Opel Corsa 4400D

Opel Corsa D
Model 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
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. Note
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.
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
2008 General Motors Corporation. All rights reserved.

Overview TRAINING
4 cyl Petrol 4 cyl Diesel
1.4L 1.3L
66 Kw 66 Kw
125 Nm 200 Nm
6.2 L/100 Km 4.6 L/100 Km
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.
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.

TRAINING Overview
Dimensions

Overview TRAINING
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

TRAINING New Technical Specifications
New Technical features

Body:
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.

New Technical Specifications TRAINING
Body Composition
Old Corsa
200MPa
57% 300MPa
23% 500MPa
The all - new Opel Corsa has been built using a
1000MPa
mixture of high strength and ultra high 18%
strength steels. For A and B posts, Boron/press Aluminium
hardened steel reinforcements are used. The Mild Steel
vehicle was awarded five Euro NCAP stars for 2%
safety in the independant assessment.
There are no new welding requirements New Corsa
however the new Corsa does require a
combination of joining and bonding methods in
repair.
200MPa
18%
300MPa
34% 500MPa
32%
1000MPa
11% Aluminium
Mild Steel
1%
4%

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.
ESP
Newest generation driving stability system with selective braking on up to four wheels. This
happens when the vehicle goes into a swerve(understeer,oversteer). It is available in every
model, and is not deactivatable.
DDS
In the case of deflation, the diameter of the affected wheel is reduced, resulting in faster
rotation during driving. When the pressure drops by 20% the red warning lamp for an under
inflated tyre, in the instrument cluster is activated.
EUC
EUC enhances the maneuverability in addition to standard ESP braking on 4 wheels instead of
1(as with standard ESP)
EPS
New compact design with increased natural frequency to improve noise and vibration
Two 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.
HSA
Supports 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
10

Front Axle
New subframe reinforcement on the front

axle:
2 fixing points
Recommended direction(marking LH)
Rear Axle
Bushing:
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 Torsional profile

thickness Version
Basis 5,9 mm Medium
Vehicle with 7,1 mm Hard

run flat tyres
OPC 8,0 mm Hard Plus
11

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
12

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.
13

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
14

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.
Note
Always remember to refit low density foam when fitting new bumper
15

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
16

New tool for removing engine/

transmission and front axle
New tool for removing/adjusting rear

axle
17

Run Flat Tyres

Run 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.
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.
18

Steering wheel heating

There 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 lighting

Dynamic 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
19

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.
20

ELECTRIC /ELECTRONIC FEATURES - NEW

PWM Controlled headlamps
The service life of the headlamps is increased significantly by Pulse-Modulation voltage regulation to
avoid voltage peaks.
Fill-up indication
In addition to the fuel gauge, a warning light in the IP cluster indicates low fuel reserves.
Low battery charge indication

To 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 warning

Malfunction head lamps and brake lamps is detected and indicated by a warning light in the IP
cluster.
Inadvertent load shutoff

To 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 warning
When a certain speed limit is exceeded, an audible warning is given. The threshold can be chosen by
the driver.
Cruise control indication

Activation of the optional cruise control is indicated by a lamp in the IP cluster.
Electric tailgate
The tailgate of the new Corsa is touch-pad-operated. To unlock, it is sufficient to touch the switch
underneath the tailgate handle.
Remote controlled windows

A 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
21

TRAINING BODY
Vehicle Identification Number

The 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 W World manufacturer code WOL Adam Opel AG

O VN1 SOVAB
L
4 O Special identification O = non special vehicle

P = post office vehicle
5 T GM code H = Agila
E =Speedster/VX220
S =Corsa-B,Combo-C
X =Corsa-C,Combo-C
M =Astra-F
T =Astra-G
A =Astra-H
Y =Vectra-B
Z =Vectra-C
V =Omega-B
6 G Model Designation A =Agila-A

B =Corsa-B
C =Corsa-C
F =Astra-F
G =Astra-G
7 F GM equipment code F =Equipment code GL

M =Equipment code CD
P =Equipment code MV
E Part of GM body style code
R Part of Gm body style code
22

BODY TRAINING
8-9 3 GM body style code 06 4-door estate

5 07 2-door coupe
08 2-door saloon
19 4-door saloon notchback
25 3-door delivery
35 4-door estate
48 4-door saloon fastback
67 2-door convertable
68 4-door saloon
69 4-door saloon
70 2-door delivery van
75 4-door estate special
97 2-door Targa
10 X Model year W 1998

X 1999
Y 2000
1 2001
2 2002
3 2003
4 2004
5 2005
6 2006
7 2007
8 2008
Position VIN Discription GM coding
11 2 Manufac- 1 =Russelsheim A =Portugal

turing 2 =Bochum B =Bertone
Plant 3 =Azambuja C =Elabuga
4 =Zaragoza D =Shin Chaung
12-17 1 Consecutive num-

2 ber
3
4
5
6
23

TRAINING BODY
Removing front bumper
1) Open bonnet
2) Release front panel:

Unscrew 4 x bolt(1) at top front
Unscrew 2 x bolt, outer left(2)
Note
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 plugs
Danger of damage. Carefully disengage the front panelling from the guide rails. Press the side of the
front panelling upwards in the guide
rail 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
24

BODY TRAINING
Removing rear bumper
1) Remove both rear lights

2) Remove licence plates
3) Remove licence plate lamps
Unclip 2x licence plate lamps
Disconnect 2x wiring harness plug
Remove licence plate lamps
4) Release rear panelling
Note
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 and
withdraw at the same time!
5) Remove rear panelling

Note: 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
25

TRAINING BODY
Removing rear Bumper with Flex - Fix
1) Remove both rear lights

2) Remove licence plate
3) Open Flex - Fix and withdraw slightly
4) 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
26

BODY TRAINING
Jacking points
1) Front jacking point

2) 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 for
handling lifting tools must be observed. When jacking up a vehicle with the on-board tool, follow the
instructions in the Owner's Manual.
27

TRAINING BODY
Sill Panelling(complete) Replace
1) Detach attaching Parts

2) Detach and drill away sill panelling
3) Prepare new sill panelling

Cut new part to size
Make 21 x slot (5x18mm)
4) Apply adhesive system
5) Adjust sill panel to fit
6) Weld in sill panelling
28

BODY TRAINING
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.
29

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.
Headlamp Brackets
In the case of broken headlamp brackets a bolt on repair kit is available. It is available from parts and
accesories.
30

BODY TRAINING
Removing Flex - Fix
1) Remove inner panelling below tailgate

2) 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
31

TRAINING BODY
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
32

BODY 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
33

TRAINING Passenger Protection
Passive safety feature

The 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
Detaching anchor
Ridges prevent rotation (red arrow) To release, lift felt and push the metal tip (red
arrow) slightly
34

Passenger Protection TRAINING
Safety Regulations for Restraint Systems
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.
35

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, Rsselsheim is no longer necessary.
36

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.
37

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.
38

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 is
available in the section "Transport and Storage". ..
Allow deployed airbag units to cool for 15 minutes before removing danger of injury.
39

Opel Corsa 4400D

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Opel Corsa D

Model Introduction Training For Approved

New Technical Specification

The self-study programme is not a repair manual!

Corsa A - 1982 Corsa B - 1993

Corsa C - 2000 Corsa D - 2007

model code model version

2008 General Motors Corporation. All rights reserved.

4 cyl Petrol 4 cyl Diesel

6.2 L/100 Km 4.6 L/100 Km

2008 General Motors Corporation. All rights reserved.

2008 General Motors Corporation. All rights reserved.

2008 General Motors Corporation. All rights reserved.

New Technical features

2008 General Motors Corporation. All rights reserved.

2008 General Motors Corporation. All rights reserved.

Bosch Brake System

New ABS functionalities:

ABS Unit with

2008 General Motors Corporation. All rights reserved.

New subframe reinforcement on the front

Screwed rear axle bracket:

Variant Rear axle wall Torsional profile

Basis 5,9 mm Medium

Vehicle with 7,1 mm Hard

OPC 8,0 mm Hard Plus

2008 General Motors Corporation. All rights reserved.

Rear shock absorber mount:

2008 General Motors Corporation. All rights reserved.

Flex- fix integrated

2008 General Motors Corporation. All rights reserved.

PAS - Park Assistant System

Pedestrian Protection - Head Impact

2008 General Motors Corporation. All rights reserved.

Ped - Pro Pedestrian - Protection Lower Leg impact:

2008 General Motors Corporation. All rights reserved.

Carrier frame and engine bridge Hood support

2008 General Motors Corporation. All rights reserved.

New tool for removing engine/

New tool for removing/adjusting rear

2008 General Motors Corporation. All rights reserved.

Run Flat Tyres

2008 General Motors Corporation. All rights reserved.

Steering wheel heating

Over Speed Warning

RLS Rain Light Sensor

Automatic lighting control (ALC)

AFL - Adaptive forward lighting

2008 General Motors Corporation. All rights reserved.

PADS - Passenger Airbag Deactivation System

2008 General Motors Corporation. All rights reserved.

ELECTRIC /ELECTRONIC FEATURES - NEW

Low battery charge indication

Bulb outage detection warning

Inadvertent load shutoff

Brake-to-crank indication lamp (MTA)

Cruise control indication

Remote controlled windows

The following settings can be selected:

2008 General Motors Corporation. All rights reserved.

Vehicle Identification Number

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

Position VIN Designation GM coding

1-3 W World manufacturer code WOL Adam Opel AG