1988 OPEL CALIBRA steering wheel

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

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.

2When the starter switch is operated, current
flows from the battery to the solenoid that is
mounted on the starter body. The plunger in
the solenoid moves inwards, so causing a
centrally pivoted lever to push the drive pinion
into mesh with the starter ring gear. When the
solenoid plunger reaches the end of its travel,
it closes an internal contact and full starting
current flows to the starter field coils. The
armature is then able to rotate the crankshaft,
so starting the engine.
3A special freewheel clutch is fitted to the
starter driven pinion, so that when the engine
fires and starts to operate on its own it does
not drive the starter motor.
4When the starter switch is released, the
solenoid is de-energised, and a spring moves
the plunger back to its rest position. This
operates the pivoted lever to the withdraw the
drive pinion from engagement with the starter
ring.
13Starter motor - testing
3
Note: Refer to Section 3 before proceeding
Testing
1If the starter motor fails to turn the engine
when the switch is operated, and engine
seizure is not the problem, there are several
other possible reasons:
a)The battery is faulty
b)The electrical connections between the
switch, solenoid battery and starter motor
are somewhere failing to pass the
necessary current from the battery
through the starter to earth
c)The solenoid switch is faulty
d)The starter motor is mechanically or
electrically defective
e)The starter motor pinion and/or flywheel
ring gear is badly worn, and in need of
replacement
2To check the battery, switch on the
headlamps. If they dim after a few seconds,
then the battery is in a discharged state. If the
lamps glow brightly, operate the starter switch
and see what happens to the lamps. If theydim, then power is reaching the motor, but
failing to turn it. If the starter turns slowly, go
on to the next check.
3If, when the starter switch is operated, the
lamps stay bright, then insufficient power is
reaching the motor. Disconnect the battery
and the starter/solenoid power connections,
and the engine earth strap, then thoroughly
clean them and refit them. Smear petroleum
jelly around the battery connections to
prevent corrosion. Corroded connections are
the most frequent cause of electrical system
malfunctions.
4If the preceding checks and cleaning tasks
have been carried out without success, a
clicking noise will probably have been heard
each time the starter switch was operated.
This indicates that the solenoid switch was
operating, but it does not necessarily follow
that the main contacts were closing properly
(if no clicking has been heard from the
solenoid, it is certainly defective). The
solenoid can be checked by connecting a
voltmeter across the main cable connection
on the solenoid and earth. When the switch is
operated, these should be a reading on the
voltmeter. If there is no reading, the solenoid
unit is faulty, and should be renewed.
5If the starter motor operates, but does not
turn the engine, then it is likely that the starter
pinion and/or flywheel ring gear are badly
worn. If this is the case, the starter motor will
normally be noisy in operation.
6Finally, if it is established that the solenoid
is not faulty, and 12 volts are reaching the
starter, then the motor itself is faulty, and
should be removed for inspection.
14Starter motor - removal and
refitting
3
Note: Refer to Section 3 before proceeding
Removal
1Disconnect the battery negative lead.
2Apply the handbrake, then jack up the front
of the vehicle, and support securely on axle
stands (see “Jacking and Vehicle Support”)
positioned under the body side members.3On DOHC models, remove the engine
undershield, as described in Chapter 11.
4Note the wiring connections on the
solenoid, then disconnect them (see
illustration).
5Where applicable, unscrew the bolt
securing the exhaust bracket and the starter
motor mounting bracket to the cylinder block
(see illustration).
6Unscrew the two starter motor mounting
bolts. Note that the top bolt on some models
are fitted from the transmission side, and
secures a wiring harness bracket (see
illustration).
7Withdraw the starter motor.
Refitting
8Refitting is a reversal of removal, but where
applicable, ensure that the wiring harness
bracket is in place on the top mounting bolt,
and tighten all bolts to the specified torque.
15Starter motor - overhaul
5
If the starter motor is thought to be suspect,
it should be removed from the vehicle and
taken to an auto-electrician for testing. Most
auto-electricians will be able to supply and fit
brushes at a reasonable cost. However, check
on the cost of repairs before continuing as it
may prove more economical to obtain a new
or exchange motor.
16Ignition coil - removal, testing
and refitting
3
Note: Refer to Section 3 before proceeding.
An ohmmeter will be required to test the coil
Removal
1The ignition coil is either a cylindrical metal
canister or a moulded plastic unit. It is
clamped or bolted to the left-hand inner wing
panel, near the suspension strut top mounting
(under the power steering fluid reservoir, on
Engine electrical systems 5•9
14.6 Starter motor securing bolts
(arrowed) - 1.6 litre model
(engine removed)14.5 Starter motor mounting
bracket/exhaust bracket securing bolt
(arrowed) - 1.6 litre model14.4 Starter motor and solenoid viewed
from underneath the vehicle. Solenoid
wiring connections arrowed
5

11
Torque wrench settingNm lbf ft
Front seat rails to floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Seat belt fixings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26
1 General description
The bodyshell and floorpan are of pressed
steel, and form an integral part of the vehicle’s
structure, without the need for a separate
chassis.
Various areas are strengthened, to provide
for suspension, steering and engine mounting
points, and load distribution.
Extensive corrosion protection is applied to
all new vehicles. Various anti-corrosion
preparations are used, including galvanising
and PVC under-sealing. Protective wax is
injected into the box sections and other
hollow cavities.
Extensive use is made of plastic for
peripheral components, such as the radiator
grille, bumpers and wheel trims, and for much
of the interior trim.Interior fittings are to a high standard on all
models, and a wide range of optional
equipment is available throughout the range.
Except for the rear quarter windows, all
fixed glass is bonded in position, using a
special adhesive. Any work in this area should
be entrusted to a Vauxhall dealer or glass
replacement specialist.
2 Bodywork and underframe -
maintenance
1
The general condition of a vehicle’s
bodywork is the one thing that significantly
affects its value. Maintenance is easy but
needs to be regular. Neglect, particularly after
minor damage, can lead quickly to further
deterioration and costly repair bills. It is
important also to keep watch on those partsof the vehicle not immediately visible, for
instance the underside, inside all the wheel
arches and the lower part of the engine
compartment.
The basic maintenance routine for the
bodywork is washing preferably with a lot of
water, from a hose. This will remove all the
loose solids that may have stuck to the
vehicle. It is important to flush these off in
such a way as to prevent grit from scratching
the finish. The wheel arches and underframe
need washing in the same way to remove any
accumulated mud that will retain moisture and
tend to encourage rust. Oddly enough, the
best time to clean the underframe and wheel
arches is in wet weather when the mud is
thoroughly wet and soft. In very wet weather
the underframe is usually cleaned of large
accumulations automatically and this is a
good time for inspection.
Periodically, except on vehicles with a
Chapter 11
Bodywork and fittings
Bodywork and underframe - maintenance . . . . . . . . . . . . . . . . . . . . . .2
Bonnet - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Bonnet lock components - removal and refitting . . . . . . . . . . . . . . . . .7
Bonnet lock release cable - removal and refitting . . . . . . . . . . . . . . . .8
Boot lid (Saloon models) - removal and refitting . . . . . . . . . . . . . . . . .9
Boot lid lock (Saloon models) - removal and refitting . . . . . . . . . . . . .10
Boot lid lock cylinder (Saloon models) - removal and refitting . . . . . .11
Bumpers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Centre console - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .38
Door - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Door check arm - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .22
Door exterior handle - removal and refitting . . . . . . . . . . . . . . . . . . . .19
Door inner trim panel - removal and refitting . . . . . . . . . . . . . . . . . . .17
Door interior handle - removal and refitting . . . . . . . . . . . . . . . . . . . .18
Door lock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Door lock barrel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .20
Door mirror - removal, overhaul and refitting . . . . . . . . . . . . . . . . . . .27
Door window - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .25
Door window regulator - removal and refitting . . . . . . . . . . . . . . . . . .26
Engine undershield (DOHC models) - removal and refitting . . . . . . . .32
Facia panels - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .37
Fuel filler flap - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .33General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Headlining - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Interior trim panels - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Interior trim panels - removal and refitting . . . . . . . . . . . . . . . . . . . . .36
Major body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Minor body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Radiator grille panel - removal and refitting . . . . . . . . . . . . . . . . . . . .29
Rear quarter windows - removal and refitting . . . . . . . . . . . . . . . . . .24
Seat belts - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Seat belt tensioners - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Seats (without tensioners) - removal and refitting . . . . . . . . . . . . . . .40
Seats, front (with seat belt tensioners) - removal and refitting . . . . . .43
Sunroof - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Tailgate (Hatchback models) - removal and refitting . . . . . . . . . . . . .12
Tailgate lock (Hatchback models) - removal and refitting . . . . . . . . .13
Tailgate lock cylinder (Hatchback models) - removal and refitting . .14
Tailgate strut (Hatchback models) - removal and refitting . . . . . . . . .15
Upholstery and carpets - maintenance . . . . . . . . . . . . . . . . . . . . . . . .3
Wheel arch liners - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Windscreen and rear window - removal and refitting . . . . . . . . . . . . .23
Windscreen cowl panel - removal and refitting . . . . . . . . . . . . . . . . .30
11•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