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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 ,;g hls,eserved.Nop.r1oflhi.bookmayboo",~orl"","_
Bmmlwt> ... " C.tI>IoguinginPYblic • • io<1 0iOlo "'~ reourd ftt lhisbockisQvaial: " 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:='d r ~4 1 ~[;OORBEVOI!;CEDEX.FrarlCe
H_. Pub~shIngNorOisl<aAB
:d all do IIV"'Y lIme we Ill'll ~"'d lh'
Ana_ageofl0peoplearflk~leodev«yday
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
"""".-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 day 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"mindto 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
II'Iqpectlon pjl. • Anothercause of fire is an eiectrlcal ~orshort-drcu lt. Tllke""' .. wh.., ~ormodifying thevehid"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.
• 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$Ong powar tools. and,.fIen working undertl'8 V<lhicIe.
'Oowwr <)loVMoruseb3rrlercre3l11to protect yow handS wl>on I"I<ICIISII8I"Y
• Do get IOI'lMIOr>II10 check perooocally that all is weH wilen working eIoneon Ihe
"" ... 'Dok88pIoQ""clQlhlngandlongM!fwell outofll16wayolnlQ\ling~nic.alpwtB.
• Do.-.sorathat urylifting orjaclong equlprnenth3sasafework1ngloadralirog adequa.le for Ihe job
wheneo:wtaonrypesofsyntl>etlcrubber,found on some O-ring.s. oil Ml8!s. fuel hoMe etc. 81e expo68d10 tempe.-aturasabove 400'C.The rubt>etchangosinloacharrador s ticky subetarlC<!lCOf1taimngtheacid.~fom>ed, lhea<;k;Jremaln.dangerous forye6r3. If It gII/$OOlothttskin,olmayoonecassatY'" MflPCItal&rhe"mb(;(}("f(;llfflf. • l'Ihendea!ing WIth a vehicJewhOchh3s sutlereclaflr1!,orwrthcomponenillsatvaged from...::l1lvehicle, ........ rprolectivegio'lffls wod~1hem aft&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&
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
• 00n1 use III-folll/l(j tooIswhdl may slip and<;il~"inj~ry
• Don'l IOavelOOl$or parts lying around wheresomeonecantripovertMm.I>ICIP up oil and flMll spUis at once
• Don't alklwcnlldron or pats to play in or near a vehocle being worI(od on .
0'6 Introduction to the Vauxhall Corsa
Theong,na1 Corsa mod~ls we,,, firsllnl'odUC«lto tne EUrope;ln ma1<etinSpringI 99Jandarecove<oo in lheOOlllparuon pubHcationlo ltusmanual - SAM 1985. The modols oovered in Ihis publication are the April 1997 onward models. whi~h w",,,lhe .ubi",,1 of a model laoel,/1 togethe, with eXlen3i~e mec~anlcal ,..,vlslon~. This manual ~ models fitted with petrol anginas. but olh ... models in the f8fI!)e
ar"avai'abkowitlld!es<Nanginoo A vanety of petrol 8I1gines are !,,,,,ilab+e in tile C0rs:3 rarl\IfI. of 1.0,
1.2, 1.4 and 1.6 lilro capacity and wlt~ single o~eme3d camshaft (SOHe) or dauble overhead cams~aft {OQIK) configurahon. All ""II'I1orr are of the four·cylinOOr. in-Iiootype. with theexcepllon of Ihe 1.0 litre engine .... f"Iictlis II three-cylinder ~M. The 8ngin .... aIIMwtIuo!l ;,,;..etion. a nd me filled wrth a range of emksion control systems.
Th e Corsa Is available in 3- snd 5-door Hatchback, CorYvan (3-ooorVan bMod on Hatcnbacl<),and Combo Van body styI&s,WIth a wioe r3flQe 01 fittIngs and inl .... ior Irim dep.",ding on lhe model speclf\calion.
Fully· lndependentfront"""psnsion i1Ifitl8d;the rBar 5UspenIIIQIlis S8I'I1I-indeplll1denl.w~hators<onbell mandtrailingarms
ThBmanual gearboxisofthefiv<H;poodali synctY~~anda
four-s~electronically·controiled tran$mi""ionisavaLlable85'" optiononcertainmod9la
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 fau lts 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 thal r 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'kfo'd WhOhe I P8din tM8prod uctlonofthl "
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 roads ide emergerlcies and breakdowns. You w il 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 angina. 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 rlka 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!reapp ioablej llr8col",,,cted f ilmly
=""
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!l ltalidles~.Switcn
on tt>e lights. rear window demister and heater bk>weI" moIOf. ttl«I discool18Ct thejumplNd.intl>ere. i ,seorder cf cOllMCtion.n.m on th ~ ~ght"etc.
Roadside repairs 0'9
Wheel changing Some of Ine d .. tail~ shown her<'> wil l 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
4 Ralselhejack wrnlstlocatingbeiow the flld<i"9pOOt{ ............ tho1too)ack~onfrm grOOSldaod1ocatedon th~COIr C<.>'r«:tly)
Finally ...
."",~.,- . = Rwnovelhewhe<!lchocks.Stowth"jackaootool~ l nthe 3pproprlat8 Ioc"'ionsinth8car.
= O>eck II1II tyrB PfflS$ure on the wheel just fitted. If ~;,. k1w. or ~)tOO don't ha~" a pressure ;a>gewtthyou. dnv" slowly to the nearest garage arld Inllate the ryre to the correct
__ 1hII damaged ~ or wheel repa,red or repiaGed, a. 800rl as possible
:'!e~i~r=r~is~OO\JP", 01 large
o Hthegroundissoft,...seallatpi_ol wood or paVIng to sprsad the load UtlOer t!>elootolth8 )ack.
6 :~~C;;g~~~~h ~~w=';~:e~~ low", the cor to thegroooo. Tight..., th<I
wheel bolts In th. ~ooqu.nc. shown, fit the ~~:n ,,00 &&Cure the punctuf'fldwheelln
0- 10 Ei?adside repairs
IdentifYing leaks
C:V~O:le~~~! g~="::~. :: undemaath Ihe car, ~ a INkttlat MMIs OnvestigaHng.I!"""~bed~to
decid .. whMe Ihe leak is coming hom. • sp"daIIyHlhe~ba,.veryd"y !llreadv·L-'lQkingoilorlluidcana/sobellk>wn rearwardsbylhapessagooolairundllrthec:ar, gi~ing /I. false ompressoon of where th(l
-~ ....
Towing Whoo all .. Ise fail., yOY may flndyoursell ha"';ng 10 get a tow home-or of coorse you may be helping somebody ~Is ... Long­ dislance.ooov"'Y should onIyba doneDy a garage or b<eakdown se.vice. For short ... distances, DIY towing uSing anothe, cilr is easy enough. but observe the following points' CU ... a pro~tow-,ope - they8Hlnot .. xpenslve, The Yehie te beinlllowed must display an ON TCNV SI!ijn in its rear window. CAlways tum Ih e i(,ln ilion k"y IOIIut '00' posrtiOO when 100 vel"lIcle is being towed, so thatth stee,ing lock Is ",Ieased,and
A Wamlng:Mo~t ... tomotw.oIIs , . ndflukh<arepe>i$onoUs.W"sh • rhemo"slrln,;mdch-..geOCll
orco"tamin .. tedclott!lng. without delay •
~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 ~ationalwithtM ooginerunning
Power steering fluid
Pcwer st""rlnglluid may I6ak ffom the pipe connectors on I""'stoo&ting rack.
n On models wllh power steering, ~r""te r­ 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!,
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 prob lems. 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 wi ll belar grealer II\an fixing the 1Ml<. for examplll
0-12 Weekly checks
Engine oil level Before you start o'Mak. sure thilt yout'car Is"""'" vcund o'Checkthe oil""'lIIbIoforllu..QI'iSdriY«I
~wi=~~~n.rtesatterthe....,.t.st-.
The correct oil ~CWIgIIleSp/lK:egntllrdem~ndsonlheir
oil. /t~->,important!hattlleeorrec'oi/for )'CUrcatJsUS«l(&M'Lubrlc8nlSandfluich)
Car Care e lf you have to add 011 freqvenUy,you should cheekwhethe.-you hav."",yoilleak$. Place some clean paper under the car ovemight, and ch""k for stain, In th"morning. ~there artI no ieaks,the engine maybe bum;ng oil
:.::~ :~I~~s:~ !e;:s [:~w;:ot~~ 3 ::~h~h~ OIIbe the bet"!:. ~ ~ If Ihe leve4 is 100 low severe damage may {MAX)marI«B)....::IIower(hliN)m;vI<W occur.OiIseallllifurelTllt)'r .... u!t.fflheengir.l! kso"erlmedbyadd~gtooroochoil
Coolant level
.&. Warning; DO NOT ."empl to , remove ,,, • • "piln$lon tank • pt'ftsu .. t:1Ip when fN.ngill.
~"ol, •• 'henJ/s.very"rNt risko f SCIlk1lng.£)onotl<lave Open eo"'",;".,,, 0' "00'.''' ~asltbpoisonoUL
The coolant level veri .... with the ternpe'8Iu"" of the engine. Wh&n the engi"", ise<>d.thecOOant Jflvel should be near tho COLO (or KALT) mark.
Car Care • Adding coolant should nol be.-sat)' ona'egularbasla-Iflrequenltoppmg-upis requir8d, ~ .. likely Ihere IS.""" CIl9d< II>B radlator,allhoseIandJlXllt.c:esfcrSl\lnsof MalnlrogOt_andrectilyasf'lllO!8Slll'}'
4 Oil is addlKlthrough the fill ... cap. Un~ .... ewlhecapand tOp-uplhe i6vel.A lunnel may help to reduce spllag •. Add
thoe oil slowly. checking the level on the dip$lickfrequently.Avoldoverlil ling(seec..r
""".
Brake fluid level
A Warning: Brake "uld ell" h8"'" , your .. yilt" 8"d will damage • paintad suriacN, ao IISI1t
IXtremecautlon when hlllldiing <I"dpouringit, A Warning: Do not US" fluid that
, /rIJS been af""ding open tor • some time, lis It absorbs
moisture from tha air, which '--'-""-______ --.J
can c"use a dangflroll,,/on of bt1ttlng."oK:t~8ss.
The MIN and MAX mark!; are i""itatoo on the reservoir. The ftuid level musl be kept ootweoo Ille mar1<s at aHtlmes.
2 ~I:~~~~f:::~~sa.~;.:;;~:.e ~~U~~i:;:m~n~: lhereserllolrcap
3 ;u~~U~I~i ~d~I~~d~8~~:~C:~ ~hoet s~~f~ ~~~~~b<;~ diIIerent types can cause damage lo tOO syst..,."Theosecurflly refit Ihe cap and wipe ()fflll1y8pi1t~uld.
Power steering fluid level Before you start: .-ParI<IheVflflicleonlev"'grolJlld. '-Serlhesl&arlngwh.-alst'a~hl-ahead
"The eng ne should berumed off.
There5e",oIrl~Ioc.oIMallhelronllef!­
hand~;rn, of the engine compartment. The power ste-er1ng ftuid level is checked
with. d ip$tic~ Qltached to the reservoir hl le< cap. Un.crew the ftller cap from the lop olthe r8S9/VO;r. and wipa all the flu id Irom the Mld with a clean rag or paper towel. Refit the reservoi" liller cap,thoo remoV<l it once more. Note the fluid level on the dIpstick. When the engine ts cold. thenuld "",elshoold be up to the lower mark on t he dipstick. When the
Weekly checks 0"3
Safety First! e lflh<!reseNOlrreqUlresrepootodtopp;og­ upthlsindicat"'lI nuid lool<~e inlhe syste m, thai should be Investigated omm9dlately
e lfa laak is susp9G'loo. tha oar sMuld oolbo doyen until the braking system has been
::"~:;~take anyriskswher8brakea
Safety First! e Theneed fOO" frequenltoppirl\l·upindic;rt"", • leak . which should be invest igat&d immecllately
::~r:.~a~~be~~~;=~:kt~ 2 ~:~rt=n~h:a~~:e~f~: ~~::~o: thedipslick. liller cap on oompie1ion.
0"4 Weekly checks
Washer fluid level Sc,eenwash additi"",s r>OI only keep the wlndscroon clean durlllQ roulweather, they also Pf'8llfln11h8 wasIw symemife8zing 11 cold
wealher-wl"iGhiswhenyooarelikelylQl'W.le(!
!c=;..~·~~P=':;~=MW:':: :: freeze du,ing cold_alhM. On no accoont use antifreeze In the washer system as this coulddiscolourordemagethe paintwork.
The sc • ..enwast- fluKJ reservoir Is located at the rear left-hand cO/TIEM"olihe enginBcomp3rtment
2 When ~p the '_"'oil". 9 """"mwash add~.iv" shoLJid be added In Iheqllal1llties recommendoo on tho botUs
Wiper blades
Tyre condition and pressure It IS very Important lhally, ... an, in good condhion,ar>d at the oorrect pressure-havi"l! a Iyrll failure ot any speed is highly oangerous. Tyre wear is Influenced by driving slyle-harsh braking and aCCflleratlon, or last comering. will all produce morerapidtyrewear.Asa gan<l<ol rulo,the/rontry.eswn,out last .. , than tho rears. Int",changingthetyreslfom front to roar rlo~~ng " the tyres) may 'Null in more ellen wear. However, ~ this Is complet&ly effeclive, you may have the DXpenOO of replacing all four lyres at ooclIl Rem!.we enplails or atones embedded In the
:~tl:'°l~ ~:v~~:'ara':llt::r~~~e:'~
1 . Th&origlnaJ IYrlls have tread wear s.afety
t.Ids(B). which will appear when the tread IIOIpthreaches approximately 1.6 mm. The -.d positions are indicated by atrlangula, -wkonthfityre siduwaiIW.
th& tyre haS been punc:tumd,refittl1enail so that hs point o1peor1e\ratioo ismaJ1<ed. Then immediatelychangethe wheel,amlhavethe t yre repairo:d by a tyre dealer R99ularlycl>eci<thetyresfordama~lnthe
form of cuts or butg"', 85pecially In Ihe • idewal ls . Periodically remove 1M wheels,
~~~=::a::~::'~~ signs of rusling. corro,ion Of other dtomage. Ughtalloy whaels ara easHy damaged by
:~~~h!rt:,:n~.:=~ isveryoflentheonlyway\oc_~_~
dam~.
2 Alternatively, tread wear Can be monilored with a stmpla. Inexpensive device knownas a lread~indic.ator!ll'uge.
Tyre tread wear patterns ,.-~~~~~--,
~tion(w&aronbolhsidnl ,.,.....-Wlatioo wj~ cause overt>aatlng01 lhe __ oac...ose the ¥e win Hex 100 much. and ... ~wilnolsitCOf"",tlyonthl!fOad ....... Dliswtll C3lJsea'=>ssolgripand __ ' wew, notlomenlkln tl>edangero!
.a."I~IaiI ... edlJ8to neat build·up. ClIok:itMtdltdjuslPlll$l)Ull!5 .....-...ct ~ camber (wewon 0 .... side) "",-"OI"ntnllWsuspttmionptJtts -....----
Over~ation Over-inflation will cause rap id ""&ar o!lhe cenlrepartollhe tyre tread.coYpledwith reduC<!dgrip,ha!Slw"ride,andtheoong<s"oi shocI<damagfloocun1nginlhetyrecasing. Cht>c:J<andadiusrpressuros
If you som .. timas M" .... 10 ,nflale yau, cars lyres to the Mig~rpressur .. s spftCififldfor maximum Io9d OF wsl9lned h!gh spHd, dofI·, z;;:e,.:a,~.redU(;e th e pre~sures to normel
Weekly checks 0.,5
N,wlyras9hoo1d be belanced wh€O"l they are fitted, but il mayl>ecome neCll'lsary10 re­ bela""e th &m as they wear, or il the balance welghts fitled 10 the wheel rim s houid faJl oIf. Unbalanced tyres "111 1 Wear more quickly. M will the s""'ring and suspenSIOOoomponoots . Wheel ImbalanCfl Is normally s4gnified by vibralion. partICu larly ala certa in speed (lypically around 50 mph). Iflhisvibration is r.ft only through tho! st!'lf!fing, thoo ~ is liklMy' th.allustthefronlwh~5needbal~""'ng. If, however . the vibta-lion;5 f"1 th rough Ihe wllolecar. Ihe rear wheels could be OUI of ~_ Wha91 balanCing should be carried OUIbyatyredealerorgarage
Froot Iyfes mftywear ...,,,,,9Iliy"" 0 r""ult of wheej mlsallgnmenl.Mosttyredealfttsftnd garagss can ch&ek and adjust the wheel
~~:~=~~!ramode", charge
0· ,6 Weekly checks
Electrical systems
COnd'l,on and Ihat Ih. clamp is tight. COIrO$loononthe trll\l ,retaifllngclampll'ldthe battery itsetl can beramoved wtthasolution 01 wal ... and baking oodo. Thora.Jgt"iy ........ cleaned a<taS with weI ..... An'! metal part~ damaged by co.,.....,n should be
tlCheckalle:<ternallightsartdtheOOm.Aefer tlVlsually check aU aeclCllble wiring to the appropnate Sections Of Chapter 12 101 connectors,lIarnesses and retaining clips for detail. ilany oltha cl,clJits .. relound to 00 securityondfOf!lign!lofctralingOfdomage. Inoperatlve
1 ~~~~~~~~~~~~~:i;~!::7~~::':r: .eplac ed. Raferlo Chaple. 1210rdelail •. II both brake lights havela,ed, ~isposslblethal
the s top·lighlswllch opet"aled bylha brake ~:~.h"" fai led. Refer 10 ellaple. \I for
coat..:lwrthazioc bosedpr;mer, lI1enpainted. "'Periodica ll y lapproximal!tly w.ery Ih ..... mOlllhs).checklhecharg9condlllonoflhe battery. as described in Chapte< 5A .,. tfthe batleryis flat llIldyou r>eBd to jump slar\)'QUfvehidtl,sooRMdskifJRepltirs.
2 ~I~:~ 1he1~igh~~::eOI :~att:.,~~; connection • . You ..tJou ld flol be able to
move them. Also ch&ekeach cable lor cracka IlIldfray&d conductors.
3 ~~':.":~ ~nn~I"7herer~~:ii~ ~~ p.o.i<I..:I. Fil a new luse 01 the Same
rat lr.g,BVallabtlll.omc","acc,,"sorysooP'S. It is impOrtant that you ftndthe'1I1I9on tt\alth\l fuse blew Isee ElectriC<Ji !(full !indin~ in Chapter 12).
Weekly checks 0·17
Lubricants and fluids Engine
Manual gearbox .
Multigrade 8flgina oil, viscosity SAE SW/4(J or 10W/40, to API SH and ACEA-A3.96
Automat ic transmission ... ... ........ ... • • .
VauxhalVOpei gear oil No 90 540 998
Dexr()t1 type 11 automatic transmission fluid (Duckhams ATF AutotTans 1/1)
Powar steering fluid reservoir
Brake fluid reservoir
DexrOf1 type 11 automatic transmission fluid (Duckhams A TF Autotrans 1/1)
Clean water and anbfree.z:e 10 VauxhalVOpel specification GMEL1301 (Dockhams Antitraaza and Summer Coolan~
Hydraulic fkjd 10 OOT 4 (Duckhams UniversaJ Brake and Clutch Fluid)
Choosing your engine oil EngorIM need 011. not ontyto lubric3temovir.g p.1I't$"r"ldminim~ewear.butal80TOrrlll. l mlae
POW .... output and to Improve fuel ecooomy. 8, inTroducing a simplified and improved ~eolengineoi ls.Ducl<.h~mshastak9n ...ay tIM confusion and made M e~~er for you IOd">ooosoi!therightoil foryourlOl"lgine.
HOW ENGINE OIl.. WORKS
..-:s, prweming wear and hoot build-up.
• Coo ling hot-spots ·~turesinside the.nQineCII.nexceed
"<IXI"C. The &nglne 011 circu lates end acts as _D:IIliInI. transferrtnQ he~1 from the hot-spots l::"SIJmP.
• Cleaning the engine Internally Good qua!ity oogine oils clean th" Inside oT your engine, coll&oli1l9 and dlipersing combustion d8po~it8 and contro ll ing them until they are trapped by the 011 niter or/lu$hlld oot at 011 change.
Oil CARE · FOLLOW THE CODE To handle Qnd dispose of used .mgin" oil sllfely , ar .... ays
• Avoid skin conl. cl with used engine oil.
~ ~:~t:~~':n°r;:~,:~ OIL CARli • DisfXJse of us .. d oil ~ anrl emp ty packs in.
"'T~ ~FEEt},~~ ~the onenearesttoyou. ~w_ .. , ....... ~ ....... Newlr tlpolfdownrlnllns
orontoth .. grrx;nrl.
DUCKHAMS ENGINE OILS For thG driver who demands" premIum qua l~y 011 for comp lete reassure""". w" r~comm<l!ld synth~tic formu la Duckhaml QX" Premium EIIg\ne Oils For the driver who r&quires II straight­ tOlWard quality oogimo 011. we rllconunend Duc:kham. H~ EngineO~s.
For furthflrinlormatlonandatJvi<;e, caJJ the DucMo!msUKH<>IoIintloo0ll002129S3.
0·'8 Tyre pressures ==~:s ~re quoted for standard lyre firmenrs (see Chapter 10); consult" dealer or Iyfe spscJat.'st for alternative or l?'IIsoo
Corsa and Corsavan Normal load (up 10 3 passengers)
1.0Iitrernodels: 145/80 R 13-75Ttyres . A1lothsrtyr9S
1.2 rrtre SOHC models:
145/80R13-75TIyres 2.1 bars (30psJl AIIotharlyres. 1.9 bars (28 psi)
1.2 litre OOHC models . 2.2 hars 132 psi) 1.4 litre SOI-IC models with singl~oint fUQI injection (X 14 SZ): '_R~~T_ u_ •• AIIothertyres. 2. 1 t>ars (30psi)
1.4 rifle SOHC modeis with mu~i- point fuel injection (C 14 SE): AIIlyressiz~.. 2.3 bars (33 psi)
1.4 litre OOHC model 2.4 bars {35 psi} 1.6 litre models
Fully laden: 1.0 litre models . 1.2 Irtre SOHC models
2.2 bam {32 psi)
2.3 bars {33 ps~
145180 R13-75Ttyres 2.1 bars (30 psi) A1lothertyres . 1.9 bars (28 psi)
1.2 litre DOHC rnodels . 2.3bars{33psi) 1.4 litre SOHC models with single-point fuel injection (X 14 SZ):
145I8ORI3-75Ttyres . 2Abars {35psi) Allothertyres . 2.1 bars (30 ps ~
1.4 litre SOHC models with multi-point fuel injection (C 14 SE): All lyres sizes.. 2.3 bars (33 ps~
1.4 1i1re DOHC models 2.4 bars (35 psi) 1.6litremodets 2.2 bars (32 psO
Combo Van Notmalload(upto3passangers} . Fullyladen.
1.Bbars(26~1 1.6 bars (23 psi)
1.9 bars (28 psi) 1.7 bars (24 psi) 2.0 bars (29 psi)
2.2 bars (32 psi) 1.9 bars (28 psi)
2.1bars{30psi) 2.2 bars (32 psi) 2.0 bars (29 psi)
2.7 bars (39 psi}
2.4 b<l"S (35 psO 2.2 bars (32 pSl) 2.9 bars (42 psi)
2.8bars(41psO 2.5 bars (36 psi}
2.1 bars (30 psi) 2.2 bars (32 psi) 2.0 bars (29 psi}
2.1 bars (30 psi) 3.5bars(51psO
1-1
Contents IWdl!0nerftnerelemenirenewal """""'1.(: transmission fttJid kmll check . ~allctransm issionnuidn","wal . .......... lictraosmis8ionsysl9lllCheck ~drlvebell checkandrenewal-
.. .... ....... :~~ ~:~~=~.st-...gchedl .. .... ........ .. :.::~ 33 Generallnfonnalion .. , ..... 1 24 Headtighlbeam abgYnentcl-*. . ... .. 12
1.D.-Idl .2Iit'eOOHCongir>es . -'-Y drtvebelt check and ranowal-
... . ..... 5 ::"a:===:·: .......... :: .::::::: :::.:: . ::2~ 19nttionHTsyslemd...:::k •• 7
1.2SOHC.l.4and l .6 1i1r&9r1gines 6 ~.ndunderbodycoodiboncheck . 11 ~a;::fi~:a:::~~.:: ....... ............ ::~~ =::=ewa;:~.c.~ .. : ::::: ::::::: :::::-:: ::.~ Rearbrak&pr~valveadjustmeotch""k-l.4ar>dl.6
I~re engi.... .. 15
~ '!::!F.ment Ch.~. :: .......... , ...... , ... .. . ~ Roor bra~eshoe. drum and ""-I cy~nder chee!<. . ..28 Reersuspensionchec:k .. 31
~ncheck ...................... . . .. 32 ~syst""'check ............ .. . ....... . . .... l1 :::~_~t.,..,.,.. ... .... ....... ....... . :: ::.1~ ~controlsystomcl1ec~ . 9 Roadwh eel boll lightness check 13 ~managemootsystem cheel< 8 Sparkplugchockand....,.,wal ...................... 34 &9w oIllfld filter ._wm .. . ..... 3 Timi ngbeit renewal-l.2aodl.4 1~reSOHCengu- . .. ..... 36 ~systemCl\eck .. , .. , . . . , .. , .... . ... .. 16 Tmi"ll beIt.--wal -l .4 and 1.6 Itt", DOHC engines . 35 ~brak.pad.ca~perand dlscchack . . ... 14
Degrees of difficulty
Capacities Engine 011 mCf\ango:!,lncIudngfiltr
1.0ilteDOHC.-vr-s .. 1.2IitaDOHC~
0-._ 10....:l12.ilreDOHC~ . 12andlAilRSOHCenginec:
~oo.:~=~van .. Manualgeartxu
Protecllonto-lll"C. Protectionto-2O"C
325litres 1.0111te
benopertorm;Jt>cegaltl.oreconomy~,bydolngso.
,.4btreSOHCengmewtthslog.poInlf\lel lnjection(X14SZ».. 95AON(Pfemium)or98RON(Super) ...... eOOed 1.4 litreOOHC engine' 95AON(PnonIom)or96RON($upef)~
,~
"""""CDC BoschFLReLDC
Braking system "IIrwoomlrontbrak9ped linir>gtn1ck'--~ Qncludlng backlng piate) 70rnm r.linmumreoarbrakeshoelirnngWckness 2.5rnm
Suspension and steering Tyrepressures Ref ... to..-.dolv.MJdyr:h8cks
Torque wrench settings CooIingsystembltl9dscrew Clankshaft pulley-to-sprocketbo/ts:
1.01L'ld 1.2 litre DOHC enl)i~
c.lIWlloushgcaptofiherhou"ng: 1.08O"ldl.2litreDOHCeogines
SOHC engines whho ut pow« ~tcer l ng SOHCengirleswithpoW<)fsleering
~~~: .. Soa'kplugs . . . . . . '3o..rq)dra,nplu-g
1.o8lldl.2 l1treDOHCengines Alottw",n..--:
" ., " ., ., '" "
" '"
Underbonnet view of a Vauxhall Corsa 1.0 litre DOHC engine
• ..... deat>era~embl1
!.!IIotMryoonditioo indicator I.::Isv>burOOessir;l1ltioo • .¥>'lem DI$ module
CUchC8tbl<l9djusl8f ··ar ..... hoosing 'Qj''''~
"1!CWJweldipsrJck ""-mostathousing .::..v~lnmldng --- __ metar
"4 Component locations
Underbonnet view of a Vauxhall Corsa 1.2 litre DOHC engine IAlrcJHn,,,...,Sfttl1bty
~ ~=~ s;::""re::::,.r;! top mounting
4 Air box
10Clutc/lC8b16~W
Underbonnet view of a Vauxhall Corsa 1.2 litre SOHC engine
1 Airci68n6rlfSS8mb/y 2T1mlngbeltcovero
~ ;:::::: ==": 10Barterynegative(eartn)terminaJ
:i:':~cood:U/e.o~t()( 13 Cooi811tllose 14 Raif",lor 15 Coo/IIIg fall 160i1/ett8l~tic/(
:~~~=sa 19 Camshaltooverbre!l!llerhose 20AII"",,,!or
22 011 fill&rctlp
23 r::::::.:::orlessignilion sys!8m (DiSJ
Component locations 1· 5
Underbonnet view of a Vauxhall Corsa 1.6 litre DOHC engine I AJr cleaner assembly
~=~=ru/topmounllng 4lntaMlIirtempe/lll'UreS<.ltlSor 5 1n1e1manJroIdllpper SflCUoo 6 Mani/okiI!bsOJufBpre!SUretMAP)""",,,,,, 7 cooJanr expansion tanh 8 Was/lerfluid rnsfNVOir 9 Battlff)'nflgative( .... rth) lwmln8l
10 BIltte.ycoodilioo 1000cator II BOlIIl9tMli-r/leff /lJarmswi!dJ 12 SecondBI)'Birin;ocoonswitchowH-v&'ve 1l Se<::ondatyl.lirin;octionpump 14Po_steMt7gtfuldrtJSftf1I&r 15Secondaly llirin;octionairduct 16:lor!eSSignllionS)'S!em(DIS)
17 0iI1ev9I dJpstJck '8 SecondaI)I air inittction oombinatioo valVe '9 OiI fi!II!!r cap 201I!ermostal/)OlJsi~
11 ...... lntake tl1.ln/{ing 22r~ b8Ilco""",
'i>e!rOlpipes lF~&npMsJoo/owerann
JI"'l:W braJ(ecal'{:>6t
Front underbody view of a Vauxhall Corsa 1.2 litre DOHC engine
.. Ftont~nsJon tle-blVtrootmounting
-Etvne oil dtainplvg
_"'tgw../rMd dri"flSh6ft
'.6 Component locations Front underbody view of a Vauxhall Corsa 1.6 litre DOHe engine
I Petro/pipes 2 Fronr suspensIoolcJww.", 3Fronrbnl/alcaJipw 4C/-=-icatlJ&ter
~:"'~MIontie-b8'l'rofIfmoont/llg
7Anfi-roilber
"""'" ,~t::=:::'7mling 71 Brakefluldp.pes 72lA1w8ha1'1,*t8r 13 Diftetenr1alco_piafe 14Rear~gN!box/llOUnMg 15~rl'rontplpeconnec/ioo
16 EngIne 011 drainp/ug 17 SrN'ing rtICk lBRlght-/>snddt1v9sh8ft 19~1lrontpipe
Rear underbody view of a Vauxhall Corsa Hatchback model
l£!IaKeffvidpJpe 2F1e8rsu~/nIiiing""" 3F!eerbrV:floacJ<plate
:~:r$lPencer 6~th/;l/lrshieJd
:~:=:::;~!f8p 14~~
The maintenance Intel'lals In this manual are provided wilh th .. assumpllon that you, not th&deale<, will bB carrying out the work. These are tOe mjnjmum maintem""" intervals based 00 tile 8d1edule recommoodad by tha manulaeturer for vehicles driven dally. If you wISh to keep your vehicle In peak C<.lfId~i<>n!ll all ~"""'.)'OO may wish 10 pe.rform soma of these procedures more ottoo. We encourage trequenl maint&nance, becauS8 it enhancM the efficiency, pertormaoceaodresalev~lveolyourvenk:1e
Ifthe~icleisdriv""indu8tysr_.uSlldtotowalrel l«.ordrt.en
trequently at slow sf)Mds (id~ng In traffic) or on shon journeys, more fn.quent mamlenance inter.als are recommended
When the vehicle Is new, It should be serviced by a faclory­ aulho<iseddealerSeNlCedepartJfW1I,inordertopre&8f\lf)thefectOl)' w_, Every 250 miles (400 km) or weekly o Refer to Weekly checks
Every 5000 miles (7500 km) or 6 months - whichever comes first o Renew the engine oil and filter (Section 3) Noho:F!'fIqU9fI'oiI.xIrdl9r~_goodrortheMglnol.w.
~dwnginglht!oi{lIflhe~fPeCJfitKJ""',or .. tlMsr l'Wioooe~JfrIM~COWIed/sIlIeu.
Every 10 000 miles (15 000 km) or 12 months - whichever comes first o Check all underbonnet and underbody
components, pipes and hoses for leaks (Section 4) Check the condit ion of the auxiliary drlvebelt, and renew if necessary (SectiollS 5 and 6)
tJ Check the condition and security of the ignition HT 9y81em components (Section 7) Check the operation of the engine management system (Sect ion 8) a Check the operation and condition of the emission control system components (Section 9)
U Renew the pollen fitter (Section 10) a C~k the operation of the hom, all lights, and the WIpers and washers (Section 11) r.r Check the headlight beam alignment (Section 12) Check the tightness of the roadwheel bolts (Section 13)
{} Check the condition of the front brake pads (renew if necessary), the calipers and discs (Section 14)
1:1 Check the rear brake pressure-regulating valve adjustment - 1.4 and 1.6 litre engine models (Section 15) Check the condition of all brake fluid pipes and hoses (Section 16) Cneck the bodywor1o; and underbody for damage and corrosion, and check the condition of the underbody corrosion protection (Section 1 T) Check the condition of the exhaust system components (Section 18)
tJ Carry out a road test (Section 19)
Maintenance schedule ,.,
Every 20 000 miles (30 000 km) or 2 years - whichever comes first o Renew the air cleaner filter element (Section 20) o Renew the fuel filter (Section 21) { . Check the manual gearboK oil level- where
applICable (Section 22) o Check the automatic transmission fluid level­ where applicable (Section 23)
t: Check the operation of the automatiC transmission -where appIlC8bIe (Section 24) Renew the coolant (Section 25) Check the clutch cable adjustment - where applicable (Secbon 261 o Lubricate all door, bonne!: and tailgate hinges and locks (Section 27)
':J Check the CooditlOl1 d tt'E! rear brake shoes (renew if necessary), the dnIns arod .nee cylinders (Section 28)
o Renew the brake I\uod /S«:tIon 29) o Check thecondrtJon of1hefrol'lta..spen$lOl"!3t"'O steenngcomponents., ~'!he"-'Xlel' gaiters and seals (Secbon 3m
D Checkthecondotloridtherearsuspe'lSlCln components (SectJOn 31) o Check 1he condI\IOtI of thedn.eshaft /01": ga~ers and the driveshBft jOints (Section 32)
Every 30 000 miles (45 000 km) or 3 years - whichever comes first d Renew the automatic transmiSSion fluid - where
appHcable (Section 33)
Every 40 000 miles (60 000 km) or 4 years - whichever comes first tI Renew the spark plugs (Section 34) LJ Renew the timing belt - 1.4 and 1.6 litre DQHC
engines (SectIOn 35) Nol.:AIthoughthtlnotmllJinllJfll8!forllmingbeltl1)fl6Wi!lonll!es& !II1gine~ is 60 000 mile!; 1'90 000 Irm), il is slrongly ro<;ommended fllal tht!;nterv<llI-S~It>4()OOO""Iss{l50000kmJ(J()V8hia.", .... hidl _$I.1bjct<;tt!dlointftflSiv!JlJS@.ift,mainly~hoItjoutn8'f'$0f8Iotof
~1Op-startdlMng. The actual oolt retlewallnler;aI is fhereforovety much up 10 the~owoor. but bearin mind thal.revere engone damageW!!lresuftlfthtlbeltbrMks.
o Renew the timing belt - 1.2 and 1.4 litre SOHC engines (Section 36)
ttot.:A/thougIlthef>OlT/'!a/;ntervalforllfflingoolltenewalOl1rtJesa engines is 80 000 milN (120 000 km), 01 iI strongly recommended IIlatlhelnte/Wli/sreducedto4()OOOmll8!(60000km)oo vehc/e'l whicharesubjectedlt> inkmsAie use. Ie. mainlyshcrfjoumeysoralo/ ol!tq.l-startdtMlIfJ. ThtIacrua/b€Jt_w'intJwtlilst~1ore ""'Y much up /0 lila Indivodua/ owner. but bear In mind that S8'.'ero engine ~wmr8&Jtrlfl"nllbeitbteaks.
1.8 Routine maintenance and servicing
1 General infonnation
ThI3Chapter IS deslgrwld to hetp the home mecI1anlc maintain hls./her venlcle for safety. 8COnomy.longl,feandpeakpolrlOO11ance.
The Chapter contains a mast .. r maJntenance schedula.foI<lwed by sections deal,ng specl1icalty with each task on lhe schedule. Visual checks, aujuslments component rMlewaland other h<!lplul It<!ms are Included. Reter to the accompanying ilk,osb'aVoos of the engine compartment and the~ofthevahiclafor tholoc8tione
oflhllYarlouscom~ts
SeMcit\gofyourvehlde lnaccordancewith the mi!oageltim"matntenanceachtK:Iula and thefoHowingstoetionswill provide a plannad malntanance programme, which should r""",11 in a long and rehableservicellle.Tnlsisa comprehe n5i~e plan. SO maintain ing seme items out noloth ers at the specified service intervals.wl llnotprOOucethe89016 r~uIts.
As you s ........ ice yoor vehicle . you will dlscoverlhal many of the procedure. can ­ and should - be grouped together. bec3useof thepartlctJlar proced ..... being porform.d. or because 01 thfl close proximity 01 two otherwise-unrelated components to one anott«. For example, if the ve!;icle is raised for ony mason, the exhaiJst can beinsp8Clad at the .ame time as the suspens;on and at-mg oomponents
The first slep in th is maintenance
programme Is to propare yoorsert belore the
:~~~:~:e~i~!. t~:~o:::'~ :.:~ out. then make a IIsl and gather togethar aJl the parts and tools requ ired. 11 a probfem I ~
encountered. seek advice from a pans apeciai~t.or ade.sorvicedepartment
2 Regular i enance
1 If.lrom the time the vehk:l" is new. the rouline malfltananoe schooule i~ followed closety, Bnd lMquenl ~hocks are made of ftuld levels and high-wear Items. as suggested throughoutlhi6 manual, the eng ine will be
~:!:~~~ff=;:~I1::~= :!. ltispossJblethattherewilibe lirn81lwhen the engll1<'l Is running pocrlyduft to the [ack of regularmainte!1Bnce. Th~,s9Y9flIllOf"'li k9ly
II a used vehicle. which lias not fe.celYfKI rogul", and frequent ma.meOlln"" checl<s, i~ purchased. In such cases. addlllOnal work may need to be carried oul. ouillioe ollhe l'OQ'Ji8rmaintenanceinterva~. 3~engir1ewear is!IUs~ad.acompression
test IChapter 2A. 28 or 2C) will provkle va luabfe Inlormallon regarding the overell
::=;!~=::~~=~~ on tho extoot01 the work to be carriadoot.If for a~~mple a compres5ion 1""1 Indiclltas ~enous inlemal engine wear. conventional
""~.
rweeJoYcOOc.l-s ') b)Ched<aJltheengjrre-relatedfluids
rWeeJdychecks,. I cjCOOdrtheeonditionandtensionoflhe
awdlilJrydriV8b<Jlt(SfJclions 5 or6) d) Renew roo spark p4)s (Saction 34) "j IflSP"CI the jgnilion HT Iead:l- whMI
spp/ic8bl8(S8c1ioo7}. f)CIlecklhecond/tlo{loft!JeaJrcJeaner
fiJtlKehImen~ Wld renew ift16ClIssaty (SfJclion2lJ).
g) COOdrrhecondilionof<lilooses.and c~frJrfluidleaks(Ssclion4).
5 Ifth8 aboveOplKatione do oot provelu lly effecti ve, carry outt~e foliowirIQ secondary operations:
Secondary operations All items ~sted under Prlrrwy O()fJfI'tiQn •• plus lheiollowing: ~ Chftck the ignition system (C~apfIK 58) b) C~"", cJwging systMl (Chapter SA) c) ClI«ktherue/ system(Chap(er4Aor48~ d) Renew the ignition HTIoods -wt......
llPf)iicable(Sectionn.
Every 5000 miles (7500 km) or 6 months - whichever comes first
~ FrequM>toHandfilt,.,
m,,;ntenanceprocedrirK whll:h "an boo undwtak.., by tI>tr Drr __ .AsengJneollages,ltb6c:omes ~9ndconl~n .. ttd, whlch/a .. ch <
to ptwnat ... engin" wear.
1 Before starttng Iht3 procedure. gllther togatller all the r'I&C88Sary tools and materiais AJsomakeSIJretha1youha~p""'tyolclean rllgS and newopap<jr.Shandy. 10 mop up any splms. Ideally. Ihe engine oil should be warm, !\S~willdra;n moreaasity. and morebu,t-up
engine oils. It Is advisable to wear gloves wheocanyingootthiawork. 2 Access to theund_ld<!otthe.,&hk:lewllf be~~y lmprOl'ad!fltcanber3lsadona litt.
driven onto ramps. Of jacked up and supported on 3~1a stands (see Jacking and ya~icle S<Jppotl). Whichever method Is chosen. ma~e su r .. thalthe "eh icte femains level. orlf lt Is at an angla. that too drain plug Is at the lowasl POInt. The drain plug Is Iocatad at the rear of the sump 3 RemoIIe lheoil filler cap from Ihe camshatt cover (twist it through a quarter-tum antl­ clockwise and wlthdr8w h). 4 Using a spanner. Of pralerably a sultabfa socket and bar. slackMl the drain plug about
\" ~
enginawithelaelllUfllp
S M ow some time for tMe oil to drain, ""I,ng that it may be "eC9ssary to :::.tl1I' container as thoo oil flow slOW9
• AlIef all the oil hasdrair>ed, wipe too drain ;a.g9rld th,,"eal ill\lw~she<with a clean ra • . ~theconditioncftn.seaiingwash9r.
.-.d renew it If II $how~ ~igM of s~oring or r;IIher damage which may pr""""t <Y1 oil-tight smLClean theama around the drain plug ::>pIWW'IQ, and "filth<! plug complete w it h tha _ nghtenlhepllJ9secur"y.preferab~
:.:.. speCiti"dtorq"",usingatOfqUe
~ Two difte<a nt type s of oil filttr "" II be .-.:ourltered on e nglne~ covered by this .....ual. On 1,0 ar>d 1.2 litre OOHC ItIlginss. :roe 001 fill .... i~ of the element type. Which Is --...d from tile oil fih'" housing and then a -..-. ltIem&nl lsflttedlolhehou'ing. Oneil =-r ang:nes, the filter is of the ....cal contain"" type, which is unscrewed
:"7:: asc:.,~:~~;o~ ~~:~~,:':~ ~.Proceedasdescrib8dur1d .... th6 ~S\Jb-Sections, lIocordif\Qtoall\llno --
3..1 501 Ftttneoapandfilterelement -w.Iy to the oil f~ter housing ••
Every 5000 miles (7500 km) "9
engines
1.0 & 1.2 litre DOHC engines 8Theoilfilt er~r>g;';located atthelmnl
left-hand side of the engine 9 Move tile contaioor into position under the o~ lilter housJng 10 Unscmw lh" 011 1I IIer hou~ng cap and wrtlldraw the cap together wilh the foliar from
i~~i;~~ra~'';;\;'t@r from Ih .. oH filter housing cap '2Uoocleoora<JStor"""",,,allr~oI.
dirtand"udgelfomthe oil@er housing. 13 Remove tha seal ing O·ring I rom the oil Hlter housing cap 14 Fit" new sealing O-ring to the oil fi~9f housfng cap then clip the new oil filter elemenc to 1he cap [S8a illus1ralions) 15 Fit the caP and fdter element aSSIIITIb/y1O the oil filter hou~ing and screw tha C(lP Into position. Finalfy.lightenlhecap lothe 8P8C,fi9d lorqU9 (see ~1u9b"8Iion9)
1.2 SOHC, 1.4 & 1.B/ltre engines 16 The ofl lifter fs located at Ihe tronl lett I_d sk1e of the engine. Note that on 1.4 and 1.6 Iltre DOI1C eng.inernodeJs. access is m<X'l1
easily obtained from undemeath lhe front 01 thev1JhJCle
:~f,~;vft tt>econtair1e<intoPOSitionU nderthe
18 Using an oil lil18r removal tool if nec9ssary.slackonthofillerlnitially.then unscr.w ,tbyhandth" restoflhewrry(_
3.15b .• .• screw theassemblyime>piace and tlghlan the cepto Iha specified torque
- 1.0 and 1.2 ~1Te DOHC eng ines
I'tustration). Emplytheoil in the old lilter into the cootaine<. To ensure that the old filter ie oomplate~amplybaforadisposal. plJr>G1ur,) the tdter dOlT1<:l in at klast tv.'O p1acesand allow any r"",aining oil to drain throltll it tha I"mr:turesn1"ldIntotl1econtaln...- 19 Use acleanrag to"emovea~oiI.dirtand
sludge lrom the filter sealing area an the engina. Chock the old lilterta make sura that Iho rubbor~Mtlno MnO has J"H)t stuck 10 tt>e eog.-.e. II ~ h~. carefully ",mo.e ~ 20 Apply" light coatl1"lg alclean engine oil 10theooaJ;ng,;,-,goothe new filter. then so::rew theilt ... in!o position on tOOoogile. T,g,ten the
~:tz~a%*'a~d:'~a~Q:~t:~ unc\efltlevehlclett>en.llappilcablc, lowert lle vehodetothe!70und.
All engines 22 FlItlwIongIootlYoognlhe filer hoiaintoo camshaftcov .... tJmlIjtruo corrl>Glllrnd"itnd ryp.ofoll(tefw"lo~c/l$Cl<$f1)l"dt1bl"" olloppong-up).Pourinhalflhe Spec'lied quantrryofolllrst,therlWMalewminulesfor Ihe 011 todrain into tho..."....,. ContiOO8 to add oif. a smal quantrty at a1irrl8.unti the Iev&l Is up 10 tha Io....e< mM<.on thcd,psllCk. Adding a further1.0~trBwilbnngthlaveluptolhe
uppermarkonllledipstlck. 23 Slart the ""!line 8nd run It lor a few mInuIes,whitecheckingtorleal<saround the oil fill'" and lhe sump drain plug. Nota th~t therorroyboadclayol atov,socooosOOfore 1M oil POUi<.Q wami"g light go., oul when 11>8 ongIne ,",first stl!l1ed .... ~ th ~ oj l circulates Ihroughthe neW oilliller and the engine oi l 9I'J!lwies belore the pr!l:lSUl"e builds up 24 Slop the engine. and wtlit a few min1Jles
:~h~:~ ::t~:~:~~~ S::~~:er~~: completely full, rochack the lavel on 11'8 dipsticl<.and OOdmOrllojlM1"IOCessary 25 O,SPQSe of t ile used engim, oil and filter safely. With ralMence to Generai rep~"
procedures in the Reference Chapter of this m8nUIIl. Do nat discard the old iilter with domestic household waste. The facility/or w,.,;te oil disposal pro , ided by many local council refuse tips genGfally has a lilter receptacle "Iong:;ido.
3.18 Uslngane>~fjlterremD"o"aftC>ofto slackenthufilWr-l.2SOHC,I.4and
1.6Iitr ..... gines
"'0 Routine maintenance and servicing
Every 10 000 miles (15000 km) or 12 months­ whichever comes first
4 Hose and ftuid leak check ¥:> ::'S:S~n'::'~~hn o::O:Pb::~ct::' ~ =~~~sl~~~ :~:~r~~I~ :a;.V::~:
1 V;suany Inspeet!he engine )<:lInt faces, gaskets IIOd seals for tnj signs ofwatef or oil leaks. Pay partlcular atlantion to the araas aroo.nd the CAII'IShafI C<I~ ... , cylinder heEld, oil ~n ... and $UIT1pjQint f"""",. aear in mind that. av ... " period of t,me. SOmf> very slight aeepagelrom!he&e,,",nlStobe.~;
what you ar. real'Y looking lor Is IIny 1odIca1lon of a serious leak. Shoukj a ieakbe fouod,reoewtheoffeodinggas"'elorollseal ~~IOlhaappropriateChapteBinlhls
2 Also chock the soc .... ityand oond~ion crI all the eng'ne"relaled p ipes and hoses. Ensw-e that mil cableti&ll O'9-9cur;ng clipsara In ptece.and In good condit'on. CI;Ps which ara broken or missing coo lead to chafirlg oflhe hoMS pipes or wiring. which could cause moreserlous~emslnthefutura. 3 Ca;e!u lly check the radiator hoses and '-191" hoooo along the~ .....,Iira lengltl. Renew any i-.Q!O(I wh'ch is cracked. swOllefl or deteriorated. C<ack8will show up boott .... Wiho hose is squeezed. PaycloH attention tollle hoMclipslhatsecure ll>ehoseslothe cooling system component:!. Hose clips can p;nchaodpunctUMhoses,resuItir>gincooM>g system looks. II w~e-type ho ... C~piII aM used, ilmaybeagoodH:l&aloraplace thamwllh screw--\ypec'PS 4 Inspect aM the cooIiflg system components (hoses. loint faces. etc) for lcaks. 'WheM 3ny problems of Itlls natura areiound on system components. renew the componeont or gasket w1threlerencetoChapte.-3.
5 Where applic8b1e •• nspect theautomalic Iransmlsslon1IIlIdcooler hoses for laaksor deterioration. 15 W~hlhevehicl"lalsed.lnspectth"petro l tarlkarldfille-rr.edt forpunclu,BS, cmoksand other damage. The conne~tion betw98n the liller neck snd tank is aspeclally critical. Sometmes. a rubber Mer neck orconne<:tlrJg
=;;:;~:'ru~~Ioo""retai",ngdOOlPsor 7 C ... efullycheck all I'Ubberhos&lland metai
d81'T'l8ged sections~s r'''':I'ssaI)'. 8 From \\I1thln the engine compartment. dleckthesecuritycrlaliluelhoseattachments and pipe unioM. and inspectthu fuel hoses and vacuum hoses lor klnI<s, chafing and deterioration 9 Whereappl icat>le. checkthecond~ionol Ihepower sleeringfIui<:Ihooeeaodpipes.
Check/ng 1 The ribbed type aw<i~ary drivebelt drives the allamator. coolant pump and the power steerlnQ pump and/or air conditioning compressor whure applicable. M automatic d'ivebe~ tensionllf is fitted. and there I! no requirement to check Ihe drtYebaIt tension 2 For improved 8e<:8SS. remove the air cleane.-assembtVasdl!scrit>edinChapter4A. 3 The beU should boo illSpM'ted along its efltlre length,and II II Is foond to be wom. frayed or cracked. ~ 8hooId be raoawed 88 a praeau~onag<lllnstbreakagein~.
Remoll'a/, renewal and refitting 4 To remova th" driv&beil. remove the air cleaner assembly (H not already done) lor improvad a<:>:::ess. as described mChapler4A.
~o:~:~edrurriog<irectionollhobett~~is 15 On modelswtthoutalroondltlonlng. obtain aw~e rod,orrolipin.oIapproximalaly4mm
diamat", which can be used to lock the tenaioner in the released position. Using 8 su itable spanner or socket and wrench ~gedwiththeteflslOflel"roilerbolt.lever the tensloner roller clockwise ag3,nstthe sprlngpress~.unt.tt>eholeinthetenslon ... roller arm is ~Iigned with the corresponding
=~::=2;~:;=:~~ L~~~III~~I11!1· p.articular attootlon 10 Iheveflt pipeS and
hole in the tenSlone' body (it may be nOC""88ry to U8" a mirror to accuralQ/y observe the pos,tion of the hola),The roller can then bft lock!d in position by ir.s&rtJJlgihe rod Or roll pin throuQh the two holes (SM illustrations) 7 On models w~h 81. conditioning, using. su~able sp3nner or socket and wrench engaged .... ith tt>e t801sioner roller bolt. lever Ihe tenslone< roller clockwi$<l against the spring pressurll,until th .. t""slon .... can I:>e '-rd 10 aeJdibly lock in Its ood position
1.0 litre IH1gine
8 Allach a su'lable hoist and lifting \ackleto theenglneliftingbrackelsontl\ecyl,nder head. and support Iheweighl of the engin" 9 Undo the three bo ilS securing Ihe right hand engiMmounting bracket to tl\e Uming
10 Worklngvnd9l"Ihovehlcle,removethenvt and bolt secunng the right"hand eng,ne mounting txacke\ 10 the mount ing block on the body and wlthdr1!w the mounting bnlcl<et. 11 Wlthdrawtheauxma/Ydrlvebeltffomthe pulleys. t2 Refittne_byslippingthebe~0_
thepu!eys..tftheoriginalbe/tisbeingrelitted. eosunlmattherunoingdimctionmarilsmadtl
5.8aleverlhedriYflbelttensl_roller clockwi", until Ihe hola In the tenaloner
arm tan-owedl Is all9ned with lIIe com"'ponding hole in lIIe t ... "lioner body_
1.2 litre DOHCenglne
releasedpoe.ition- l .2l1treOOHC8rl9ine
hub and tighten the SIX bolls to \tle so..cifi8d torqoo 31 Engage theauxitiary drivebeltw,th th., ~ r""k5h~ft pulle y and check th.u the belt is cormctljl located 011 all tile other pulleys. 32 Using the method dsscrit-j pn"";ous!y, klv<l<"ti><) t(ll1s1on O)r" roIl(,r urrtll theloo:::l<ir'll tool (where used) can be removed Irom the backplate. Use th o spanner or_enoCh !o ~ rlldual ly release the tens,on"" in 0«1 .... to tension the be~. Do not allow the tenSlOllef 10 spring back urlrestraiood. 33 Refit the whoolarch liner and the roadwha"', tightMirl(J tn.. roactwhMI bolts 10 the~liedtorql.le
34 Dioconnect the hoist and littingtackle. then Iower the c~r tothe ~rOlind. 35 Raflt the air claaner IIsgernb/y as describe<:l l1 Chapler4A
;~,F ~ ~~
& AuJtilia::rdrivebeitcheckand ~ ffik: renew. . . . -1..2 SO!:l .. C, 1,:4 and ~ m}>a·~:m ~ Vwbe/t models
Checking and adjustment 1 Correct tel1sion irog of lheauxd'lII'fdrMlbelt will ensure thaI it has a long life. Beware.
~~;~~~ ~r~~~~~~r~hiS C<Wl cruse
2 The ellXiliary d~vebelt d"""" the alternator. arid th" po .... "r steering pump an<l/or atr conditioning compressor .... hereapplicable. 3 For improved access. remove IhIt au'
cleooerassamt>lyasdoscrlbad in Chapter 4B 4 The beltshQuld be Inspected along Hs entire length. end il it is found to be .... om. frayed or cracked. it shoold 00""''' ..... 00 asa precillitlon agaiMtbr8l'lkag .. in S8lVic!I. hil! ad\lls3ble to carry a spare drl~ ebf1 l ! 01 tOO corr8Ct I'lPl' inthe....nicleataHtimes.
on 5 Allhough spocial tools are a ... ai lablef Of
measur ing the belt tension. a g<>Od approximationcanbeach iev edifthe~! is
tensioned so that t llere is epproximate/y 13.Q mm of Iotal free movement under firm mumb and fin ger pressu ... ~tth .. mid-point 01 tho loIIgestrun between puUeys.
a1l<!mator , Tum too adjuster bolt as necessary to apply lenslon to the belt, until thecor",c l t9fl9ioo is achi9v&d.Tl\l ht8nth. adjust...- . t,ul and 1IItematot mounti"lg. on comp"'tkm.
Removal, renewal and refitting 7 To remove Ihe belt, simply loosen the mounting bolt nulls). ~n d fully . Iack .. n t il .. adjuste, oolt. as d ~ scnbed pr~vlously. Then $Ilptoo bGItfromthopul lilys. 8 Refit the be ll. andtonsion it as descflbed """"",,,. Ribb9d belt models without power steering or air comIition;ng
Checking and adjustment 9 Pnxeed asdescribed in paral)laphs 1 104 10 Anautom;mc drivebe/t lensioner is fi tted. ~:'::":reQUlrom""ttOchoo~too
Removal, renewal and refitting 11 To""""",~thedrwet>elT. remov~th~ air
cleanerassembl)r(dnoCal' .... dy dane)for ~~ .. doa:rbIdinChapt ... 4B.
:210~.!:...t. runnng dncbon "'!he bet! ~ it
13 LJs.ngasurt.lblo~...-orsoci<et and
Wl'enchefl!POllld_thl~roI!8rbolt. lever !he 1 __ roll ... 3gaJMI TI>o $prtng
pr ............ ihltroilercanThon 00 locked in pos!oon.ust'lg a Sl.ttablepinpuncllorsimilar toolinsMlildlhroughlh!tlugonthltroU .. r assemIlIy, IOIIf'I9'I9I' .... 'lhltlecotrl'!:<pondlng hoi .. in the 1 __ backplate ($~~
lluatnllonsj. 14 WMlthel~lock8dinposlbon • ..tip tne_lromlhepufley$ 15 RelitthedrMbelt~$Ilppt11gthebeh<lVer the~If"""original beltis oo<ng rer itted.
""""'" that IhII nnning direction marl<.$ made :.!:..r.tMlh aff>p<>shionedas noted before
11!1 Usingthemethod described previously. ... ... '~·_rolleruntil the l ocki .... tool can be removed from the b3c1<plnl o. Uselh9
:=: :=c~t~:i~~Ut~ ~~e~ ;:
:tt~n~~~~~~~ln~ ~~~u~~~) :~~~: =:: Ir\\ ;"4 __ "'''"'" ~ ~- .. '"'"
6.138 L.everthe tensiOO8r roll .... "gainel 6.131:1 .•. unl~ Ih" rol ler can be locked in thelprlngpressure.. position using a suitebiotoDi (arrowed)
'·'2 Every 10 000 miles (15 000 km)
J\ u,vertlle Mn~IoMr ~n~ 1M spring pressure
B Dlmoosionsoflockinglool T~~tOOI(",roWlld)inposition
2 RMiiusJ(),Omm 3 R<ldlus35.0mm
allow the ' ... nsio"", to spring book yrorestral!led 17 Check that the bell i' C(lfrectly l(X;8.t8d on 31Ithapull..,.". 18 Relit Ihe air claanar assembly
6.25 Remove the nut and bolt (arrowed) """uring the right-hand engine mounting
bra<:k'ttothe mounting block
RIbbed belt models with power steering and air conditioning Checking and adjustment 111 Proceed as described in paragraphs 1
"'. 20 An aulomati~ dri""bett tensioner is frtled, "00 there Is flO requir8m&nt to ch""k the drivebeHlension.
Removal, renewal and refitting 21 Procood as descriOOd in p>I'ag,aphs I t aI1d12. 22 Dblaln Ilwirll rod 01 approximately 4 mm (O.16in)diameterx280mm(l,lin) . . Makeu~a suil""~tooltolock the tens.orw",posrtion
as the belt is removed { .... III\JllntIonJ 23 U~ing a suitable spanner Of $OCket and wrenchoogagedwithlhe t __ .o/IerboU.
19var th8tension .... roller aga,n$1 Ihe spring presslJte. The roller CIlIl then be locked in position,usinl/thetoolillS<lftedtnroughth9 l ugontl1eroliOj(a988111b1y,to~withth8
correspondinl/ hol8 In the tensiooe< backplate, 24 Attach a surtBbl8 hoIsI and IftIng tril8 to th .... ngine Irlting br.1ckelSOO the cy1lnder head,and suppon lhewl'li!lhl 01 thol ellgine, 25Working underth~W!NcIe,~lhe nlJt
and bolt S9CUrlng therlght-haod engine mounting txacket to the mounting block on the bOO~ ( .. ""illustration) 26 Remove therlght-handlrontlluspltllsion tie-bar M d ... cribftd inChapier 10. Xl Using the lifting 1IK:kIo!.lowsrthol Mlgin8 approximalely 50.0 mm. 28 Unboiltheenginebracke!lrornthe!X>V18I' $t"ringP'Jmpt>rnc~et (seel.ustration). and withdrew ~ downwards from th .. 8ngine ~ment 29 Withdraw 1heatD<~""Ydnvet>elt from the pull..,. ... 30 Proc...,d Mdtoscoibed in paragraphs 15 to 17 h:lusive 31 Refitlheengin"br9Ci<e!. andtighlen the s9Cur;ngbo1ts. 32 Rllisethe MlgiM.usang thoI iftif1\jlackloo and relit the 1iqht-hai1d Iront suspension ~e­ borwithrefereoceloChaplerl0 33 Refit ih8 nut and boItsocurir>g the righl­ Moo engine ~ to the mounting block 00 the body. and Itgh!en tile nul arld bclt to thespccHioot",que
34 OiSOOflooct the hoist <YId Imlngtackle. 35 Refilthe air cI&anerassembly.
1 To ctJeck the HT leamo. j)I'OC@fldasfoilows. notinglhattherearen<.> KTleadson l .0 aAII 1.2 litreDOHCengines 2 On 1.4 and 1.6 li t r~ DOHC M~ln ..... unscrew th" i'.vo secLifing scr"'~s, and l ift 011 lhe plastic ghield which fits over Ir.e carrt!IhIII
3 Workln~ on each HT lead in tlKn, puH It. end of the lead from the spark plu~ b)­ gripping the end connector. not th~ lead other-vise th~ lead conncc~on may biI fraclured. NOle that On OOt-iC engines .. plasliclool Is provld&d (atltlChEod 10 ooa of lhe HT leads) 10 pul l th e lead~ from thE spar\< plugs. 4 Check inside Ihe cann.",-tor for signs ~ corrosion. wnic~ wi~ look like a white crust"\' powder. Push the conneclor back onlo IhI! spark pILg,en8uring that it is alighlfiton ttw plug. ~ It is not. remo~e tOO lead again , arod use pli~ \0 car~fully crimp the metal t ... mma iMideti1econnectorunlll ~fftssecurflly,," the 8nd 01 the sp<rk plug 5 Using a clean rag''''''petM .enlirele.rlQlhoi th"I\Oad to r&rnov.any bullt-upd<rl a": grease. Oncelhe lead is elMn, check f", burrm, cracks and oIher damage. Do not bena the IC:ld exce~~i . ely, Or pull Ihe I_ :~~~Wise ~ the conductor iMide m,!OI'I
6 o;SGonMCtthe 0lh8l' end 01100 lead from the DIS modulo. Ag:lln, pull only on the caml8C'tQf.Ch&ck for COt1'OSiOOaJldatighl It 3sdescribedpreviaus./yforlhespar1<pUg 8nCI of the "'ad. Refit the lead sBCuraly on comple1lon. 7 Check the remain ing KT leads onto at ~ limo, 11 tr.e sa.me way 8 If new HT I~ads are requir&d, purchase I setloryourspeclflcveh icleandef1\jlnelY\"l<!. 9 Evoowilh theignilionsysteminl'ir9t-clas condition,"orne engi""" may slill oc:casi OMfy ~xperl""co poor sI(lItIng, ntlt1btJtable to dlmp ;gntioncomponents
1 Applytha handbraktl, then jack lJj'> tho! front Of t~e vehicle and support securaly on axle stands; remove the madwh ools (5"" JaclillfJ 8fldvehidasupporf). 2 Foraquickc:hack,toothicknessotfriction material rnmaining on each pad can be measured thf<>l.lgh thilslot ifl thil froot of tho! cal iper body. If any pad i~ wern to the spOlc if1ed minimum thlcknes9 or kiss. all four pads must be renew&d (see CI'1apter9). 3 Feracompnoh'lnsiwochd.lh9b<ak6pOl(l$ shou ld be <"moved and cleaned. Thi5Will aHow the operation 01 the cal iper 10 be cooded,arid 100 DOIldition ollho brake disc
1 The brake hydraulic system includn a numb8r 01 metal pipes, which run from the master C\'llndel to the front and rear brake ass&mblies, arid the hydraulic modulator on modet~ with an antl-tock braking system [ASS). Flexibiehosesarelitted betwe""tho! pipes and the 1mnt and raar brake assernblies, to allow lor steering and sus.pertSIon movemoot. 2 Wl'l8f1 ct\ockjng the system,f;"st look lor 3'l1"" of leakoge at the pipe orhosa unions, then examine tne fl exible hoses for signs 01 cmcking, chafing or deterioration of the rubber. Bend Ihoo hoses sharply betwaan the fi"lJ'lfll (buI do not actually bMd thern double. Of theC3$.ng May be damaged) and check thalth,s does not re.-eaJ prev,ously-hidden cracks, cuts or spltts. Cl>eck thllt the pipes andhoses~secr.nlyfastenedr.thelrc:lips.
3 Carafutlyworl<ing aloog Ihe length 01 tha ""'1IIf pOpes, look torderm<, k.inks, damage of any sort, orcorrOllioo.lq1tcorrosioocanbe polished 011. but II the depth 01 pltIlng Is significant, th .. pipe must be .--wtd.
1 Once tho! car has boon wa~hed , and al l tar spotsaridothersurfacoblemishosha." b&on cleaned off, carefuHy cheo:;k all paintwork, looking closely lor chips or scratches. Pay particular attention to vulnerable areas such as the front panels (bonnet and spollerj,and around the wheelart:hM. Any dama!J8 to lhe paintwork must De rllCUlled as sooo as posstble, to comply with the terms 01 the manufacturer's anti-co"rn;ion wananties; chtICk wthaVauxhllllOpeldealerfordelails. 2 If a ch 'p or tight scratch isloood which fs recent and still Iree from rust, ~ can be \olJCh&d-upusing the appropriate touch-up stick w!lid1 can be obtained lrom VauxhaiVOpel dealers. Any more sefious damag ... Of rU$t8d stoM chips. can be repalreod as described In Chapter 11, but if d~orcorr'C8ionrsso"v .. ethatapanei must be renewed, ~8k profe$oonallld\'ice as SOO!1asposslble. 3 Always c:Mcl<. that the door and ventilation opoolng drain hoIasand plpesarecomplete~ cloar,soihatwat,.,-"""dr.:o.,out
Underbody corrosion protection check 4 The wal< -based undefbody protocti.e coaling ~hou ld be inspected annually, p'ef9l'ably just prior to Winter, when the
"14 Every 10 000 miles (15 000 km) wil USUS"Y st-.Jw up as a black sooly stain in the vfcinity 01 the leak 3 Rattles and other noises can oMen be trac.ed to the exhaust 5ystem. espoc;atlythe bracl<ets andmoooting5{see HlustrattonJ.Try to mo~e the p ipes and silencers. If the components are abla to Goma mtocontact with the body or suspension parls,sea.wethe syst<.>m with new mountinos. OtherwIse soparatethejoints(ifpossiblejat>dlwflltlhe ~::':': necesswy to prol'lde oo"dltlonal
driveistak9ll<J?&moothly,andthat tt>epeoa. trav~ is not excessive . Also listen for lII'lJ noises""fle<o thecl<.Jtc/1ped<llis depre5~. 10 Onrnanual gearboxmodels,ched< that. gears can ba engaged smootkty wrthOUl rris" , iiI1d that tne gear Iov .. r action issmootll arolnotabrJOml allyvagueo,'notchy' liOn automatictran . missioo mod,"" rna. sur&tl1atallg .. arch"ng,,"occursmoot~. w~i1outsnatcr.:ng, ilnd without an incr ....... . eng i n&sp9tldbootw~ncharl\les , Ch8Ck l~ 3Ilth<!g!>ar po!litonscanoo5elected\'JIth1ho vehid8atrest , lrwWprobierns8refound,they
18.3 ctwckthot condtiDfl of the exhaust system rr1oO<KItings (typical example l!nTowedj
underbody should be washed down as tnorClUQlU\l""P<lssiblewithootdisturbing ti1e prot8C~ .. ecoatirl\j,Anydam"getoth8coating stlould be rep3i red ~slng a SoUrtable W3X­
b8sed S8818'. If an~ of th 8 body p8nel ! are dlsturbadforre-paiTorrenev.'al,do not forget to r&-apply the coating. Wax 5h o ~ ld be injected into door cavities. sil ls and box sect ions, to maintain the level of prntect ion proviOOd by tho vooicle manulac1urer-seek thead..-ice of a Vauxhalll0pe4 dealer
%: ~~t: ~~;,,:~~~~~~ac'::'c~~g~;;::~ ~ :~;':~~f~~~e:;~n"'lh~S"~~'~:~:
1 With t ho! ""'girl('! cold I~t l&!Ist an hour ~It~r the vehic le has been driven). check the <XlI1lpiete exllaust system trom the eIlgine to theeond afthet~·lpip". n.. exhaust system is mosteMIy~he<okedwiththe ve hicle~is!ldoo
a hoist, Ofsuitabiysupponoo 011 axle stands i\Othattheilxhaustcomponentsarereadi~
,'i 8ib le and acc",,"ibl~ (BOO Jacking ~nd veh!clewpport) 2 Check the e~h1llJ"t pipes and coonect ions lor .. " idence of lea~s, severe corrosioo atld dHmage. Make 5ure th3t all brack8ts and mountings are in good conditlM. ""d thnt ni l relevant nuts and bolts are t iQht. Leakage at 3nyofthiljointsor inotherparts ot thesystem
Instruments and electrical equIpment 1 O1<lck the ope<ation oflllt IMtru""""slInd 818c1rtal&quipmef1t 2 Make sure that all instromBnts read correctly. and switch on all e'ect~cal
eqLJipment;ntum, tocileGkthat~functioos prOptlrty
Steering and suspension 3 Check for any abnormalitioo in the stooring suspei1:sion,handlingorrnad·foel'. 4 Drive the 'flhicie. and chock ltIat 1tI...-.. are nounusual ~btatonsornoises.
5 Ct1eck that 1he st-w,gf ...... positi\le,with ~ o u c@ssive 'BIopp;r-', or roug~, and che-:k lor any suspensioo nmses when co",aring ~nd driving ov ... bump!!.
DrIvetrain 6 Check the per'ormafICe 01 the engine ciu tGh (where appl icable) gMrbo"/tr.msmissionlWldd~...",;halts. 7 Listen for any unusual noises from the engitle,clutcll8rldgearbo>Jtntnsmission. 8 Make s~re that ltIeenolne runs smoothly when idl ing, and that there is 00 hesitation whcnoccele<ating. 9 Check that, where appiiGabk>,the clutGh act ion Is smooth and progressi~e, that the
Every 20 000 miles (30 000 km) or 2 years - whichever comes first
iIDAlr~oerfijterelement t ==.:~~~~;~~~~ renewal <4 ~ ~~t::=i:~:er=
1 The air deaner assembly is located at the 4WipeoutthecaSl/'"OJ8odthecov&r.Fitlil/l front ri ght-hand corner 01 the eng ine ne-..' l iiter, noting that the rubber locating
Cafr)' out this Ch8Ck in bath di'''''tions. lla dlcklngooseishoord,this lndlcat&Swear in. drh·98haftj<Jint.;nwhichc~S&rerlewtt>e jOir.
Ifn~~S$nry
Check the operation and perfonmmce of the braking system 13 Makewrethatthe.ehicl e doesnot~ .. on& side when braking. Bndthatth9wl\e8is donot lock prematurely when briloklng hard.. 14 Ch8C~ thpt there is no libration throug/' the steering When brakinq 15 Check that the handbrake operates <X>tTactiy without excessive movement 01 tI'lII lever, aM that it holds the vehiGiB sta~,,,,,,,,,,
onaslop.l 16 Test the opemtian 01 the brake servo ....
:~:~;:~s 'f:i~o;~r.:n~~:so~' ~~~r:; :: vacuum, Hold the brake pedal depressec then start Ihe engine, As the engine starts there 'Muld be a notice~ble 'gi"8' in 1M brake pedal asva<;uum ooi lds ~p . Allow !he engine to run for at least two rrin~t e~, VIC th on switch it oiL II tho brake pedal ... depressed now, It shou ld be possible 10 detect a hiSS i ,om the servo as the pedal", depressed, Aftar about lour or r .. ·• applica~io ns, no iurthcr hi •• in<;j should ~ ~="ndthepedal st>ould l~COnS1dernbl!o
~~=":::e o.ocuring clips, and lift the air ~:~I!"tI100~~~t, and socura thG 20,3 Remo'i:~trCI&ar'lerf~ter
Every 20 000 miles (30 000 km) "'5
21 Fuel filter renewal direclionarrowonthemterbodypcitWng
~ mthedirectionoffuelfiow(see ~ lIIuslrtltlrNI) ""' b) Ensure 1M! tile /"Ios$S ~~ ~O<V1ected to
1 Thell.lOlfilleris locatedundertne,.-olthe VO!hicIe t ... iUustration). :l Disconnect the batte()' ne<;latl~e terminal (rele' to OisconMcting tile battery in tha ReferenceCnapter), 3 Depr""SlIrise the IueI s)"8tem as dese,ibfKj on Chapte< 4A Of 48. 4 Chock the front wheel"then jack up th .. f<!aI"Of \he vohicle, and support seourely on axIfIStand8(_~llfIdV8hic!ewpport)
5 Loosen the clamp nut and bolt. and Mthdraw the fill9f from its clamp (,a. illustration). NQle the orientalioo of thll fool IIowd.-..c1ion8ITow II Position a surtable contairoor beiow tho fuel Nlar, to catch sp<llfuel T Release the oomoctors and discorr.ect the fuel ho~"" from the fu .. llilt ..... noting til";, IocJlions to &rlsure correct refitting (SH ilusttationa). AVaW<halllOpei spec;", tool is available to disconn'ICt Itle hose <:<>r1Il<'!Ctors. botprov id8dcare istaksn,theconn..ctions Can be released using a pair of pl lors. 8e pteparedk:<fuelspillage,andtal<eadeq...at" precalrtiorls. , Re<;over the moon!in!! rubber fmm the old M .... and transler it to tho oow fiher. I Filb"ll the oow fiRe. Os a reversal of .emoval. beating in mind Ihelollowing points. eJ El'lsurerhatrhefiIUIIlsffttedwitllltleflow
22.2 Manuel geerboxQil level plug , . ..-
ttreirCOfTOCtlocatioos,asnoledbefonl removal.
22 Manual gearbox. oille'ltll """,k 1 En&Urethatthevehlcl&ks$landirogoolevei groyndOlndthehandbrakeapplied. 2: WorlUng undomo~lh Ihe vohicle. ynscrew tMgearboxoillev8lpfug. II,I1K:hislocallKlin t~9 rear lelt 01 the dille'ential hous,ng (see IIlu",",lionl. 3 n 1f,oIIlevatsl1ouldboruptothelowe<1KIge ofthel&~ptughalt>
4 II necessary. top-up with oil through the Or"eather/fil lerorlflce In the gear selector cove<. Unscrew the Or"eather/filler plug, and top·upwrththespecifiOOgradeofoil.t.ontiloil ju&t begm to run from the level pfug hote. A lun ..... ffiIlyba I*plul.lo avoid vpillage ( .. e IIlustrationll.Oonot<M!l1ill- lltoomLJGhoil IS added. wa~unmlheexcesshas ru" aut d the level pluQhoIe. ReI"rtthe ...... eI pfug ondthe breatherl11~erptugoo completion.
22.46 Unscrewtl1ebl"eatherl1iUerplug ••
• •• en<ltop-upwitttthespectl\ed glllde of oU
"'6 Every 20 000 miles (30 000 km)
, Tochecktl1e~uid ....... , the vehicle must be parked on kMoI ground. AWfIhe handbralla 2 If thl! transml$5ionfluid is cold (ie, If the anglne il cold), thllievel Chack must be completed wrth the eng"'" idling, WIthin one mioutBoIthe~beingstarted
1J6ing8p8CialdoJdicatootestequipment.SUch taS1ing w,1I allow ihe test equipment to read anyfauflcodesstored'nlheeolectroniccontrol (lflitmemory. 2 UnIo:o$$a laulti$suspected. thostest is oot _tial.aJthough~sl'lcUdbenotedthatltls
recommended by ttle manufacturers. 3 If """"""to 9uitable test "'lUlpmllflt is not possible,mai<eathoroughcheckolalcontrol 'ystemcomponents and .... lrlng lor 98CUrlty and obvious signs of damege. Further "-'ail. of the control syslem can be lCUId in CI1apler79.
cannot be drainedoompI8!ely. Cara should therefore betaken when refilling the ')I$tem. to maintain BnttlreezfI strenglh. If the system Is bfllng dralned for coolant reMwal,il rs recommended that the coollllg Ian ,witch II UflSCrewOO Irom the radl3tor (see Chaptor 3) In o.d...- to allow the maximum possible quantiryofcoolanllobedraine<'l 4 If the cook\nthas beMIdrair>8dlor Bl6Boon oth.".lhanf""ewal,tMnprovid.d~isc"",,,
and less Ihan two yoors old, ~can be,e-used..
Cooling .ystem flushing .5lfooolantrenewalhas~n.eglected.or .
3 With the engme Idling. tully depr.s~ the brakepoK,W,.-.d moY<!th&gea. selector lever smoothly Itvough all positions. finishing in ll'*!oonP. 4 WJttl the eooln.e 5111t idling, w~hdraw the trans/TIis$ion~lev<Odlpslick(locatedat!he
lett-hand sldaof Ihe anll,ne compartment, IlfIxl to Ihe engine oil level dlpsllck). Pull up thele'leronlhetopofthedipsticl<. torel&asert /l'omlhetub8. Wipe the OIpgtlck doon with a 1Im-frat!mg,f'1!-Inse<tHBndwillldraw~again
5 lithe transmiss>oonuid wucold allhe baqinnlngoftheprocedure,thetluldlft'llel should be on !he MAX mari< on !he siOe 01 the d ipstick markoo +2O"C. Nota ihal 0.4 fllres 01 fWd is reQUIrad to raise the level lrom the MIN 10 !he MAX mart lsN iQUS\retionj.
25Coo1antr-' ~~~~~~?~ ..... restrlcteddl.-e tOrusl,scaJedeposib.andolhel
6 If the transmission Iluidwas at operating temperat.....,atthabegironiflgoflheprooeob"a (Ie. H Iha vehicle had been drtven for at 1eas1 12 mllesJZO kin). the lIuld level shou ld be bet .... "" the MIN and MAX mar1<s on the side of the d'pstlck marl<oo +8O"C. Nota lhat 0.2 Htres 01 IlIJid isrequi ... od 10 "' .... thft kwellrom !heMIN 10 the MAX mark. 7 Iftopping.ypis necessary,.toplheenglne. and top-up with Ihe spoclfled Iype 01 fluid through thft transmission dipstick tube 8 Recheck the level. and refit the dipstick on completion.
Not.: V.wchalilOpe/do not sp«>fyrene .... aI jnterliEI for the .ntifrRZe mi.o:tu .... n the mixture uMd to tm the system when thl veI1Icleisnew/sd&slgnedto/astlhl ~fe~ of tM vehicle. Ho __ . It Is strongly recommenderJlf1atlhecoolellfis~.1 thajntflfll8Issp«IlierJin!he ·M.tint_m:e sChedulfl',1Isspl"fKA'(J!!OnMgSin$tpo$$lble eflginer.:orrosionproblems. 71Wsi$pwfJClJIarly IidviMblfl if the cooiant has beerI mne .... l!d. I1Sinp~antll=otherth.Jnih.tspecifil!d
byVflUXhaIIlOpeI.WittJII*Iy a"lIllA!>eze I)pes. rtlecOtT05lonlntvbilCK$becomeptOf11fWiw!ly lesseffflctiwt .... ith¥.ltlSllptortNoindividueJ ownerw/letheroroottolblowthlsllMce.
24 Automatic transmission _,hock ~ :::::::===011~"',;.,r:::; ~ ~;'=:c!.~=~u;.=w .. y
~ , -.<-,~~
dlp.tlckmarl<lngs
.rtracteOb¥ItsS..-Ismot«,bcJtltrllifr'H:Zl i1lfeftJ/if/ngNI.a. 1 Todraonthecoc*lgsystem.mlcc_the e~pansloo tank cap with e wad of rig. and slowly tum ttle cap 8fllklockwiw 10 ~ieve thoopre:ssurelnlhecooiL<lgsyslem(ahisslog sound"';llnorma1Iy be_d).W"'lunt~any pressu(l! remaining in the system Is released. :::;tin..e to tlWfl the CI\P until il CIIn be
2 Position asu~ablecontamerber.eath the radiator botlom hose connec1lon. Ihen slacken the ho5eclipand ease the ho6elrom t~e radiator stub. II tne hose joint has not been d isturbed lor some time. It win be nllCes~to!l8"tlymanlpuletethe hO$flto
brsaktn..;o;nI.00 not..-exCMSiveforoe.or the radiator stub COUld oedamaged. Atrow Ihe oooIanttodralninlolhecontainer. 3A!;oocylinderblockd"aonplvgislitted.a"ld the radiator bottom 00"" may be situa ted above the bottom oIrtleradtator. lhesystem
sedimenlThecoc*ngsyslem\lf1\ciencyQlnbe ItI8tored byftusl*lg the system dean. 8Tne radiator should be lIushed independently of th<! engine, to avoid unn&eesSa!)'contamlnation. 7 To nush the radiator. disconnect Ihetop hoeeattheradlalCM'".lheninsertagard~nT"lo5e
In to Ihe radiator top Inlet. Direct a 110"" 01 clean waterttvough the radiator. andcont ...... flu8hing until clean water emerges lromtlM! radiator bottom outlet (the bottomradiltor Iloseshould havabeen dlsconnected lod"eon the $)"Slem). H after a reasonable period. tile ..... lerstiIlOO"Snotrunclear.theradiator Cltl beflush8d .... ittlB(IOodproprletarvclearolng agent. It is Important thai the cJeaning agen! manufact~rer's instructions Bre followed carelully. if the contamlnallon Is partk:ular1y bad. Insert the hose In the radietor boilOIl' oullet •• nd lIu&h the radiator In tha rBVerM dltectlon('"""erse-ftushiog") 8 TO flush Ihe eng ine block. thethermMIat must be removed, because ~ .... 11 be shut, """ would otherwise prevent the flow 01 wat. around the engine. On SOHC engines. remow thelnermostalasdescribedinCl1apter3.thltl tempo<.rlly relit the thermostat cover. Or! DOHC engines. the U"'mIO$tat cannOI be remove<:I/rom the OOV<!f. Jnor09rloftushlhrl bIock,ttlelhermostatcc_mustbe femovec! •• dacrit-J in Chapter 3. and theapertln tempotarlly COItered over. Take care not to irrtroducedirtorclebrlslnlothftsl"-'temltlhil approech Ia used. 9 With lhe rediato< lop and boltom hOllet dillCQrV"leCted lrom Ine radiator. insert a I">OM Inlo Ihe radiator bottom hose. Oltect a cI-. now 01 watar through the engine. and continue flushing until clean wat .. remerges Iromthe radlatorlop hose 10 On completion of flushing, rem thft tnermostal andlo< cover with reference to Ct\apter 3,and reconnect the hoses.
Cooling system filling 11 Before Ittemptlr>g 10 fill the cooling system,m""ewrethatallh~andclips .. in good COnd~>on, and that the clips are tight. NoIel""t"" an!ifreezemlxt~remustbeusea all yurround,to p<evenl corrosion 01 the
alQy ~glne component.. Where appl icabl<&,
~ ~~~~: ~~a~!h~:!~9 fan swHch hn
12 0nSOHCenglne\l,disconnectlhewlre ""'~_thecoolanttolmpe.at ure .. rJd ... Iromthelnletm30lfoId (I" ~lustr8Uon), On 1.4 and 1.6 litre DOHC Nlgin .... , liMC,aw lhto blel!d 5Cl"ew which Is situated In the lhefmostathousingCO'>W 13 Remoo.tetheexpansjontricap,an(lfillhe systernbyslowtypourlr>gthecoolantintothe IIXparlSIQI1t;11ktoprwentai1ocksfTomtormlrog. l a ilihecoolantisbeingreneweo:i.beglnby povringinaCOlJpleofjitre$oIwat .... ,I~~ trytOOCQfr&e1q .. ""Utyolanlllre8Ze.tt>eolop­ upwittlmo<ewalef. 15 W'->COQIant lrooofairbubbles....-1JII'I fromtheonfi~,r.fiI lhecooianttemper'"'ure &ende, and tighten it securely (SOHC .-.glnes). Or r.fil th. bleed !K>'ewar>dlighton ~ to Ihl! specified lorque setting (f.4 and I.SIit ... OOHC ""gines) 1_ Wlustrationj f6Top-Uplt>ecoolantie'fflllotheKALT(0f COLO) marl< on Ihe exparnoion tank, then refit the expansion lank cap. 11 Start the engine and run ~ unijl,t reaches normal operallngtem para\ur., then StOp tt> 8 .ngine and allow ~Io 0001. 18 Check tor leaks, par1lcula~y around disturbed components. Check tile coolant leIIelln theexpanslon l<lnk,andlop-up H
:::::'!::r~~I:~~:t:I=;d~ncl: OlI<panslontank. II the expansion lank cap ie .....avedwh~elhe engine Is stlliwarm,ccver the ClIp with a itllckclclh. and un8crew Ihe c:apsicwlyIe gradually relieve the system prtIssure (a hissing ~ound will norm~11y be _d).Waitun~l anypres.sure remalnlngin
Ihe system is n.I..a&ad. then continue tc tu,,' Ihe cap until it can be remove<:l
AntifrtHJze mixture
~t=::~~~ ::':~~~8~';-~~!~ ..... tal COOling systems. The quantity of .. Idreaze 31\d levels 01 pr<>tection are ndicatedinthe$pecifW;atic>ns. 20 BeToreadding antilreezo,lnecooilng system should be completely drained
2&. la Measu'e tlledlmenslon(A)f.omthe top edgeoftheped;ltothelowestpointof
the steering wheel ..
25.120nSOHC enl/ines,remo\Iathe cooIanttemperalUJe &ender jarrow.dj
belora niling the coollng syslem
pretarablyflushed. Bndall hOSBII ftnd clops checked lor condition 3ndsecUrtly 21 Att ... ftmngwithBntilreez8.al.beI~
be attar;hoo:.f to the radiator or expansion tank, statmg the type and concentrat,on of anlifrea.zaused. an.d Ihe date Installed. Any subsequent toppng-upshooldbem!tdeWllh the""""'typeandconcetliraltonofantiireeza. 22 Do not useenglr>e antllrMla In the windscr