2004 VAUXHALL CORSA C Service and Repair Manual

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 reseed. 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 I I I I I I I I I I I I I I ,--, ' J r- I I I I 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.

2004 VAUXHALL CORSA C Service and Repair Manual

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