Opel Corsa C 1.2 Z12XE 55 kW 2003

Changing of handbrake cables

Remove the handbrake gaiter and release cable A from the handbrake lever (10 mm. nut)

Underneath the car there is a heat shield which has to be undone in order to get to the connection between cable A and cable B. Unhook cable B.

 

There is another connection point, close to the brake drum. Unhook it to separate cable B from cable D on the left hand side. 

 Pull cable B out of the connection point which is located above the rear axle, on the left hand side.

Unhook cable C as well.

 
 There is another connection point for cable C, close to the brake drum.
 

In order to get to cable D. Remove the brake drum. A 27 mm nut is located underneath the metal lid, in the centre of the drum. Remove the retaining lock ring from cable D, on inside of the drum, unhook cable D and pull it out.

Remember to change the cable guides as well. Parts-number GM: 9191985 or Opel: 526701. These plastic guides will rub the plastic coating of your new cables, if they are slightly worn. If you have a problem with handbrake cables which are not releasing, it might be because of worn out guides.

Put the cables together in this order: 
put the 10 mm. nut in place on cable A
push cable A through the handbrake lever and the chassis
clip cable B together with cable A
slide cable B into the connection point at the rear axle
pull cable D (left hand side) through the drum, put the cable clip in place and hook the cable inside the drum
clip cable B together with cable D (left hand side)
slide cable C into the connection point at the rear axle
pull cable D (right hand side) through the drum, put the cable clip in place and hook the cable inside the drum
clip cable C together with cable D (right hand side)
adjust nut at the handbrake lever

Opel Corsa C 1.2 Z12XE 55 kW 2003

Cleaning and fixing a slow retracting seatbelt.

Front Seat Belt, Remove and Install (Model F 68)

Remove upper inner panelling of B-pillar. There is a TX25 screw underneath the plastic cover.

Detach guide fitting from seat belt height adjuster (blue square).
Pull carefully to release the plastic clips (yellow circles).

Remove inner panelling lower B-pillar.
Pull carefully to release the plastic clips (yellow circles).

Two plastic pins are holding the floor panelling and the lower B-pillar panelling together. (Red circles on the photo above and the red circles on the photo below.) Move the pins to the side in order to release the hooks.

Detach reel retractor from B-pillar. A 13 mm. nut is reached through a hole from the outside of the vehicle. A plastic cover has to be removed in order to see it. You can see a photo of the reel retractor with the bolt, below. A special tool is required. (GM tool KM-6008-A or like the one I got)
 

Unscrew bolt from seat belt height adjuster (TX 50).
I sprayed some silicone on to the seat belt height adjuster guide. In my case it fixed the slow retracting seatbelt. It could be wise to use a 600 grit sandpaper first, in case there are some "marks" in the plastic guide.

Detach cover from front seat panelling

Pull the seat panelling in order to release the panel (yellow circles above and under) and unhook the panel (red circles above and under).  Unscrew bolt to detach seat belt from front seat frame (TX40).

Inside the reel retractor. (Red circle) to release the belt before extracting. The other side of the reel retractor contains a spring coil. Be careful not to open it.

I left the seatbelt overnight in a bath of soap and water before I brushed it with a soft brush. It was well worth it. :) I think the previous owner was a coal miner which never washed his hands :)

Opel Corsa D 1.2 A12XER 63 kW 2010

How to remove the rear door panel

Remove the glossy black cover over the door closing handle. There is one "hook" in the front end and one "hook" at the rear end of the cover. Be careful!

Remove the two Torx screws (TX 20)

Behind the chrome door handle there is a small circular plastic blanking plate. Remove it with a small flat headed screwdriver and undo the Torx screw (TX 20).

The window winder handle needs to be removed in order to remove the door panel.
Push the panel behind the handle with a flat headed screwdriver.
Look between the handle and the panel and you will see a small metal clip. You need to pull the clip away from the handle. Remove the handle from the shaft.

The panel is held in place with 6 trim panel clips. Use a trim clip remover tool or something similar (flat, no hard edges) to pry the clips. When the clips has come loose, slide the panel upwards to unhook the panel.
 

Remove the wire from the door opening handle. There is a plastic clip to undo before you can unhook the wire.

 To remove the load speaker. Remove the 3 x Torx screws (TX 25) and the connector at the back of the speaker.

Opel Corsa D 1.2 A12XER 63 kW 2010

Repair of rear bumper on a 2010 Opel Corsa.

A metal rod had almost gone through the bumper (yellow circle).

I removed both rear lamps, license plate and the rear bumper.
The bumper is fixed with 8 hex socket (Allen) screws. 2 screws behind the license plate. 2 screws underneath the bumper and 2 screws on each side in the wheel arch.

To remove the bumper from the plastic "locks", push it downwards at the same time as you lift it away from the body.

I used an old iron on the inside of the bumper in order to push the bump back out again and to flatten the plastic.

Then I used some plastic filler and 600 grit sandpaper to make it "smooth" on the outside.

I took the whole bumper to a paintshop and had it resprayed. The color code for the Corsa you will find on the B-pillar on the right hand side. In this case it was Y474 (yellow circle) Casablanca white.
Y474 is equal to 10L and 10U.
 

The final result was nothing less than perfect.

Opel Astra H 1.6 Z16XEP 77 kW 2005

Replace Brake Pads and Brake Backing Plate on rear axle.

Note:   All the brake pads on one axle must be replaced as a matter of principle.

Remove

Release parking brake cable
Release parking brake lever
Detach cover of diagnostic connection
Detach parking brake bellows
Release parking brake cable by unscrewing adjusting nut

Remove rear wheels

Detach parking brake cable from brake calliper
Press brake calliper actuating lever downwards using screwdriver and detach parking brake cable.

Note:   Ensure that dust sleeve between actuating lever and brake calliper is not damaged.
Remove retention clip and pull parking brake cable out of bracket

Remove brake pads from brake calliper
Detach bolt from brake calliper
-counter hold using open-ended wrench
Fold brake calliper upwards

Unscrew brake piston

Note:   Brake fluid level increases in brake fluid reservoir. Remove brake fluid with siphon bottle if necessary.
Unscrew the brake piston as far as the stop - then pull it out of the brake calliper until the next cutout in the brake piston is flush with the opening on the brake calliper.

Remove the brake calliper from the brake support

Note:   The brake calliper must be completely removed from the brake carrier before mounting the brake pads.

Detach upper bolt from brake calliper
-counter hold using open-ended wrench
Detach the brake calliper from the brake carrier.
Suspend it from the rear spring with a suitable wire.

Take out brake pads and guide plates

Clean guides for brake pads in the top and bottom of the brake carrier and contact surfaces with brake pads on the brake piston and the opposing surfaces.

Note:   Make sure that residues of adhesive on the brake pad surfaces are removed and the surfaces cleaned afterwards.


Install

A special tool is required to screw the brake piston (clockwise) into the brake calliper.


Important:   Replace brake calliper and/or brake carrier if the brake calliper is leaking, protective cap on piston is damaged or sealing sleeve on the brake carrier is damaged

Insert new metal guide sheets in brake carrier
Apply grease to brake carrier below the metal guide sheets
Insert metal guide sheets

Important:   The protective film on the back of the brake pads must be removed after inserting the brake pads. Brake pad with mechanical wear indicator (if present) must be on the inside.

Insert new brake pads in brake carrier

Attach brake calliper to brake carrier
Place brake calliper on brake carrier.

Note:   Make sure that the sheet metal guides are not bent and the adhesive surfaces of the brake linings only contact the brake calliper after they have been correctly positioned.

Slide the brake calliper from back to front, on brake carrier.

Attach brake calliper bolts to brake carrier

Clean thread and insert new bolts with locking compound
-counter hold using open-ended wrench
Tightening torque 25 Nm

Attach parking brake cable to brake calliper
Attach parking brake cable to bracket with retaining clip
Press actuating lever downwards using screwdriver and attach parking brake cable.

Fit rear wheels 110 Nm

Actuate brake pedal repeatedly

Start engine

Keep brake pedal depressed for approximately 30 seconds using medium pressure

Top up brake fluid to "MAX" mark

Parking Brake, Adjust

I changed the Brake Backing Plate as well. In order to do that I had to remove the Wheel Bearing Unit. It is kept in place by 4 nuts which you will see from behind.

Opel Corsa C 1.2 Z12XE 55 kW 2003

Changed water pump.

Changed brake pads.

Outside temperature just showing  -,--

I changed the sensor which is located in the front bumper (Yellow circle).

Here is a picture of the sensor:

GM number: 09152245



Opel Corsa C 1.2 starting problem. 

Problem:
While driving the car: the dashboard randomly lose all power. The speedometer, rev counter, fuel gauges all return to stop. The mileage display goes blank and all indication lights go off. After a few seconds the power will return to the dashboard and all gauges, displays and anticipated lights return to normal. If you switch of the engine while this is the case, the car will not start again.

If you try to cold start the car and there is no power to the instruments or the instruments are flickering: The starter will turn the engine, but the engine will not fire up.

Fault:
A bad connection in the instrument wiring harness plug.

Solution:
Remove plastic panels
Remove instrument cluster
Remove wiring harness plug from instrument cluster
Secure wiring harness plug with silicon or adhesive mounting strip and 2x cable tie
Apply light coating of special grease to wiring harness plug and every pin on the instrument cluster
Reconnect wiring harness plug and refit instruments and plastic panels

How to remove plastic panels in order to get to the instrument cluster:
Remove the lower panel; two screws are located close to the pedals.
Unhook the tabs that hold the small pocket in place and remove it.
Remove the two screws that are revealed.
Remove the steering column covers. There is one screw pointing upwards in the lower centre.
Turn the steering wheel and unhook the two plastic tabs at 3 and 9 o'clock.
Pull the top cover upwards.
Remove the two screws pointing downwards close to the indicator/wiper switches in order to remove the bottom cover.
Unhook the two switches and leave them hanging from the wires.
Remove the upwards screw in the centre and the instrument surround will come away.
Two screws will be revealed. These screws hold the instrument cluster in.
Pull the instrument cluster out in order to get to the instrument wiring harness plug.