Opel Corsa D - automx.co.za · The first Opel Corsa rolled off the assembly line at a brand new GM...

Opel Corsa DModel Introduction Training For Approved Motor Body Repairers

The first Opel Corsa rolled off the assembly line at a brand new GM manufacturing plant in Zaragoza, Spain, in May 1982. From its initial roll out in Europe the Corsa has gone on to become a global success — produced on four continents, sales are heading for 14,5 million units as the new fourth generation enters South Africa.

Contents

Note

General overview

New Technical Specification

Body

Passenger Protection

This self-study programme highlights the design and function of new vehicle models, new automotive components or new technologies.

The self-study programme is not a repair manual!All values given are intended as a guideline only.

For maintenance and repair work, always refer to the current technical literature.

© 2008 General Motors Corporation. All rights reserved.

4

TRAINING Overview

Corsa A - 1982 Corsa B - 1993

Corsa C - 2000 Corsa D - 2007

model code model version

L 68 1.4 Essentia 5 door

1.4 Enjoy

1.4 Enjoy Flex-fix

1.4 Cosmo

1.3 CDTI Enjoy

L08 1.4 Sport 3 door


5

TRAININGOverview

There are currently two engine choices in SA for the new corsa range, namely the 1.4 petrol and 1.3 diesel.

The Ecotec Petrol engine uses twinport technology to give unparalleled economy. By using a variable length intake manifold and high rates of exhaust gas reirculation, the demands of engine breathing efficiency and low emissions are met.

4 cyl Diesel

1.3L

66 Kw

200 Nm

4.6 L/100 Km

The Ecotec diesel engine uses common-rail technology and a variable geometry turbocharger and is equipped with a five-nozzle multi-injection system to ensure a fine fuel spray that translates, in real terms, to reduced fuel consumption and lower emissions.

4 cyl Petrol

1.4L

66 Kw

125 Nm

6.2 L/100 Km


6

TRAINING Overview

Dimensions


7

TRAININGOverview

The three door gets a coupe - like roof line, a look emphasised by the design of the side windows that form a large, stretched arch from the “A” pillar to the rear of the vehicle. The family orientated five door model offers a longer roof line and more generous side window surfaces for more head room and greater visibility for the rear passenges.The side window - line bears a strong family resemblance to the larger Opel Astra but the Corsa has a different transition of the “C” pillar to the rear window


8

TRAINING New Technical Specifications

New Technical featuresBody:

● Body composition

● Bosch Brake System

● ESP - Electronic Stability Program

● EUC - Enhanced Understeer Control

● DDS - Deflation Detection System

● EPS - Electronic Power steering

● Hill Hold and Start System

● Front and rear Axle with brakes

● Stabiliser on the front axle

● Rear Axle Characteristics

● Rear end Carrier(Flex - Fix System)

● Park Assist

● Ped-Pro Pedestrian Protection

● Engine Bridge

● Run Flat Tyres

● Sunroof

Interior:● Steering Wheel Heating

● RLS - Rain Light Sensor

● Over Speed Warning

● AFL - Adaptive forward Lighting

● PADS - Passenger Airbag

● Deactivation System

● Electric/Electronic Features - New Functions

● Personalization.


9

TRAINING

57% 23%

18%

2%

200MPa300MPa500MPa1000MPaAluminiumMild Steel

4%1%

11%

34%

18%

32%

200MPa300MPa500MPa1000MPaAluminiumMild Steel

Body Composition

The all - new Opel Corsa has been built using a mixture of high strength and ultra high strength steels. For A and B posts, Boron/press hardened steel reinforcements are used. The vehicle was awarded five Euro NCAP stars for safety in the independant assessment.There are no new welding requirements however the new Corsa does require a combination of joining and bonding methods in repair.

Old Corsa

New Corsa

New Technical Specifications


10

TRAINING

Bosch Brake System

New ABS functionalities:

CBC - Cornering Brake Control - Improves vehicle stability while breaking in curves by reducing the brake pressure on the inner front wheel.

DTC - Drag Torque Control - ABS function that prevents lock - up on driving wheels when clutch is engaged and during downshifting in turns.

SLS - Straight - Line Stability Control - ABS function that detects the tendency to instability, by taking into consideration steering angle in rlation to wheel speed during breaking.

ESPNewest generation driving stability system with selective braking on up to four wheels. Thishappens when the vehicle goes into a swerve(understeer,oversteer). It is available in every model, and is not deactivatable.

DDSIn the case of deflation, the diameter of the affected wheel is reduced, resulting in fasterrotation during driving. When the pressure drops by 20% the red warning lamp for an under inflated tyre, in the instrument cluster is activated.

EUCEUC enhances the maneuverability in addition to standard ESP braking on 4 wheels instead of 1(as with standard ESP)

EPSNew compact design with increased natural frequency to improve noise and vibrationTwo versions available: non-adjustable and adjustable.Adjustable version : Rake and telescopic

Two different EPS versions with high and normal power assistance to match vehicle weight and dynamic demands.

HSASupports the driver during drive off on a slope. After releasing the brake pedal, brake pressure is maintained for 1.5 seconds to enable an easy changover from brake pedal to accelerator.As soon as accelerator pedal is activated and car gets forward momentum, brake pressure is

released.


ABS Unit with ESP


11

TRAINING

Front Axle

New subframe reinforcement on the front axle:

– 2 fixing points– Recommended direction(marking “LH”)

Rear AxleBushing:

– Increased wheel track– Increased wheel travel– Compound crank rear axle with 3 different

torsional profiles to match vehicle- specific demand

– V- shaped bushing position(25o) to reduce side load oversteer effects.

Screwed rear axle bracket:– Rear axle bracket screwed instead of welded

to the underbody allowing more precise positioning.

– Increased bushing size in comparison to the previous car to improve noise insulation.

– During installation, pay attention for the correct pretentioning! (similar to Astra)


Variant Rear axle wall thickness

Torsional profileVersion

Basis 5,9 mm Medium

Vehicle with run flat tyres

7,1 mm Hard

OPC 8,0 mm Hard Plus


12

TRAINING

Rear shock absorber mount:

– Only exchange the rear shock absorbers in pairs.

– Difference between left and right absorbers.– Right side absorber with a hole.(1)

Pedal blocks– The pedal housing is made of plastic– During a serious frontal collision the brake and clutch pedal are released from their fixed position– Different for LHD and RHD– New special tool for removing the clutch pedal



13

TRAINING

Flex- fix integrated bicycle carrier

– The first of its kind in the world,the revolutionary Flex- fix is a fully integrated bicycle carrier system,which is not visible when not in use.

– Flex- fix is released using a lever at the rear end of the luggage compartment,which once pulled,allows the carrier system to move out from the rear bumper by a few centimeters.

– When Flex - fix is pulled out to its end position,it locks in place.

– When reverse gear is selected, an acoustic signal warns the driver that the Flex - fix system has been extended.

– This system is only available on the ‘Enjoy’ model

– The Flex - Fix system is replaced as a complete unit, which can be ordered from the parts department.



14

TRAINING

PAS - Park Assistant System

– Factory - installed Park assistance for Corsa offers obstacle detection in the rear.– The distance to the obstacles is indicated audibly via a pulsing sound.– Detection of external ultrasonic waves – Self - diagnosis of covered or disturbed sensors(snow or ice)– A tell - tale at the instrument cluster is blinking PAS-module in the trunk.– 4 Ultrasonic sensors, diameter of only 23mm, discreetly intergrated into the rear bumper.– On/Off button– Loudspeaker - standardised in the instrument cluster.– Activated by shifting into reverse gear.– Deactivated either by a swith in the centre console or when the reverse gear is disengaged.– For cars equipped with the rear end carrier, a special Park Assistance System is available via

aftersales.– Only available as rear version.


Pedestrian Protection - Head Impact– Hood is built of thin steel– Hood interior has a “muffin-tin” design


15

TRAINING

Always remember to refit low density foam when fitting new bumper Note


Ped - Pro Pedestrian - Protection Lower Leg impact:

– Knee bending angles and tibia accelerations are optimised by the low density foam structure in front of the bumper stiffener to limit the knee bending angle. A special bumper upper support ensures facia stiffness.


16

TRAINING

Engine bridge– New tools– New procedure for fixing engine bridge to engine

Carrier frame and engine bridge Hood support

New adapters– To hold the engine



17

TRAINING

New tool for removing engine/transmission and front axle

New tool for removing/adjusting rear axle



18

TRAINING New Technical Specifications

Sun Roof– Very large opening without booming

noise.– 25% more opening travel compared with

previous Corsa.– Reduced interior noise through two -

chamber sealing system.– The complete steel roof is substituted by a

sandwich module.– The assembly is glued into the body.– Intergrated are antenna fixing, side rails

and roof rack recognition.– Two variants, 3 door and 5 door, different in roof size and curvature.– The sandwich consists of a plastic outershell and a backside foam in LFI (long fiber

injection) Technology.– Intergrated in the sandwich roof is a spoiler

sunroof.

Run Flat TyresRun flat tyres have reinforced, self - supporting sidewalls, which ensure that the tyres always have a certain amount of driveability, even after a rapid loss of pressure. Run flat tyres are only permitted on vehicles with ABS/ESP and deflation detection System. They are only permitted in combination with Opel approved alloy wheels.


19

TRAINING

Steering wheel heatingThere are two variations of switches in the upper midconsole:

– Only steering wheel heating– Steering wheel heating plus seat heating

Over Speed Warning

Preset a maximum speed and this handy safety device sounds an audible warning should it ever be exceeded. Settings can be stored and activated within the memory chips of individual car keys.

RLS Rain Light Sensor– Rain light sensor generates control information for wiper/washer system– Also used by other systems in the vehicle

Automatic lighting control (ALC)Automatic lighting control is controlled by 2 sensors:

– The ambient light sensor (ALS) measures general brightness.– The far- sight sensor (FSS) measures the lighting conditions on the road ahead

This enables the system to look forward and to detect tunnels ahead. The system can distinguish between tunnels and bridges, where the lighting is not activated. (ALC) is available as an option.

AFL - Adaptive forward lightingDynamic bending light:

– Controlled via the steering angle– Activated automatically whilst the vehicle is in motion– Main headlamp swivels up to 15o outwards and 8o inwards– Depending on the direction of travel,speed of the swivelling is adjusted automatically to the speed of

the vehicle– Also happens with the main beam

Static Bending light:– An additional left or right reflector is switched on which illuminates the road in the direction of travel– On tight bends or when turning off– At speeds below 40 km/h– Depending on the steering angle– Or depending on the indicator light signal– Static bending light goes on to illuminate the parking area when reversing



20

TRAINING

PADS - Passenger Airbag Deactivation System

The two lights on either side of the switch will be illuminated when the airbag is de-activated.

There will also be a light on the instrument cluster that shows the passenger airbag is de-activated.



21

TRAINING

ELECTRIC /ELECTRONIC FEATURES - NEW PWM Controlled headlampsThe service life of the headlamps is increased significantly by Pulse-Modulation voltage regulation to avoid voltage peaks.

Fill-up indicationIn addition to the fuel gauge, a warning light in the IP cluster indicates low fuel reserves.

Low battery charge indicationTo warn the driver in case of low state of charge, the charge indicator lamp blinks for 10 sec. after starting the engine.

Bulb outage detection warningMalfunction head lamps and brake lamps is detected and indicated by a warning light in the IP cluster.

Inadvertent load shutoffTo avoid low battery charge, inadvertent power consumption- i.e. glove box illumination is shut off.

Brake-to-crank indication lamp (MTA)If the car is equipped with Easytronic/MTA, an indicator lamp in the IP cluster reminds the driver to engage the brake pedal before starting the engine.

Speed warningWhen a certain speed limit is exceeded, an audible warning is given. The threshold can be chosen by the driver.

Cruise control indicationActivation of the optional cruise control is indicated by a lamp in the IP cluster.

Electric tailgateThe tailgate of the new Corsa is touch-pad-operated. To unlock, it is sufficient to touch the switch underneath the tailgate handle.

Remote controlled windowsA constant pressure on the relevant switch of the remote control car key opens and closes the windows simultaneously.

Personalization

The idea is to find the vehicle in a personalised condition on entering it, regardless of whether someone else has been driving the vehicle in the meantine.Personalisation is based on remote control and the immobilizer transponder code of each key (5 keys per vehicle).Body control module detects which remote control is being used to open vehicle.

The following settings can be selected:– Speed locking enabled/disabled– Tip blinking– Selective unlocking– Lead me to the car light– Smart rear wipe functions– Speed warning limit– Chime volume



22

TRAINING BODY

Vehicle Identification NumberThe VIN plate is situated on the B pillar in the drivers door opening.The VIN number is also displayed on the bottom left of the front windscreen.There is also a VIN plate on the inner right front wheel arch.

Designation of the individual positions based on the example (WOLOTGF35X2123456)

Position VIN Designation GM coding

1-3 WOL

World manufacturer code WOLVN1

Adam Opel AGSOVAB

4 O Special identification OP

= non special vehicle= post office vehicle

5 T GM code HESXMTAYZV

= Agila=Speedster/VX220=Corsa-B,Combo-C=Corsa-C,Combo-C=Astra-F=Astra-G=Astra-H=Vectra-B=Vectra-C=Omega-B

6 G Model Designation ABCFG

=Agila-A=Corsa-B=Corsa-C=Astra-F=Astra-G

7 F GM equipment code FMPER

=Equipment code GL=Equipment code CD=Equipment code MVPart of GM body style codePart of Gm body style code


23

TRAINING


8-9 35

GM body style code 06070819253548676869707597

4-door estate2-door coupe2-door saloon4-door saloon notchback3-door delivery4-door estate4-door saloon fastback2-door convertable4-door saloon4-door saloon2-door delivery van4-door estate special2-door Targa


10 X Model year WXY12345678

19981999200020012002200320042005200620072008

Position VIN Discription GM coding

11 2 Manufac-turingPlant

1234

=Russelsheim=Bochum=Azambuja=Zaragoza

ABCD

=Portugal=Bertone=Elabuga=Shin Chaung


12-17 123456

Consecutive num-ber

BODY


24

TRAINING

1) Open bonnet

2) Release front panel:– Unscrew 4 x bolt(1) at top front– Unscrew 2 x bolt, outer left(2)

– Unscrew 2 x bolt, outer right(4)– Unscrew 2 x bolt(5) on front panelling reinforcement, bottom– Unscrew 3 x bolts(6) on radiator crossmember– Unclip external temp sensor(3)–

3) For vehicles with front foglamps, disconnect left and right wiring harness plugsDanger of damage. Carefully disengage the front panelling from the guide rails. Press the side of the front panelling upwards in the guiderail area and at the same time pull it outwards (arrow).

4) Note: This requires a second person– Unclip the front panelling from the right guide rail– Unclip the front panelling from the left guide rail

Note

BODY

Removing front bumper


25

TRAINING

1) Remove both rear lights 2) Remove licence plates3) Remove licence plate lamps

– Unclip 2x licence plate lamps– Disconnect 2x wiring harness plug– Remove licence plate lamps

4) Release rear panelling– Unscrew 2x bolt, outer left (4)– Unscrew 2x bolt, outer right (1)– Unscrew 2x centre bolts (2)

Carefully detach the rear panelling from the guide rail. In the area of the guide rail, press the rear panelling upwards to the side andwithdraw at the same time!

5) Remove rear panellingNote: This requires a second person

– Release rear panelling from side guide rail– Release rear panelling from rear outer guide rail (1)– Remove rear panelling– On vehicles with park pilot: release Parkpilot wiring harness plug

Removing rear bumper

Note

BODY


26

TRAINING

1) Remove both rear lights2) Remove licence plate3) Open Flex - Fix and withdraw slightly4) Remove Flex - Fix outer cove

– Unscrew 2 x bolts (1)– Unclip 16 x clips from interior cover

5) Remove Flex - Fix interior cover– Unscrew 4 x bolt(2)

6) Release rear panelling– Unscrew 2 x bolt, outer right (1)– Unscrew 2 x bolt, outer left (3)– Unscrew 2 x centre bolts (2)

7) Remove rear panel as per bumper without Flex - Fix system

BODY

Removing rear Bumper with Flex - Fix


27

TRAININGBODY

Jacking points

1) Front jacking point2) Rear jacking point

• Service:To prevent damage to components and aggregates when raising vehicles, apply lifting tools at the points shown. The manufacturer's guidelines forhandling lifting tools must be observed. When jacking up a vehicle with the on-board tool, follow the instructions in the Owner's Manual.


28

TRAINING

3) Prepare new sill panelling– Cut new part to size– Make 21 x slot (5x18mm)

4) Apply adhesive system5) Adjust sill panel to fit6) Weld in sill panelling

Sill Panelling(complete) Replace

1) Detach attaching Parts2) Detach and drill away sill panelling

BODY


29

TRAINING

To simplify painting operations of the tailgate or roof, spacers have been introduced. This makes it possible to paint the tailgate on the vehicle. There is no need to remove the tailgate and seperate the wiring harness, even when painting the roof. Furthermore it is substantially easier to mark off adjacent parts because of the resulting gaps.

Tailgate spacer

To simplify painting operations of the tailgate or roof, spacers have been introduced. This makes it possible to paint the tailgate on the vehicle. There is no need to remove the tailgate and seperate the wiring harness, even when painting the roof. Furthermore it is substantially easier to mark off adjacent parts because of the resulting gaps.

BODY


30

TRAINING BODY

Air Compressor

There is no spare wheel for vehicles fitted with the Flex Fix system. For this reason a compact air compressor is fitted to the right rear(boot) of the vehicle.The use of tyre repair kits are not recomended.

In the case of broken headlamp brackets a bolt on repair kit is available. It is available from parts and accesories.

Headlamp Brackets


31

TRAINING

Removing Flex - Fix

1) Remove inner panelling below tailgate2) Detach rear end panelling(bumper)3) Remove Flex - Fix protection plate(1)Unscrew 5 X screws (arrows)

4) Remove bowden cable(2) and spring(1)5) Detach wiring harness.

6) Detach Flex - Fix system– Unscrew 6 x bolts (arrows)

NOTE: The arrows indicate where the bolts are from the bottom.7) Remove Flex - Fix

BODY


32

TRAINING

Location of the main modules in the vehicle

POS. Abbreviation Part name

1 FZM Front zone module

2 BDU Body distribution unit

3 UHP Universal hands free phone

4 DAB Digital audio broadcast

5 EHS Electrical heater system

6 BEC Body electrical centre

7 FFS Flex fix system

8 PAM Park assistance module

9 EHU Entertainment head unit

10 SDM Sensing diagnostic module

11 CSM Column switch module

12 BCM Body control module

13 AFL Advanced forward lighting

14 ECM Engine control module

BODY


33

TRAINING

Removing outer door handle

1) Detach rear door panel– Prize off panel with a plastic wedge

2. Remove fixed handle part, rear door– Pull moving handle part (I) to the

outside and hold– Turn screw (II) to left to the perceptible

stop

Note: Moving handle part must now be fixed in the pulled position

– • Remove fixed handle part with lock cylinder (IV)

3. Detach door handle• Pull moving handle part (III) towards the back

3. Detach door handle• Pull moving handle part (III) towards the back

BODY


34

TRAINING

Detaching anchor

Ridges prevent rotation (red arrow) To release, lift felt and push the metal tip (red arrow) slightly

Passive safety featureThe new Corsa features an advanced front safety belt system to ensure maximum passenger protection and Euro NCAP performance.The system cosists of the following elements:

– Body mounted lap tensioner– Belt retractor with load limiter– Seat mounted buckle tensioner



35

TRAINING

General

● Operations on restraint systems must be performed by certified, trained and qualified personnel. This is assured at all Opel/Vauxhall affiliated dealerships.

● The restraint system incorporates the following components:– Full-size driver's and full-size passenger's airbag (subsequently referred to as driver's and passenger's airbag)– Full-size side airbag (subsequently referred to as side airbag)– Full-size curtain airbag (subsequently referred to as curtain airbag)– Mechanical and pyrotechnic seat belt tensioner with safety belt.– Airbag control unit– Decentralised front airbag sensor– Decentralised side-airbag sensor– Mounting plate for decentralised front airbag sensor– Installation plate for decentralised side-airbag sensor– Contact unit– Steering Column Electronic Module / Column Integration Module (CIM)– Wiring harness, with yellow or orange identification– Sensor pad– Airbag system indicator lights– Indicator light for child safety seat with transponders

● The handling of pyrotechnic units (airbag and pyrotechnic seat belt tensioners) is subject to varying national legislation which must be observed at

all times.

● The version with driver's airbag can be recognised by the inscription "Airbag" on the steering wheel and by the sticker on the inside of the door frame (driver's door open). If a driver's airbag has been installed and there is no sticker in this position, a sticker must be attached.

● The version with passenger's airbag can be recognised by the inscription "Airbag" above the glove compartment and by the round child seat warning sticker on the side of the instrument panel (passenger's door open) or by the rectangular warning sticker on the windscreen.If a passenger's airbag has been installed and there is no sticker in this position, a sticker must be attached.

● The version with seat occupied detection can be recognised by the indicator light for child safety seat with transponders, which illuminates for approx. 4 seconds after the ignition has been switched on, and the warning sticker on the side of the seat console, which is visible when the passenger door is open. If seat occupied detection has been installed and there is no sticker in this position, one must be attached. On vehicles without seat occupied detection, this warning sticker must not be present. The issue of loose warning stickers to final customers is not permissible.

● Versions with a side airbag can be recognised by the "Airbag" sticker on the outside of the front seat backrests. The inscription is engraved into the airbag cover (all cars, except Corsa-B). A material label containing this inscription is stitched onto the front seat backrest in the Corsa-B.

● The version with curtain airbag can be recognised by the lettering "Airbag" on the A and B-pillar panelling.

● Service installation of accessories in the deployment area of the airbag and storage of objects on the passenger's airbag cover is not permitted. Consoles for phone receivers, drink holders, cassette trays, additional mirrors, etc., which have not been authorised by Opel/Vauxhall may be torn off and propelled through the passenger compartment when the airbag is deployed – danger of injury.

● .Objects (e.g. clothing) must kept away from the deployment area of the curtain airbag, as they may affect the functObjects (e.g. clothing) must kept away from the deployment area of the curtain airbag, as they may affect the functioning of the curtain airbag. Only light items of clothing with empty pockets and without coat hanger are permissible. Objects in the items of clothing may endanger the occupants if the curtain airbag is deployed.

● The sale of pyrotechnic units is only permitted to authorised third parties in accordance with explosives legislation.

● Components of the restraint system must never be interchanged or replaced by used parts.

● Repairs to components of the restraint system are not permissible. These components must never opened using excessive force and must not be modified. This also applies to deployed units – injury hazard.

The pyrotechnic units and airbag control unit are sensitive to impact. They must not be installed if they have fallen from a height exceeding 80 cm.

Safety Regulations for Restraint Systems



36

TRAINING

● Cables connected to gas generators for pyrotechnic units must not be repaired, removed, replaced or cross-connected.– The wiring harness on the curtain airbag module may be replaced in the following vehicle types:– Corsa-C– Astra-G– Vectra-C (to MY 03.5)

● Never compress, bend, kink or twist curtain airbags.

● The airbag units and the airbag control unit must not be subjected to a temperature exceeding 80 °C/176 °F – even for short periods.

● Always disconnect the ground cable from the battery when performing welding operations on the vehicle. Always attach the earth terminal of the welding equipment to the immediate vicinity of the welding point.

● For soldering or welding operations in the immediate vicinity of sensitive components (e.g. electrical/electronic/pyrotechnic components, control units, wiring harnesses and airbags), the components must be removed.

● For soldering or welding operations on front doors or door pillars / B-pillars in the vicinity of the side airbag sensor (vehicle specific), this must be removed (store in a dry and safe place). For minor installing or body operations (no use of, e.g. slide hammer) in this area, switching ignition OFF suffices. Remove the ignition key and keep in a safe place during the repair operation.

Transportation and Storage

● Pyrotechnic units may only be purchased, transported and stored, according to the safety regulations, by trained personnel of a franchised Opel/Vauxhall dealer or authorised Opel/Vauxhall Service Dealership.

● Pyrotechnic units may be returned only if one of the following six conditions has been fulfilled:– .. In accident-damaged vehicles that are not to be repaired and pyrotechnic units that have not been

deployed, an attempt must first be made– to deploy the units in the vehicle with the relevant special service tools, as described in the Service

Instructions. These units must be– returned as non-deployable pyrotechnic units only following an unsuccessful ignition procedure. Local

disposal of non-deployed pyrotechnic– units is prohibited.– .. Incorrect deliveries– .. Electrical defect (e.g. as determined by diagnostic tester)– .. Electromechanical defect (e.g. retaining lugs or on wiring harness plug housing damaged)– .. Mechanical damage (e.g. if pyrotechnic unit has fallen from a height exceeding 80 cm)– .. Visual damage (e.g. cover panel scratched or damaged)

● The units may be returned in the original packaging only. If this is not available, it must be ordered.

● The pyrotechnic units may be returned to the following address only (the same address is applicable for procuring the original packaging):.

● For vehicle repairs requiring longer periods of time, non-activated, removed airbags must be stored under lock and key. Storage with other hazardous materials (e.g. paint) is prohibited. The storage area must identified with the corresponding hazard symbol and contain suitable fire prevention equipment.

● Store curtain airbag such that it cannot be compressed, bent, kinked or twisted.

● Deployed pyrotechnic units can be disposed of as normal refuse.

Registration

● Until now, Aftersales parts have been accompanied by registration cards and an envelope for registering replaced restraint system components.

● As of now, filling out and returning the registration cards to Adam Opel AG, Rüsselsheim is no longer necessary.



37

TRAINING

Diagnosis

● If the pyrotechnic units are in perfect working order the airbag indicator lamp must illuminate when the ignition is switched on and go off again after about four seconds. If the light does not go off or it comes on whilst driving the vehicle, there is a fault.

● The system must only be tested using the diagnostic tester.

● During the diagnosis or programming of airbag systems, the following sequence must be followed:– Ignition OFF– Connect the diagnosis tester to the ALDL connector– Ignition ON– Note: During diagnosis or programming (the period between switching on and switching off the diagnostic

tester) no persons are– permitted in the vehicle.– Switch on diagnosis tester– Select system, follow menu– De-select system– Note: If it is not possible to exit the "Airbag" menu the ground cable must first be disconnected from the

battery and the negative– terminal covered (exceptional case). Wait for one minute until the capacitor in the airbag control unit has

discharged.– Switch off diagnosis tester– Ignition OFF– Detach diagnosis tester from ALDL connector

● If there are no fault codes in the airbag system, a diagnosis in the vehicle (e.g. seat occupied detection test) is permitted.

● Vehicles with active fault codes must not be handed over to the customer – danger for occupants.

● In order to prevent unintentional deployment, never use a test lamp or multimeter to perform measurements on the pyrotechnic units – danger of injury.

● Connections for pyrotechnic units and control unit must be disconnected when using test lamp or multimeter to check the wiring harness – danger of injury.

● If there is bodywork damage in the vicinity of the decentralised front airbag sensors, inspect the securing panels and replace if damaged.

● Testing with TECH2 (four test operations) and an Opel/Vauxhall child safety cradle with transponders (part no. 09 121 858, catalogue no. 17 46 704) is required whenever the passenger seat upholstery is replaced in vehicles with seat occupied detection . If the test proves unsuccessful, the seat occupied detection is not suitable for operation. The vehicle must not be handed over to the customer. Exception: Driving is permitted for workshop staff, provided that the passenger's seat remains unoccupied.

Repair Information

● Before commencing work on the restraint system:– Ignition OFF– Disconnect the ground cable from battery and mask the negative terminal.– Wait for one minute until the capacitor in the airbag control unit has discharged. It is adequate to switch off

the ignition before starting to work on the pyrotechnic seat belt tensioner. Remove ignition key and retain during the repair.

● When working on the steering (steering gear, track rods, steering column etc.) the steering must in the straight-ahead position during removal and assembly.

● When removing the steering wheel, lock the steering column in the "straight ahead" position to avoid destroying the contact unit/CIM during subsequent reinstallation of contact unit/CIM and steering wheel.

● If a driver or front passenger airbag has been deployed because of an accident, these and the contact unit/CIM and the airbag control unit must be replaced. The steering wheel, the steering column and the steering column attachment must be subjected to a function test and inspection and replaced if damaged.

● Never grease, oil, spray or retouch contact unit/CIM. Lubricants (greases, oils etc.) can attack the winding tape of the contact unit/CIM and cause malfunction of the airbag system.

● Visually inspect wiring harness and wiring harness plug following deployment of pyrotechnic unit. The wiring harness must be replaced if charring or other damage is evident.



38

TRAINING

● Programming airbag control unit– At the start of programming the airbag control unit, there must be no active fault codes apart from the fault

code/ message "control unit not programmed". By way of verification, the diagnosis tester function "ERASE FAULT CODES" should be selected before programming is started. Persons are not allowed in the vehicle during programming.

● If the side airbag is deployed, the decentralised sensor must also be replaced. After the side airbag (fault code) has been deployed once to three times (vehicle specific), the airbag control unit must also be replaced.

● For vehicles with side airbag sensors in front doors only:

● If the side airbag has been deployed the distributed sensor mounting plate and the door wiring harness must be replaced (vehicle-specific).

● The driver's and passenger's side-airbag sensors are not interchangeable. The sensor housings and wiring harness plugs are colour-coded to prevent them from being unintentionally interchanged.

● For vehicles with side airbag sensors in front doors only:– After work on the front doors has been completed, it must be ensured that the door film (water repelling film)

is undamaged and is bonded all round at the edges. The side airbag sensors will only operate correctly if the door film is undamaged and correctly bonded and the front door inner panelling is correctly mounted. Inspect door film and inner panelling for damage and replace with new part if necessary.

● During operations behind the curtain airbag, never partially release the unit but always remove the complete module. Bending the curtain airbag can result in serious damage which is not externally visible. This may cause partial or non-deployment of the curtain airbag in case of triggering.

● In order to remove a wiring harness or hose located behind the curtain airbag, loosen all affected screws by 2-3 threads. After repair, replace all loosened screws individually, one after another.

● Use only new screws when reinstalling. Observe tightening sequence and torques in accordance with the Service Instructions (vehicle specific).

● Following deployment of the curtain airbag, the following components must always be replaced:– Curtain airbag– Roof headlining– A, B and C-pillar panelling.– Handles– Self-locking screws– After the side or curtain airbag (fault code) has been deployed once to three times (vehicle specific), the

airbag control unit must also be replaced.– Side airbag components including sensors.

Before installing the curtain airbag, a visual check of the following components must be performed:– Wiring harness– Sliding / tilting roof– Rivet nuts– Attaching parts– D-pillar panelling– Retaining net (rod) and retaining net sleeves– Sun visors

Always replace damaged parts.– If only the pyrotechnic seat belt tensioner has been deployed because of an accident, it must be replaced

with a new part. After three deployments of a pyrotechnic seat belt tensioner (fault code) the airbag control unit must also be replaced.

● The airbag steering wheel may be replaced with steering wheels approved by Opel/Vauxhall only. ..

● Always put airbag units down with the padded side on top. ..

● Always transport or carry airbag units with the padded side facing away from the body. ..

● The impact cushion of the steering wheel and the instrument panel padding must not be cemented or otherwise altered. Under no circumstances may cleaning agents (aggressive materials) or grease be used – clean with a dry or moistened cloth and using a cleaning agent approved by Opel/Vauxhall only.

● Before installation, check once more that the ground cable is disconnected from the battery, the negative terminal is masked and the ignition key is in the OFF position. ..

● After completing work on restraint systems, reconnect battery; no persons should be present in the vehicle. Disconnecting the ground cable from the battery automatically erases the contents of certain electronic system memories (e.g. electric window winder, time and date). After reconnecting the ground cable to the battery, these volatile memories must be reprogrammed and audio equipment decoded.



39

TRAINING

Deploying Pyrotechnic Units in the Vehicle

Deploy using provided special tool KM-799-B and suitable adapter. Connect power source right at the end.Park vehicle in open area. ..Before deployment of pyrotechnic units:

– Ignition OFF– Disconnect the ground cable from battery and mask the negative terminal.– Wait for one minute until the capacitor in the airbag control unit has discharged. ..– Remove all loose objects from the airbag deployment area. ..– Vehicles with belt tensioners only: fasten seatbelt into belt lock. ..– Connect special tool KM-799-B to vehicle using suitable adapter. ..– Open the front side windows and close the doors. ..– Stand approx. 10 m in front of the vehicle – this also applies to uninvolved bystanders. Provide advance

warning regarding potential noise level. ..Connect the voltage source and deploy the pyrotechnic unit.Note: Disconnect the voltage source if the unit fails to deploy and approach the vehicle only after a period of 5 minutes. Further information isavailable in the section "Transport and Storage". ..Allow deployed airbag units to cool for 15 minutes before removing – danger of injury.


Opel Corsa D - automx.co.za · The first Opel Corsa rolled off the assembly line at a brand new GM...

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