1997-2000 Vauxhall Opel Corsa Service & Repair Manual

--------- - Vauxhall Corsa Service and Repair Manual John S. Mead MISTC Models covered Corsa models witl1 petrol engines, including speciaillimited editions Hatchback, Corsavan & Combo Van 1.0 litre (973cc)3-cyl petrol 1.2 litre (1196cc & 1199cc), 1.4 litre (1389cc) & 1.6 litre (1 598cc) 4·cyI petrol DoosNOTcoverdiesel6flgjnemodals DOOlS NOT covet" OOW Gorsa range Inlroduced October 2000 AlI , ;ghls,eserved.Nop.r1oflhi.bookmayboo",~orl"","_ In any form o'by'ny "' • ...,s,.I.ct'onio armtloh. nic.l. including pI><>""'opying,l'OOOrdlflyorby.n~info"".Uon . to,.~or""~ ••• ls)'$t..". wilhotJIpermis>i""inwr~j"91rom·"'eOl)rrigh·hoI_. Bmmlwt> ... " C.tI>IoguinginPYblic • • io<1 0iOlo "'~reourdfttlhisbockisQvaial:"lro,'nlh<rSri1is/1li1;l.""Y HoynnPubiiohing 5p<orl<:fotd.Y"".I,s,,""' ..... SAZ' 7JJ,Engianc H._oNorttrArnMca. Inc 861 Lawr~nceom...N~"'bur)' Pork, [;"lomja~132{l, USA ~R':';o~a:='dr ~41~[;OORBEVOI!;CEDEX.FrarlCe H_. Pub~shIngNorOisl<aAB s.,,' 504, 15,45UFPSMASwodon (3f}21·384)

Advanced driving Many people see l"a words 'advanced driWIg'aodbeleveltiatHwon'tr.terwtl>em {)fth81h;'as~ofdrivingo.yondlheirown .bl~;es. Nolhll'lg cO<.Ild be further lrom tkto troth. Advanc.ddn"iogilstrlighllorw3rd Mfe.~ibled!Mrlg-thesortoldrMngw. :d all do IIV"'Y lIme we Ill'll ~"'d lh' Ana_ageofl0peoplearflk~leodev«yday ooUKroltd s andB70mor.arefnjur9d,some seriously. Uvea are ruined dalty, usually because somebody d,d something ~Iupid ~hinglik.95"ofal1aecidefltsaredue to human error, m~tly driver railure Sam.t"nes we make genuine mistakes _ evetyOI1adofiol. Some("'l\I!:Iweh a~lapsesoi concentration. Sometimes we delib .... III .. ly taktorisl<s. For many peopIa.IhePfO(*SoI1Mrniog10 drlwo'doesn'tgomuctoUttwtt.l1eaminQ howlopa55_~lest~seol. common beMI II-. good drNers_rnade by 'expflll\era' Learntnglodnv.by·.~·1.3chn three drIWIg sIcits: OOuielcI'MCtions.. (Whc>op&.ltWw,," - o Good "-dIg""'" tHom._. """".- o ReIlanc."" ..... rec:trdogy.{Greet slut1Ih1sA8S.SUlp"no~"""'in thewM. .. ) Drive" whose skills;we 'experienc<l based' generally ha'o •• lot oI.- ............ nd th. oddacQdent,The.-.ftseantleseMeverv d ay In our courta.od o..hos.p,tal casually --. Advancedd~v"", 1'Ia ... leam! !Oconlrolthe risksbycontrollinglheposlllOnand~ol thelrvet\ic:Ie.ThaylMlidaccodenr.andn....,. misseS.even~thediv.-samuncithemmakl! TI>II key ekill801 IIdvancecl driving ate concentration, etleclive all-round ob ...... alion, antk:lpatJon and planning. When good vahlele Mneliing Is added to Iheseskllls,al l drivings<tuationscanbe approached and negotiated In a safe. meIhodicalw"'I,leiMngnothingtochance. Concantnotion """""applY"'II)'QUI"mi ndto saf.. drMng, complelllly ... dudlng anything tl>;!.l·'not ..... """1. Drivnglsl,lSually\tleJTlO5t dangerousac\ivitythat....wolusundertake ~n:~.ailyroulln .. s. Iideservesourtull Obse .... ation means not just looking. but !lllelngandseei<inQOI.IIthelr1formatlonlolll>d in Ihe (!riw.g enWonment Anticipation means askingyoulW~ what Is hsppenong,whstyouCllllreasonal.>lyaxpact 10 happen and whsi eould happen unexpectedly.(Ontoolthe~lwords used In compiling ac.:ldent reports Is ·.l.Iddenly·.) Planning Is the link between seeing something and laking the appropriale aclion. For many dnvert. planning Is the m~"'IIlrok. If yoo w..u 10 bacome a saferand more r.kItful (!.lver.nd you .... ant 10 enjoy your drlvlr.g more. contact the Inst,tute of Advanced MotorlslSon 0208990\ 4403 01 write to lAM House. ChIswIck Hlgh Road,LondonW44H$ loran inlOITII8tion pacI<

WorkJngonyoorcarcanboodanglW'OUS. Thill page shows juslsome of the potentlal l'isk!Iandhazard"wlthlhealmofcre~tlnga lIIlfety·consdOUSII1t~ud. General hazards Scalding -Qon',removelherad<;dororexpanslon tanl< cap whiNl tl'Hl OOgl09 Is hot • Engtne o~.al.llomatictrarlStnjssionlruid or powersteerlnglUidmlly alsobe dang0r0u6iy hot ~Il>eengi""has recently beenrunnmll. Burning • Beware of bums from the exhaust system _fromsnypllllo! lh.. engtnfI.S ...... di>Ios n drums can al50 beelClremely hot mmedlately after use Crushing · ...n-workl"llo.Kldwor.- .r ... $Odvehic~, ... ,. ~w:e::e (, stands,o,use ""00 ....... -.. vwoture ...... ClJrwhit:h it oo/y supponed by II Jilek. • Take Cllre If IoosI>ninIl or tig./l18l1Ong t.gh- IOrqIM nuts when the vlhcle Is on sta!lds ntiaI klosenIng and ftnal lighl9lling should be donewilhthe ""-Iaonthtl ground. R,. • FueI .. hiogNyft....., mable;fuelvapoo.ris -. • Don't lei fuel splH onto II 001 8I1111ne • 00 001 amok<l or allQw naked lights ncIudin<;J~lotlighl$)anywhereneara "'IhicIebeirog worked 00. Aiso beware of ...... -- ~Ilyorbyuseoltoola). · Fuelvapoo.ri$ hGiI~tr.analr,!;Odon't -" on the ru..I system with the vehicle DVfIr II'Iqpectlon pjl. • Anothercause of fire is an eiectrlcal ~orshort-drcult.Tllke""' .. wh.., ~ormodifyingthevehid"wiring • Kaep afire elClinQulsher tIandy, 01 a type ~kJrllSeonfoelandekioctricalf"" • Mains voilall" i$ also Qan{IlIrOUS. Make sure Ihat any malns-operated equipment '" COf1"ecl'y earthe(l.Mainspowetpotlltsshould ooprotocted by a raSlduaIClJmll1tdeYice (ReO) CU"Ct.I~ break ..... Fume or gas intoxication • Exhaust f1Jmes ara =C:: 0ften mooo><idll.whichi$ rapidiy fatal If Inhaled. Never run Ihe ""!I'Mna conflnedapaoa ::t:~a:ut. Si!r~fIG~;, • FUIII vapour i$ also poisonous, as are the vapoors Irom some d8!lrlingsc>venilland paintthnne!"$ POisonous or irritant substances . Avoidsl<ineonla.clwilhbMterytoeidlltld witnanyfuel,lIlJodorlubricanl.espocIaIty antifreeze,brak&hydraullcfitJidandOi8sel lueI.t)on·lsypllonlhembymo",h.Hsuclle. ==S;;~orget$intOIheeye&, • Prolonged eontact wilh used engine 01 can COWOl skin concet. We. gkwH or ~ e. barrier .... ""'" ~"""""'sary. ChBngaoutofoi- !IOakeddothesanddonolk8epoityragsn yOII"pocket . • A!rcondltJornng rafrigefanl fotms 8 poosooous gas if exposed to a naked fIa .... =:-';':8fle).ItC8lla!socaUHskin Asbestos • AsbesIOSdvstcan callS&carocetII iMaied Of 8wallow9d. Asbestos may 00 foor><l In gaskets aod In braka and clutch linings I'Ihen dNl,ng with such components ~ Is safestt08SSUmelh8ItheyCOf1tain~0II. Remember ••• DO .00llS&eyep<otoctionwhenll$Ong powar tools. and,.fIen working undertl'8 V<lhicIe. 'Oowwr <)loVMoruseb3rrlercre3l11to protect yow handS wl>on I"I<ICIISII8I"Y • Do get IOI'lMIOr>II10 check perooocally that all is weH wilen working eIoneon Ihe "" ... 'Dok88pIoQ""clQlhlngandlongM!fwell outofll16wayolnlQ\ling~nic.alpwtB. 'DoremOYfl rings, wrm Wlllchetc, before work"'lloothevehtcle-esp8daftythe eIectrlcalsystem • Do.-.sorathat urylifting orjaclong equlprnenth3sasafework1ngloadralirog adequa.le for Ihe job Safety first! 0-5 Special hazards Hydrofluoric acid ' Thlsextr""""YCOfTO~ acldisforme<f wheneo:wtaonrypesofsyntl>etlcrubber,found on some O-ring.s. oil Ml8!s. fuel hoMe etc. 81e expo68d10 tempe.-aturasabove 400'C.The rubt>etchangosinloacharrador s ticky subetarlC<!lCOf1taimngtheacid.~fom>ed, lhea<;k;Jremaln.dangerous forye6r3. If It gII/$OOlothttskin,olmayoonecassatY'" MflPCItal&rhe"mb(;(}("f(;llfflf. • l'Ihendea!ing WIth a vehicJewhOchh3s sutlereclaflr1!,orwrthcomponenillsatvaged from...::l1lvehicle, ........ rprolectivegio'lffls wod~1hemaft&ruse The battery • BIItterils contain suIpho.6lc 8cid. which sttad<adolhong. ey.s ancI skin. Tak8 c"'"" whenIOpptnO-tJpOlcanyr.gthebattery. • Thehyli-ogenllllSg..,...,ott bylhe tlattery is hII1IIy 8XpIosIwt. N8YtIO"ClIusea spao1< or lIIfow.nakodlightnear1;ly.fIe~wI>en COMeCtIr\g and disconnecting battery cIulrg8nIotjump~s Air bags ' />Mb:lgscancause/{lfJrylltheygootl BCCidentally.Takec.arawhenramovingttle s1eerhg_andIotflOCia.SJ-:""~orag& inoIructionsmay apply Diesel injection equipment • Dt8seIonjectioo pumps suppfy fuel at vary high pressure. Take C8ra when wotkIngon Ihe fuel injectors ancI fuel pipes. DON'T • Oon1 attempt 10 lift a ~yY component =~:bebeyoodyrxJlcapablll""-get ~r:~;:~f=aiob,ortake • 00n1 use III-folll/l(j tooIswhdl may slip and<;il~"inj~ry • Don'l IOavelOOl$or parts lying around wheresomeonecantripovertMm.I>ICIP up oil and flMll spUis at once • Don't alklwcnlldron or pats to play in or near a vehocle being worI(od on .

0'6 Introduction to the Vauxhall Corsa Theong,na1 Corsa mod~ls we,,, firsllnl'odUC«lto tne EUrope;ln ma1<etinSpringI 99Jandarecove<oo in lheOOlllparuon pubHcationlo ltusmanual - SAM 1985. The modols oovered in Ihis publication are the April 1997 onward models. whi~h w",,,lhe .ubi",,1 of a model laoel,/1 togethe, with eXlen3i~e mec~anlcal ,..,vlslon~. This manual ~ models fitted with petrol anginas. but olh... models in the f8fI!)e ar"avai'abkowitlld!es<Nanginoo A vanety of petrol 8I1gines are !,,,,,ilab+e in tile C0rs:3 rarl\IfI. of 1.0, 1.2, 1.4 and 1.6 lilro capacity and wlt~ single o~eme3d camshaft (SOHe) or dauble overhead cams~aft {OQIK) configurahon. All ""II'I1orr are of the four·cylinOOr. in-Iiootype. with theexcepllon of Ihe 1.0 litre engine .... f"Iictlis II three-cylinder ~M. The 8ngin.... aIIMwtIuo!l ;,,;..etion. a nd me filled wrth a range of emksion control systems. The Corsa Is available in 3- snd 5-door Hatchback, CorYvan (3-ooorVan bMod on Hatcnbacl<),and Combo Van body styI&s,WIth a wioe r3flQe 01 fittIngs and inl .... ior Irim dep.",ding on lhe model speclf\calion. Fully·lndependentfront"""psnsion i1Ifitl8d;the rBar 5UspenIIIQIlis S8I'I1I-indeplll1denl.w~hators<onbellmandtrailingarms ThBmanualgearboxisofthefiv<H;poodalisynctY~~anda four-s~electronically·controiled tran$mi""ionisavaLlable85'" optiononcertainmod9la A wide rangB of standard and oplion<li equlpmenl is available "M!hin theCO<1HIrangetosu;tmosttasl88. incllidingC<'>'ltral locklng.1IIecttIc wlnOOW3. ~rtc :woroof, anH~ock braldng system, e!ectronir; alarm $)'$temandsuppkln"!entalrestr'ltlfltsystems For the horne mecnan;c. theCors~ iSi! reiative/y$tralghtlorward vehicle to maintain , and most of lhe ~8m8 r",,~ifing Imquen! attenbOO are M'ttyaccMslbte Your Vauxhall Corsa Manual n...MTl 01 this JTI8I"03l isto r.elp you get thc best val ue from your YdlicIe. It can do :so in se.erat ways. II can help you decide what wak rrwJSI be doone (eYftIl sh<luld you cl>oose to \let it done by a garage). PI"'I"id<r on!ormaIlon on routir1e malnt9Mr"><XI and ~C<"\o1clng, 3110 give II logical cow,. of aCllon and diagnosis w~en random faults OCClI Hc>woe¥er. ~ IS hoped thai you 1Ioi~ usa the manual bylackling the wOll< ~.On!limplerjOOs~may"",,,,,bequick,,,thanbool<ingthacar nto a garage and QO<n'J there twIoo. to loove and conect It. Perhaps mIIOIt mp;.rtInt. a lot of money can be"".ed bya.olding the costs 8 g;wagelllULltc:t\aroelocover ~al .. bovr andoverhe8ds. Tho! ........ lIaS drawing" and d9scriptioos 10 show the Il.I"ICIion of \he v ... ouscompone"I' so that thalr layout can be ullderstood. Tas1<3 ...... described and photographed in ~ cisar step-by-step ~ Acknowledgements CenaIn ilustratk>ns a"" the copyr1ghl ofVau,h3J1 Motors LlmlteO. and _ UMd woth their permISSion. Thanks are due to Drape< Toots Urnoted. who provided 80me 01 the workshop tools, and 10 ~peopleiltSpa'k fo'd WhOheIP8din tM8productlonofthl" We lake great pride in th"accuracyof information given In this manuaJ,butvehicl"manutacturers make alterations and design changesdurlnu the productior1 run of a pjlrticulllrvehicla 01 which they do not inform us. tw llabllrty can be accepted by the authors Mpubltshef"sfor 1055, damage or injury cauaed by ..... ors in,or omissioMfrom, the Informatlongtven.

The/allowing pages are intended to help in dealing wi th common roadsi de emergerlcies and breakdowns. You wil l find more detailed fault finding information altha back althe manual, and rapair iniormation in the main chapters. If your car won 't start and the starter motor doesn't turn o If it's a mooel with automatic transmission, make sure the selector is inthe P orNposrtion. n Opoothebonnet andmakesurelhatthebatleryt6rmina.ls are clean and tight. o Swrtch on tM headlights snd try 10 slarttha angi na. If the h98dlights go very dim when you arelrying to start, the battery is probably flat. Try 'jump starting' (see next page), using Moihercar Roadside repairs 0'7 If your car won't start even though the starter motor turns as normal o Is therefuel .. thetank? U Is tlleremoistureoneiectrical componf!ntsunderlhe bonnet? Switch off the igndion. then wipe off any obvioos dampoesswithadryclolh.Spraya water-repellentaerosol product (W[).40 or eqUlVa/enI) on ignrtion and fuel syslem ~ectrical COMecIors r lka those shown in the photos. Pay special attention 10 the ignition COil, WIring comector and HT leads, as applicable. A Ch9<:kthatthQSpark Plug HTlaad." (whI!reappioablej llr8col",,,cted f ilmly B Tt>elu'-irjactk>nsystarnwiling plug may cause prot.>lems it ""t connected =""

0' 8 Roadside repairs Jump starting When jump-starting a car using a v Make sure that the booster battery is booster battery. observe the fallowing the same voltage as the discharged precautions one in the veNeta y' Before connectJng the booster battery, make sure Chat theigndion is y' If th" battery is being jump-started SWItChed off from the battery in another vehicle, the two vehicles MUST NOT TOUCH v Ensurs that aI electrical equipm9llt each other (lights. hea!er, Wipers, stcj is .... """'011 c- , , , , , , , , , , , , , ______________________________ .J I MakeSl.«llhattl\tliumpl8adswillnol oome imo contact with th~ lan, drtve- belts Or ott-moving parts 01 tt'e engine. I Stan tl>llengiootlSin9tlleboOSl9r • batteryaodr\l!lltalidles~.Switcn on tt>e lights. rear window demister and heater bk>weI" moIOf. ttl«I di scool18Ct thejumplNd.intl>ere. i ,seorder cf cOllMCtion.n.m onth~~ght"etc.

Roadside repairs 0'9 Wheel changing Some of Ine d.. tail~ shown her<'> will vary ac:cordinglomodol. &. W .. mlng:Do notch,.,,~. wh .. /ln., sJtulltlon wlM"'~ rlskbe;nfJ inJuradbl' , oth", traffic:. On bU8Y roJjd~, try to stop In " Illy-by or gafe w. y. Be WillY of • P8sslng frame while c:hanfl/nll the w"-l. It is ""sy to become dlstrH;ted by the job in h"nd. Preparation U When a punctl.lre occun;, Slopwh"" it " 0 Ifyoo Mveone, LJSeawamiog triangI8 to ~etoooso. atert olh.r drivoors 01 your pt'esence. o Par1<onfitmle'i<OgrOU'1d,if poss;bie.aod U Applylhehandbfakear>d engagelir$tQt well out 01 the way of olhertralTi(:. ""'_gear. o Use hazard warnonglights, H _sary U Cllockthe wheeldiagona/ly opposotelhe Changing the wheel R ... r.: .... lhetool holder aM unscrewlt1e splW"ewhe<'clamp 4 Ralselhejack wrnlstlocatingbeiow the flld<i"9pOO t{............ tho1too)ack~onfrm grOOSldaod1ocatedonth~COIrC<.>'r«:tly) Finally .. . ;.. , ;:0- ., ; ;. , ~ :;z) " "" ' ~ft! ."",~.,- . = Rwnovelhewhe<!lchocks.Stowth"jackaootool~ lnthe 3pproprlat8Ioc"'ionsinth8car. = O>eck II1II tyrB PfflS$ure on the wheel just fitted. If ~;,. k1w. or ~)tOO don't ha~" a pressure ;a>gewtthyou. dnv" slowly to the nearest garage arld Inllate the ryre to the correct __ 1hII damaged ~ or wheel repa,red or repiaGed, a. 800rl as possible :'!e~i~r=r~is~OO\JP", 01 large o Hthegroundissoft,...seallatpi_ol wood or paVIng to sprsad the load UtlOer t!>elootolth8 )ack. 6 :~~C;;g~~~~h ~~w=';~:e~~ l ow", the cor to thegroooo. Tight..., th<I wheel bolts In th. ~ooqu.nc. shown, fit the ~~:n ,,00 &&Cure the punctuf'fldwheelln

0- 10 Ei?adside repairs IdentifYing leaks C:V~O:le~~~! g~="::~. :: undemaath Ihe car, ~ a INkttlat MMIs OnvestigaHng.I!"""~bed~to decid .. whMe Ihe leak is coming hom. • sp"daIIyHlhe~ba,.veryd"y !llreadv·L-'lQkingoilorlluidcana/sobellk>wn rearwardsbylhapessagooolairundllrthec:ar, gi~ing /I. false ompressoon of where th(l -~ .... Towing Whoo all .. Ise fail., yOY may flndyoursell ha"';ng 10 get a tow home-or of coorse you may be helping somebody ~Is ... Long- dislance.ooov"'Y should onIyba doneDy a garage or b<eakdown se.vice. For short... distances, DIY towing uSing anothe, cilr is easy enough. but observe the following points' CU ... a pro~tow-,ope - they8Hlnot .. xpenslve, The Yehiete beinlllowed must display an ON TCNV SI!ijn in its rear window. CAlways tum Ihe i(,lnilion k"y IOIIut '00' posrtiOO when 100 vel"lIcle is being towed, so thatth stee,ing lock Is ",Ieased,and A Wamlng:Mo~t ... tomotw.oIIs , . ndflukh<arepe>i$onoUs.W"sh • rhemo"slrln,;mdch-..geOCll orco"tamin .. tedclott!lng. without delay • ~IhedjreClionlndicatorandbrakelfght. 'lOnly allach the tow-rope to tho tOW'1"lg ..,...,.provide<.! ~S::t~'"t~edti...~~kO o Nevertowrul8utome.ticrTlOdelbackward$ ~theautomalictr~appearntot>ejn wori<ing order. the vellicle can be towed fora =.Imum distaroce ol62 rTIiIfIs (100 km), at no more than 50 mph (BO km/h). Thto vehicle can ::n.:;~ .. :eate< dlstancM wllh the fmnt o Note that great .... -than·u$ual ped81 pressure .... 11 be required to op..-ate Ihe brakes, 8inoe !I>e vacuum S«Vo unit Is only ~ationalwithtMooginerunning Power steering fluid Pcwerst""rlnglluid may I6ak ffom the pipe connectors on I""'stoo&ting rack. n On models wllh power steering, ~r""ter- than-usual s1-mg lIffort will abo be required. o Make soxe that both drlvern mow the route beioresettllgoff o The driver of tho carbeinl/towed muSI keeplhelow_,Opetautalat ltimestoavOid ""atching. o Only drive al moderate speeds and ksep the distance towed to a minimum. Drive smoothly and aDow plenty ol time for sIo .... ng down at joJIctIons. A Warning: To p",vent damage to , tllecatalytlcconvarter,avahwlo • mllst not be Pllsl>-,tart.ci, Or startlK1 by tOWing, WI>Wl tha engina is .. t op_ting Itmlperature; usa jump leads (s .. 'Jump starting1.

Introduction Too..earesom&verysimp,,"ched<SthalrleeO only take a lew mino,rteo! 10 carTYoul,bu\ that could salte you much inC(lllveniooce IlI'Id expenH. TheseWeeWycl!ecksrequirenogreat.kiII <)I:spo>COaItooIsandlhesmall amountottime Ihey take to perform could prove 10 be very well spent, lor axamplo!, SOHC engine dipstick B Englllfloilfiliefcap C Cooiante~ D Bnlkefluidreservc>'r E Screenwesherlluld F Batte<)' UKeeplng an eye on lyre c(>nd~ion and P«",u'on. will lIot only help 10 'lOP them wearing ouI prematurely but could aJoo !l8.V8 your Ii/e. DMany bfeakdolOflS are caused byel!lClJical problems. Batlery related faults are partlculartycommon and aquicl< check on a ;;:::',basiswiUoIIenpreverrtthemajorityo! Weekly checks 0- 11 :::JJf you< CiW"dllv8lops a brake fMd IBak, the li,sltime you mi<;;Jht know aboot ,t is when y(lur brakesdon'l work propOOy. Checking the~eI~rtywiIIQi~wamtngot!hiskfnd cfpwbwl1. :)If theoil or coolant levels run klw, In..c08l a/repairIng any engine damsg<I will belar grealer II\an fixing the 1Ml<. for examplll

1997-2000 Vauxhall Opel Corsa Service & Repair Manual

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