Repair of Opel Corsa C, from 2000 to 2005 release.
1. Operation and maintenance of the car
2. Engine
3. Transmission
4. Running gear
5. Steering mechanism
5.1. General information
5.2. Preliminary checks
5.2.1. Check of a side play of a steering wheel
5.2.2. Check of effort on a steering wheel
5.2.3. Pumping of system of the amplifier of steering
5.2.4. Check of tips of steering drafts and sealants
5.2.5. Check of hinges of equal angular speeds
5.2.6. Check of tightness of the power steering
5.2.7. Check of level of working liquid of the hydraulic booster
5.2.8. Malfunction elimination under operating conditions
6. Brake system
7. Onboard electric equipment
8. Body
9. Schemes of electric equipment
 















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5-2-8-ustranenie-neispravnosti-v-usloviyakh-ehkspluatacii.html

5.2.8. Malfunction elimination under operating conditions

Noise and knock in steering during the movement
Too big side play in the plug of the bearing of the steering mechanism can be the cause of malfunction.

Malfunction elimination
In case of malfunction establish a repair kit of the steering mechanism.
For replacement of the plug it is necessary to prepare an assembly arm for the steering mechanism.

NOTE
Production of an assembly arm is described in points 1-4.

1. Cut off a steel pipe of the square section of 40х40 mm 500 mm long.
2. Drill 2 openings with a diameter of 12,5 mm.
Distance between centers openings of 400 mm.
3. Fix the steering mechanism on a square pipe 2 by M12x130 screws (1, 2).
Use podkladny washers and nuts.
4. Take spot welding of a head of screws (1, 2).
5. Remove forward wheels.
6. Suspend a radiator on the air deflector.
Use 2 cable collars.
7. Disconnect an intermediate steering shaft 2 from a steering gear wheel (fig. II).
Turn off and take out a bolt 1.
8. Disconnect 2 pendular levers 1 from a basic pipe of a depreciation rack (fig. III).
Hold an open wrench for two lyska on a bolt of a rotary fist.
9. Disconnect 2 tips of cross steering drafts 1 by means of KM-507-C 2 adaptation from rotary fists (fig. IV).
10. Remove a forward exhaust pipe 1 from the catalyst (fig. V).
Turn off 3 nuts 2.
11. Remove the depreciation block of a back jet bar.
Turn off the screw.
12. Disconnect the exhaust system.
Remove 2 rubber suspension brackets.

NOTE
Attach the exhaust system to the bottom suitable means.

13. Disconnect the socket of a plait of wires of the sensor of oxygen.
14. Disconnect a front bumper from the bridge case.
Take out 3 plastic rivets.
15. Disconnect the mechanism of switching (fig. VI).
Remove a fixing clip 1 from the mechanism of switching 2.
To unhook the switching mechanism from above from a switching mechanism arm.
16. Establish under the case of the forward bridge a hydraulic jack together with KM-904 and KM-6168 devices.

NOTE
To be convinced that the directing pins of KM-6168 are inserted into the directing openings on both sides on the case of the forward bridge.

17. Turn off 4 screws on the case of the forward bridge (fig. VII, shooters).
18. By means of a hydraulic jack lower the case of the forward bridge until access to screws of the steering mechanism opens.

NOTE
You watch that the case of the forward bridge did not rise from KM-6168 adaptation.

19. Remove the steering mechanism from the case of the forward bridge.
Turn off 2 screws.
Remove the steering mechanism.
20. Install the steering mechanism on the prepared assembly arm (see fig. I).
21. Remove 2 boots.
Remove 4 collars.
22. Remove 2 cross steering drafts (fig. VIII).
23. Install the steering mechanism in average situation (fig. IX).

NOTE
Measure a vystupaniye of both ends of a steering shaft 1 concerning the case 2 by a caliper 3.

The size has to be identical on both sides.
Vystupany a gear lath it is possible to adjust, turning a steering shaft.
24. Put marks (fig. X, shooters) on the case of rather lock nut 1 and the adjusting screw 2.
25. Put marks (fig. XI, shooters) on the case of rather steering shaft.
26. Release a lock-nut (fig. XII).
Use KM-280 2 adaptation.
27 Turn off the adjusting screw 3.

NOTE
Change of provision of a lock-nut of rather adjusting screw is not allowed. It is necessary to provide the correct assembly situation.

28. Remove a sealing ring (fig. XIII, 2).
Use the suitable tool 3 to press a sealing ring in the case.
Take out a sealing ring from the case, working with the screw-driver 1 as the lever.
29. Remove a lock ring (fig. XIV).
Remove lubricant.
Remove a lock ring.
30. Take out a steering shaft from the case.
31. Take out a gear lath from the case and check a surface.

NOTE
If the surface is damaged, for example, furrows were formed, it is necessary to replace the steering mechanism.

32. Take out the old plug of the bearing (fig. XV).
Release the bearing 1 plug by means of the suitable tool 2.
Push out the bearing plug from the case from the opposite side by means of the long tool.
33. Clear a nest for the bearing.
34. Install the new plug of the bearing (fig. XVI).
Insert the bearing plug against the stop.
Establish a lock ring 1.
35. To slightly grease the plug of the bearing with the applied lubricant.
36. Establish a gear lath.
Evenly grease a gear lath with the applied lubricant.
Insert a gear lath into the center of the case.
37. Establish a steering shaft.

NOTE
The gear lath has to be established in average situation.
Marks in the helmsman to a shaft and the case have to coincide (see fig. XI).

Measure a vystupaniye of both ends of a steering rack concerning the case by means of a caliper.

NOTE
The size has to be identical on both sides.

If the vystupaniye is not identical, repeat operation for obtaining the required result.
38. Establish a lock ring.
39. Establish a new sealing ring (1, fig. XVII).
Enclose the applied lubricant in the case.
Press a sealing ring fingers.
40. Twist the adjusting screw with a lock-nut.

NOTE
Change of provision of a lock nut of rather adjusting screw is not allowed.

41. Tighten a lock-nut with the moment of 80 N · m. Marks in the case and in the adjusting screw have to coincide.

NOTE
If necessary hold the adjusting screw. Surely observe adjusting marks.

42. Establish 2 cross steering drafts.
Apply lock mastic on a gear wheel shaft carving.
Tighten 2 tips of steering drafts (the moment of an inhaling of 70 N · м).

NOTE
Hold an open wrench for lysk on a gear lath.

43. Establish 2 boots.
Establish 4 collars.
44. Remove the steering mechanism from an assembly arm.
Turn off 2 nuts.
45. Attach the steering mechanism to the case of the forward bridge.
Insert 2 new bolts.
Use 2 new washers.
Tighten 2 new nuts with the moment of 45 N · m + 45 ° + 15 °.
46. Install the case of the forward bridge.
By means of a hydraulic jack carefully lift the case of the forward bridge with KM-6394 devices on KM-6168-A and KM-904 to the car bottom, an arm of a back jet bar or a forward jet bar.
47. Fix the case of the forward bridge.
Tighten 4 new screws with the moment of 90 N · m + 45 ° + 15 °.
48. Attach the switching mechanism.
Insert the switching mechanism in кроншейн the switching mechanism from above.
Establish a fixing clip.
49. Attach a front bumper to the case of the forward bridge.
Insert 3 plastic rivets.
50. Attach the socket of a plait of wires of the sensor of oxygen.
51. Attach the exhaust system.
Establish 2 rubber suspension brackets.
52. Install the depreciation block of a forward jet bar.
Tighten the screw with the moment of 60 N · m.
53. Attach a forward exhaust pipe to the catalyst.
Tighten 3 nuts with the moment of 25 N · m.
54. Attach 2 tips of steering thirsts for a rotary fist.
Tighten new nuts with the moment of 35 N · m.
55. Attach 2 pendular levers to a basic pipe of a depreciation rack.
Tighten nuts with the moment of 65 N · m.
Hold an open wrench for two lyska on a bolt of a rotary fist.
56. Attach an intermediate steering shaft to a steering gear wheel.
Tighten a nut on a clip bolt with the moment of 24 N · m.
57. To remove a radiator suspension bracket to the air deflector.
Cut off 2 plastic cable collars.
58. Establish forward wheels.

"on the page back
5.2.7. Check of level of working liquid of the hydraulic booster
on the following page"
6. Brake system