eye is supplied in the vehicle
toolkit which is stored in the luggage
compartment with the spare wheel (see Wheel
Changing). To fit the eye, unclip the access
cover from the relevant bumper and screw the
eye firmly into position. Note that the eye has
an anticlockwise thread. The wheelbrace can
be used to tighten the eye.
[Zi Before being towed, release the handbrake
and select neutral on the transmission.
Caution: On models with automatic
transmission, do not tow the car at speeds
in excess of 50 mph (80 kph) or for a
distance greater than 60 miles (100 km). If
towing speeds/distances are to exceed
these limits, then the car must be towed
with its front wheels off the ground.
Cl 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.
C7 The driver of the car being towed must
keep the tow-rope taut at all times to avoid
snatching.
I? Make sure that both drivers know the route
before setting off.
C1 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.
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The OPEL CORSA C COMBO 2000-2006 Full Service Repair Manual is the comprehensive and detailed guide you need for maintaining and repairing your Opel Corsa C Combo vehicles. This manual is designed to provide you with all the necessary information and step-by-step instructions to keep your Opel Corsa C Combo in top-notch condition.
- Covers various models of Opel Corsa C Combo from 2000 to 2006
- Includes detailed specifications, diagrams, and illustrations
- Provides step-by-step instructions for all repair and maintenance procedures
- Offers valuable tips and tricks for efficient troubleshooting
- Contains comprehensive information on engine, transmission, electrical systems, suspension, brakes, and more
Whether you are a professional mechanic or a DIY enthusiast, this Full Service Repair Manual is an indispensable tool for anyone working on Opel Corsa C Combo vehicles. With its clear and concise instructions, detailed diagrams, and comprehensive information, you can confidently tackle any repair or maintenance task on your Opel Corsa C Combo from 2000 to 2006.