1988 OPEL CALIBRA steering

12
Wiper blades
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ins. Champion X-4803
Fuses
Rating:
Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A
Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A
Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 A
Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 A
Torque wrench settingsNm lbf ft
Airbag unit to steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Airbag control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Brackets, passenger airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16
Passenger airbag to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
Steering to column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Chapter 12
Body electrical systems
Aerial - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Aerial mast, electric - removal and refitting . . . . . . . . . . . . . . . . . . . .48
Airbag - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Airbag contact unit - removal and refitting . . . . . . . . . . . . . . . . . . . . .58
Airbag control unit - removal and refitting . . . . . . . . . . . . . . . . . . . . .61
Airbag unit, drivers side - removal and refitting . . . . . . . . . . . . . . . . .56
Airbag unit, passengers side - removal and refitting . . . . . . . . . . . . .59
Anti-theft alarm - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Anti-theft alarm system components - removal and refitting . . . . . . .54
Bracket, passenger airbag unit - removal and refitting . . . . . . . . . . .60
Brake lamp switch - removal and refitting . . . . . . . . . . . . . . . . . . . . .12
Central door locking components - removal and refitting . . . . . . . . .46
Check control system components - removal and refitting . . . . . . . .21
Cigarette lighter - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .15
Clock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Courtesy lamp switch - removal and refitting . . . . . . . . . . . . . . . . . . .10
Direction indicator/lighting switch - removal and refitting . . . . . . . . . .5
Electric door mirror switch - removal and refitting . . . . . . . . . . . . . . . .8
Electric window components - removal and refitting . . . . . . . . . . . . .44
Electric window controls - programming . . . . . . . . . . . . . . . . . . . . . .45
Electrical fault-finding - general information . . . . . . . . . . . . . . . . . . . . .2
Exterior lamp bulbs - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Facia panel switches - removal and refitting . . . . . . . . . . . . . . . . . . . .7
Front indicator lamp unit - removal and refitting . . . . . . . . . . . . . . . .29
Front foglamp - removal, refitting and adjustment . . . . . . . . . . . . . . .31
Fuses and relays - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . . .1
Handbrake “on” warning lamp switch - removal and refitting . . . . . .13
Headlamp aim adjustment motor - removal and refitting . . . . . . . . . .26
Headlamp dim-dip system - general, removal and refitting . . . . . . . .28
Headlamp unit - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .25
Headlamp washer fluid non-return valve - removal and refitting . . . .43Headlamp wiper motor - removal and refitting . . . . . . . . . . . . . . . . . .40
Headlamps - alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Heated front seats - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Horn(s) - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Ignition switch and lock cylinder - removal and refitting . . . . . . . . . . .4
Instrument panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . .18
Instrument panel components - removal and refitting . . . . . . . . . . . .19
Interior lamp bulbs - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Interior lamps - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .23
Luggage compartment lamp switch - removal and refitting . . . . . . .11
Number plate lamp - removal and refitting . . . . . . . . . . . . . . . . . . . . .33
Oil pressure warning lamp switch - removal and refitting . . . . . . . . .14
Radio/cassette player - removal and refitting . . . . . . . . . . . . . . . . . . .50
Rear lamp unit - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .32
Reversing lamp switch . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 7A
Side repeater lamp - removal and refitting . . . . . . . . . . . . . . . . . . . . .30
Speakers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Speedometer cable - removal and refitting . . . . . . . . . . . . . . . . . . . .52
Steering wheel (with airbag) - removal and refitting . . . . . . . . . . . . . .57
Sunroof motor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .51
Sunroof operating switch - removal and refitting . . . . . . . . . . . . . . . . .9
Tailgate wiper motor - removal and refitting . . . . . . . . . . . . . . . . . . . .39
Trip computer components - removal and refitting . . . . . . . . . . . . . .20
Wash/wipe switch - removal and refitting . . . . . . . . . . . . . . . . . . . . . .6
Washer fluid reservoir - removal and refitting . . . . . . . . . . . . . . . . . . .41
Washer nozzles - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .37
Washer pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .42
Windscreen wiper motor and linkage - removal and refitting . . . . . . .38
Wiper arms - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Wiper blades - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Wiring diagrams - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
12•1
Specifications Contents
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321

to-metal contact between components, due
to flexible rubber mountings, etc.
To check whether a component is properly
earthed, disconnect the battery, and connect
one lead of an ohmmeter to a known good
earth point. Connect the other lead to the wire
or earth connection being tested. The
resistance reading should be zero; if not,
check the connection as follows.
If an earth connection is thought to be
faulty, dismantle the connection, and clean
back to bare metal both the bodyshell and the
wire terminal or the component earth
connection mating surface. Be careful to
remove all traces of dirt and corrosion, then
use a knife to trim away any paint, so that a
clean metal-to-metal joint is made. On
reassembly, tighten the joint fasteners
securely; if a wire terminal is being refitted,
use serrated washers between the terminal
and the bodyshell, to ensure a clean and
secure connection. When the connection is
remade, prevent the onset of corrosion in the
future by applying a coat of petroleum jelly or
silicone-based grease.
3Fuses and relays - general
Fuses
1Fuses are designed to break a circuit when
a predetermined current is reached, to protect
the components and wiring which could be
damaged by excessive current flow. Any
excessive current flow will be due to a fault in
the circuit, usually a short-circuit (Section 2).
2The main fuses and relays are located in a
panel at the lower right-hand side of the facia,
under a hinged cover (see illustration).
3The circuits protected by the various fuses
and relays are marked on the inside of the
panel cover.
4A blown fuse can be recognised from its
melted or broken wire.
5To remove a fuse, first ensure that the
relevant circuit is switched off. Then open the
cover and pull the relevant fuse or relay from the
panel (see illustration). If desired, the lower
end of the panel can be tilted forwards, after
releasing the retaining clips to improve access. 6Before renewing a blown fuse, trace and
rectify the cause, and always use a fuse of the
correct rating. Never substitute a fuse of a
higher rating, or make temporary repairs using
wire or metal foil, as more serious damage or
even fire could result.
7Spare fuses are provided in the blank
terminal positions in the fusebox.
8Note that the fuses are colour-coded, see
Specifications. Refer to the wiring diagrams
for details of the fuse ratings and the circuits
protected.
Relays
9A relay is an electrically operated switch,
which is used for the following reasons:
a)A relay can switch a heavy current
remotely from the circuit in which the
current is flowing, allowing the use of
lighter-gauge wiring and switch contacts.
b)A relay can receive more than one control
input, unlike a mechanical switch.
c)A relay can have a timer function - for
example, the intermittent wiper relay.
10Most of the relays are located at the rear
of the main fusebox (remove the securing
screws and pull the fusebox forwards to
improve access). The rear wiper motor relay is
located in the tailgate, behind the tailgate trim
panel. On some models, additional engine-
related relays are located in the relay box
mounted on the left-hand side of the engine
compartment.
11On certain models, additional relays are
located in a box at the left-hand rear of the
engine compartment (see illustration).
12If a circuit or system controlled by a relay
develops a fault, and the relay is suspect,
operate the system. If the relay is functioning, it
should be possible to hear it “click” as it is
energised. If this is the case, the fault lies with
the components or wiring of the system. If the
relay is not being energised, then either the
relay is not receiving a main supply or a
switching voltage, or the relay itself is faulty.
Testing is by the substitution of a known good
unit, but be careful - while some relays are
identical in appearance and in operation, others
look similar but perform different functions.
13To remove a relay, first ensure that the
relevant circuit is switched off. The relay can
then simply be pulled out from the socket,
and pushed back into position.
4Ignition switch and lock
cylinder - removal and
refitting
3
Removal
1Disconnect the battery negative lead.
2Turn the steering wheel as necessary to
expose the two front steering column shroud
securing screws, which are covered by plastic
caps. Prise out the caps and remove the
screws.
3Remove the three securing screws from the
underside of the lower column shroud, then
remove both the upper and lower shrouds.
4To remove the lock cylinder, insert the
ignition key and turn it to position “II”.
5Insert a thin rod into the hole in the lock
housing, then press the rod to release the
detent spring, and pull out the lock cylinder
using the key.
6The ignition switch is secured to the
steering lock housing by two grub screws.
Disconnect the wiring plug, and remove the
screws to extract the switch (see illustration).
Removal of the steering wheel, may aid
removal. Refer to Chapter 10 or Section 57, as
applicable. It is recommended that the switch
and the lock cylinder are not both removed at
the same time, so that their mutual alignment
is not lost.
Refitting
7Refitting is a reversal of removal.
Body electrical systems 12•3
3.11 Relays in engine compartment box -
2.0 litre SRi model shown
4.6 Removing an ignition switch securing
screw
3.5 Removing a fuse -
2.0 litre model shown3.2 Main fuses and relays in facia panel -
2.0 litre SRi model shown
12

5Direction indicator/lighting
switch - removal and refitting
2
Removal
1Disconnect the battery negative lead.
2Turn the steering wheel as necessary to
expose the two front steering column shroud
securing screws, which are covered by plastic
caps. Prise out the caps and remove the
screws.
3Remove the three securing screws from the
underside of the lower column shroud, then
remove both the upper and lower shrouds.
4Disconnect the wiring plug from the switch.
5Depress the switch retaining clip, and
withdraw the switch from the housing.
Refitting
6Refitting is a reversal of removal.
6Wash/wipe switch - removal
and refitting
2
Proceed as described in Section 5.
7Facia panel switches -
removal and refitting
2
1Disconnect the battery negative lead.
Lighting switch
Removal
2Turn the switch to the “dipped beam on”
position, then insert a small screwdriver or rod
through the hole in the bottom of the switch
knob to depress the knob retaining clip. Pull
the knob from the switch (see illustration).
3Press the two now-exposed switch
securing clips towards the switch spindle,
then pull the switch from the facia and
disconnect the wiring plug (see illustrations).
4Note that the switch assembly cannot be
dismantled, and if any part of the switch is
faulty, the complete assembly must be
renewed.
Refitting
5Refitting is a reversal of removal.
Push-button switches
Removal
6First check beneath the switch, if there is a
small hole in the facia, insert a slim
screwdriver or metal rod into it. Release the
switch retaining spring clip by pressing it
upwards against the switch, then remove the
switch and disconnect its wiring. If there is no
hole, remove the switch by prising it out of the
facia using a small screwdriver. Lever gently
under the switch’s lower edge (use adhesive
tape or a piece of card to protect the facia’s
finish). Disconnect the switch wiring plug and
withdraw the switch (see illustration).
Refitting
7Refitting is a reversal of removal.
Headlamp aim adjustment
switch
8The procedure is as described for push-
button switches.
Hazard warning switch
Removal
9Using a screwdriver, carefully prise the cap
from the switch (see illustration).
10Using a screwdriver with a piece of card
under the blade to avoid damage to the facia
trim, prise the ventilation nozzle from the
facia.
11Prise the switch from the facia and
disconnect the wiring (see illustration).
Refitting
12Refitting is a reversal of removal.
Heater blower motor switch
Removal
13Remove the heater control panel, as
described in Chapter 11.
14Disconnect the wiring plug from the
switch, if not already done.
15Prise the switch out from the rear of the
heater control panel.
Refitting
16Refitting is a reversal of removal, but refer
to Chapter 11, when refitting the heater
control panel.
12•4Body electrical systems
7.2 Using a thin rod to depress the
lightning switch knob retaining clip
7.3B . . . then pull the switch from the facia
7.11 Withdrawing the hazard warning
flasher switch from the facia7.9 Prising the cap from the hazard
warning flasher switch7.6 Prising a push-button switch from the
facia
7.3A Press the switch securing clips
towards the switch spindle . . .

3To remove the cigarette lighter assembly,
simply pull it from the illumination ring
assembly. If desired, the illumination ring
assembly can be removed, by pulling it from
the housing after depressing the retaining
clips.
Refitting
4Refitting is a reversal of removal.
16Clock - removal and refitting
2
Removal
1Disconnect the battery negative lead.
2Using a thin-bladed screwdriver, carefully
prise the clock from the facia panel.
3Disconnect the wiring plugs and withdraw
the clock (see illustration).
Refitting
4Refitting is a reversal of removal.
17Heated front seats - general
2
Heating pads are fitted to the front seats of
some models. Before attempting to remove a
seat so equipped, disconnect the battery and
the leads from the heating pad.
18Instrument panel -removal
and refitting
3
Removal
1Disconnect the battery negative lead.
2Remove the steering wheel, (Chapter 10).
3Remove the steering column shrouds, and
the instrument panel upper and lower trim
panels, (Chapter 11).
4Remove the single upper, and two lower,
instrument panel securing screws (see
illustration).
5Carefully withdraw the instrument panel,
and disconnect the speedometer cable and
the two wiring plugs. Note that the
speedometer cable is retained by a clip, which
must be pressed towards the speedometer to
release the cable (see illustration).6If desired, the instrument panel can be
dismantled, with reference to Section 19.
Refitting
7Refitting is a reversal of removal, but ensure
that the speedometer cable is not kinked or
twisted between the instrument panel and the
bulkhead as the panel is refitted.
19Instrument panel
components - removal and
refitting
3
1With the instrument panel removed, as
described in Section 18, continue as follows.
Panel illumination and warning
lamp bulbs
Removal
2Twist the relevant bulbholder clockwise,
and withdraw it from the printed circuit board
on the rear of the instrument panel (see
illustration).
3The bulbs are integral with the bulbholders,
and must be renewed as a unit.
Refitting
4Refitting is a reversal of removal.
Voltage stabiliser
Removal
5Remove the single securing screw from the
rear of the instrument panel, then pull the
voltage stabiliser from the contacts on the
printed circuit board (see illustration).
Refitting
6Refitting is a reversal of removal.
Fuel and temperature gauges -
“low series” models
Removal
7Pull the trip meter reset pin from the front of
the panel.
8Release the two retaining clips at the top of
the panel, and remove the panel shroud (see
illustration).
9Unscrew the two securing nuts, and
withdraw the relevant gauge through the front
of the instrument panel.
12•6Body electrical systems
16.3 Disconnecting the wiring plugs from
the clock
18.5 Disconnecting an instrument panel
wiring plug. Note speedometer cable
retaining clip (arrowed)
19.8 Removing the instrument panel
shroud19.5 Instrument panel voltage stabiliser
(arrowed)19.2 Withdrawing an instrument panel
illumination lamp bulb
18.4 Unscrewing a lower instrument panel
securing screw

6Remove the three securing screws, and
withdraw the speaker from the door.
Disconnect the wiring plug (see illustration).
Refitting
7Refitting is a reversal of removal, but note
that the speaker can only be fitted one way
up, so that the lug on the bottom of the
speaker rim engages with the corresponding
hole in the door skin.
Rear speaker -Hatchback
models
Removal
8Remove the upper rear quarter trim panel,
as described in Chapter 11.
9Remove the four securing screws, and
withdraw the speaker.
Refitting
10Refitting is a reversal of removal.
Rear speaker Saloon models
Removal
11Carefully prise the trim cover from the
parcel shelf, to expose the speaker.
12Remove the four securing screws,
withdraw the speaker and disconnect the
wiring.
Refitting
13Refitting is a reversal of removal.
50Radio/cassette player -
removal and refitting
2
Removal
1All the radio/cassette players fitted to the
Cavalier range have DIN standard fixings. Two
special tools, obtainable from in-car
entertainment specialists, are required for
removal.
2Disconnect the battery negative lead.
3Unscrew the four grub screws from the
corners of the radio cassette player, using an
Allen key or hexagon bit (see illustration).
4Insert the tools into the holes exposed by
removal of the grub screws, and push them
until they snap into place. Pull the tools
outwards to release the unit (see illustration).
5Pull the unit forwards, and withdraw it from
the facia.
Refitting
6To refit the radio/cassette player, simply
push the unit into the facia until the retaining
lugs snap into place, then refit the grub
screws.
51Sunroof motor - removal and
refitting
3
Removal
1Ensure that the sunroof is fully closed.
2Disconnect the battery negative lead.
3Prise the courtesy lamp from the roof trim
panel, and disconnect the wiring.
4Remove the two trim panel securing
screws, and withdraw the trim panel from the
roof, disconnecting the wiring from the
sunroof operating switch.
5Disconnect the wiring plugs from the motor.
6Unscrew the securing nut, and withdraw
the motor assembly.
Refitting
7Refitting is a reversal of removal.
52Speedometer cable - removal
and refitting
3
Removal
1Remove the instrument panel, as described
in Section 18.
2Pull the cable through the bulkhead into the
engine compartment, noting its routing.
3Working in the engine compartment,
unscrew the securing sleeve and disconnect
the speedometer cable from the top of the
transmission (see illustration).
4The cable can now be withdrawn from the
vehicle, noting its routing so that it can be
refitted in the same position.
Refitting
5Refitting is a reversal of removal, ensuring
that the cable is correctly routed. Make sure
that the cable is not kinked or twisted
between the instrument panel and the
bulkhead as the instrument panel is refitted.
Note that the cable should be routed to the
right of the steering column support bracket.
12•18Body electrical systems
49.6 Withdrawing a front door-mounted
speaker - wiring plug arrowed
50.4 . . . and withdraw the radio/cassette player using the special
tools52.3 Speedometer cable securing sleeve (arrowed) at
transmission - SOHC model
50.3 Unscrew the grub screws . . .

53Anti-theft alarm - general
1Certain models are fitted with an anti-theft
alarm as standard equipment.
2The alarm system is triggered by door,
bonnet and boot lid/tailgate mounted
switches, and by ultrasonic sensors mounted
inside the passenger compartment (see
illustration).
3The alarm features a self-diagnostic
function, and any faults should be referred to
a Vauxhall dealer, who will have access to the
necessary specialist diagnostic equipment.
54Anti-theft alarm system
components -removal and
refitting
4
Control unit
Removal
1Disconnect the battery negative lead.
2Remove the driver’s side lower facia panel
as described in Chapter 11.
3If necessary, remove the footwell side trim
panel as described in Chapter 11.4Undo the control unit retaining bolt,
disconnect the wiring plug and remove the
unit from its location.
Refitting
5Refitting is a reversal of removal.
Ultrasonic sensor
6Disconnect the battery negative lead.
7Remove the centre body pillar trim panel as
described in Chapter 11.
8Carefully release the ultrasonic sensor trim
panel and withdraw it downwards.
9Release the ultrasonic sensor from its
location, disconnect the wiring plug and
remove the unit from the car.
Refitting
10Refitting is a reversal of removal.
Bonnet contact unit
Removal
11Disconnect the battery negative lead.
12Using a screwdriver, depress the catch at
the base of the contact unit and withdraw the
contact from its location.
13Disconnect the contact wiring and remove
the unit.
Refitting
14Refitting is a reversal of removal.
55Airbag - general
All 1993 Cavalier models are available with
an airbag that is designed to prevent serious
chest and head injuries to the driver during an
accident. A similar bag for the front seat
passenger is also available on certain models.
Sensors in the centre of the car measure the
vehicle deceleration rate and pass these
signals to a microprocessor. This unit
analyses the sensor data and compares the
information with pre-programmed values
stored in its memory, triggering the airbag if
the deceleration is severe. The airbag is
inflated in 50 milliseconds by a gas generator
that forces the bag out of the module cover in
the centre of the steering wheel.
No repairs are possible on the airbag unit or
its associated parts. The contents of the
following Sections are confined to removal
and refitting of the airbag, purely for access to
other non-related components.
Should a fault be suspected on the airbag
unit, indicated by the warning light on the
instrument panel, or if the car has been
involved in an accident, however minor,
consult a Vauxhall dealer immediately. Do not
attempt to dismantle any of the airbag
components or carry out any work
whatsoever, other than the procedures
described in the following Sections.
On vehicles fitted with a passenger side
airbag, do notfit accessories in the airbag
zone. Items like telephones, cassette storage
boxes, additional mirrors, etc., can be ripped off
and cause serious injury, if the airbag inflates.
Body electrical systems 12•19
12
53.2 Anti-theft alarm system component
locations
(Calibra model shown - component locations
identical on Cavalier)
1 Control unit
2 Ultrasonic sensor
with LED
3 Ultrasonic sensor
with probe4 Radio contact
5 Bonnet contact unit
6 Horn
7 Relay
Warning: Before starting any
work on airbag or related
components, disconnect the
battery. Cover the battery’s
terminals and wait a minimum of 1
minutes as a precaution against
accidental firing of the airbag unit. This
period ensures that any stored energy in
the back-up capacitor is dissipated.
Handle the airbag unit with extreme care
as a precaution against personal injury,
and always hold it with the cover facing
away from the body. If in doubt
concerning any proposed work involving
the airbag unit or its control circuitry,
consult a Vauxhall dealer or other
qualified specialist.

56Airbag unit, drivers side -
removal and refitting
4
Note:On power steering models in particular,
it will be advantageous to jack up the front of
the car and support it on axle stands placed
under the body side members, so that the
steering wheel can be turned more easily.
Removal
1Disconnect the battery negative lead and
cover the battery terminal. Wait a minimum of 1
minute.
2With the steering wheel positioned in the
straight-ahead position, turn it 90°clockwise
so that the left-hand spoke is accessible from
the rear.
3Using a Torx type socket, undo the first
airbag retaining bolt from the rear of the
steering wheel (see illustration).
4Turn the steering wheel 180°anti-clockwise
so that the right-hand spoke is accessible
from the rear.
5Undo the second retaining bolt from the
rear of the steering wheel.
6Return the steering wheel to the
straight-ahead position then carefully lift up
the airbag unit.
7Disconnect the wiring plug and remove the
airbag from the car.
Refitting
8Refitting is a reversal of removal.
57Steering wheel (with airbag)
-removal and refitting
4
Note: Read warning at the beginning of
Section 55, before starting work. A
two-legged puller will be required for this
operation. Note also that the steering wheel is
a very tight fit on the shaft.
Removal
1Remove the airbag unit as described
previously.
2Ensure that the steering wheel is in the
straight ahead position.
3From the centre of the steering wheel
unscrew the two screws securing the airbag
contact unit.4Using a screwdriver, prise back the tabs on
the lockwasher securing the steering wheel
retaining nut.
5Unscrew and remove the steering wheel
retaining nut and the lockwasher.
6Make alignment marks between the
steering wheel and the end of the column
shaft.
7A suitably small two-legged puller must
now be fitted to the steering wheel in order to
pull it from the column shaft.
8Once the steering wheel has been released
from the column shaft, disconnect the horn
wiring and remove the steering wheel.
Refitting
9Begin refitting by positioning the steering
wheel on the column shaft, ensuring that the
marks made on removal are aligned, and that
the wheel correctly engages with the airbag
contact unit. It may be necessary to tap the
steering wheel fully home on the column shaft
using a metal tube and socket.
10Reconnect the horn wiring.
11Refit the lockwasher and the steering
wheel retaining nut, and tighten the nut to the
specified torque. Bend up the lockwasher to
secure.
12Refit the two screws securing the airbag
contact unit.
13Refit the airbag as described previously.
58Airbag contact unit -removal
and refitting
4
Note: Read warning at the beginning of
Section 55, before starting work.
Removal
1Remove the airbag and the steering wheel
as described previously.
2Remove the steering column upper and
lower shrouds, referring to Chapter 10, if
necessary.
3Disconnect the contact unit wiring plug
below the steering column and withdraw the
contact unit from the column, noting its fitted
position as a guide to reassembly (see
illustration).
Refitting
4Before refitting the contact unit, ensure that
the front wheels are in the straight-ahead
position.
5Place the contact unit on the column in the
correct position as noted during removal.
6Route the wiring harness under the steering
column lock/ignition switch and connect the
wiring plug.
7Refit the steering column shrouds.
8Refit the steering wheel and airbag as
described previously.
59Airbag unit, passengers side
- removal and refitting
4
Note: Read warning at the beginning of
Section 55, before starting work.
Removal
1Disconnect the battery, cover the terminals
and wait at least 1 minute.
2Remove the glovebox assembly. Refer to
Chapter 11, for further details if necessary.
3Remove the right hand ventilation air duct.
12•20Body electrical systems
58.3 Airbag contact unit retaining screws
56.3 Airbag, steering wheel and contact unit details
Warning: Read warning at the
beginning of Section 55, before
starting work.
Warning: Stand the unit with the
cover uppermost and do not
expose it to heat sources in
excess of 100ºC. Do not attempt
to open or repair the airbag unit, or apply
any voltage to it. Do not use any airbag
unit that is visibly damaged or has been
tampered with.

8Alternator drivebelt -
removal, refitting and adjusting
2
V-belt type (not-ribbed)
Removal
1Disconnect the air inlet trunking from the air
cleaner, and the air box or throttle body, as
applicable, and remove it for improved
access.
2Correct tensioning of the drivebelt will
ensure that it has a long life. Beware,
however, of overtightening, as this can cause
excessive wear in the alternator.
3The belt should be inspected regularly, and
if it is found to be worn, frayed or cracked, it
should be renewed as a precaution against
breakage in service. It is advisable to carry a
spare drivebelt of the correct type in the
vehicle always.
4On models with power steering, the
alternator drivebelt also drives the power
steering pump.
5To remove the belt, on 1.8 and 2.0 litre
models first remove the power steering pump
drivebelt, as described in Chapter 10.
6Loosen the two alternator mounting nuts
and bolts sufficiently to allow the alternator to
be pivoted in towards the engine.
7Slide the belt from the pulleys.
Refitting
8Ensure that the correct type of belt is used,
if it is being renewed. Fit the belt around the
pulleys. Take up the slack in the belt byswinging the alternator away from the engine
and lightly tightening the mounting nuts and
bolts.
Adjusting
9Although special tools are available for
measuring the belt tension, a good
approximation can be achieved if the belt is
tensioned so that there is approximately 13.0
mm (0.5 in) of free movement under firm
thumb pressure at the mid-point of the
longest run between pulleys.
10With the mounting bolts just holding the
unit, lever the alternator away from the engine
using a wooden lever at the mounting bracket
end until the correct tension is achieved. Then
tighten the mounting nuts and bolts. On no
account lever at the free end of the alternator,
as serious internal damage could be caused.11Where applicable, refit and tension the
power steering pump drivebelt, as described
in Chapter 10.
12Refit the air inlet trunking.
13When a new belt has been fitted, it will
probably stretch slightly when it is first run,
and the tension should be rechecked and if
necessary adjusted after approximately 250
miles (400 km).
Ribbed V-belt type
General
14Later models equipped with power
steering are fitted with a ribbed V-belt type
drivebelt in conjunction with an automatic
tensioning roller. Once the belt is installed, no
further adjustment is necessary as the correct
tension is maintained by the automatic
tensioning roller. Removal and refitting
procedures are as follows.
Removal
15For improved access, remove the air
cleaner assembly and air inlet trunking.
16If the original drivebelt is to be refitted, mark
the rotational direction on the belt with chalk.
17Using a spanner or socket on the
automatic tensioning roller hexagon, turn the
tensioning roller clockwise (as viewed from the
right-hand side of the car) and hold it in this
position. With the drivebelt tension released,
slip the drivebelt off the pulleys, then allow the
tensioner to return to its original position.
18Support the engine under the sump with a
jack and interposed block of wood.
19From under the car, unbolt the right-hand
engine mounting block from the body.
20Lower the engine support jack just
sufficiently to allow the drivebelt to be
withdrawn from between the mounting block
and the body.
Refitting
21Slip the new drivebelt between the
mounting block and body then raise the
engine, by means of the jack, to its original
position.
22Clean the threads of the mounting block
retaining bolts, apply locking fluid, and refit
the bolts. Tighten the bolts to the specified
torque (see Chapter 2A).
23Rotate the automatic tensioner roller anti-
clockwise and route the drivebelt around the
pulleys as shown (see illustration). With the
belt correctly positioned, release the tensioner
that will automatically apply the correct
tension to the belt.
24On completion, refit the air cleaner
assembly and the air inlet trunking.
5•6Engine electrical systems
7.5 Sectional view of the Delco-Remy
“compact” series alternator
1 Drive end bracket
2 Stator
3 Rotor4 Slip rings
5 Fan
6 Rectifier
8.23 Correct routing of the ribbed V-belt