1988 OPEL CALIBRA ECO mode

9Remove the two securing screws and
withdraw the sensor from the throttle body.
Refitting
10Refitting is a reversal of removal.
11On Motronic M4.1 system models, before
tightening the securing screws, adjust the
position of the sensor as follows:
a)Turn the sensor body anti-clockwise until
resistance is felt, then tighten the securing
screws.
b)When the throttle valve is opened, an
audible click should be noticeable from
the sensor, and similarly, this should be
repeated as the throttle valve is closed.
c)If necessary, adjust the position of the
sensor until a click is heard just as the
throttle valve begins to open.
12On M 1.5 systems, no adjustment is
required when refitting, as the sensor can only
be fitted in one position.
24Throttle valve potentiometer
- removal and refitting
3
Removal
1Disconnect the battery negative lead.
2Disconnect the wiring plugs at the inlet air
temperature sensor and at the hot film mass
airflow meter.
3Undo and remove the bolts securing the air
box to the throttle body. Remove the air box
complete with air trunking.4Disconnect the wiring plug at the throttle
valve potentiometer, then undo the two
screws and withdraw the potentiometer from
the throttle body.
Refitting
5Refitting is a reversal of removal.
25Airflow meter (if fitted) -
removal and refitting
3
Note: If the air funnel is removed, a new
gasket must be used on refitting. The airflow
meter securing bolts must be coated with
thread-locking compound on refitting
Removal
1Remove the air cleaner assembly, as
described in Section 4.
2Unscrew the single bolt securing the airflow
meter to the front of the air cleaner cover (see
illustration).
3Unscrew the four securing bolts from inside
the air cleaner cover, recover the two
reinforcing plates, and withdraw the airflow
meter (see illustration).
4If desired, the air funnel can be unclipped
from inside the air cleaner cover.
Refitting
5Refitting is a reversal of removal,
remembering the following points.
6If the air funnel has been removed, refit it
using a new gasket.7Coat the threads of the four airflow meter
securing bolts that fit inside the air cleaner
cover with thread-locking compound.
26Air mass meter (if fitted) -
removal and refitting
3
Removal
1Disconnect the battery negative lead.
2Disconnect the wiring plug from the air
mass meter. Recover the sealing ring (see
illustration).
3Loosen the clamp screws from the air
trunking on either side of the air mass meter,
then disconnect the air trunking and withdraw
the meter.
Refitting
4Refitting is a reversal of removal, but
inspect the air mass meter wiring plug sealing
ring and renew if necessary.
27Hot film mass airflow meter -
removal and refitting
3
Removal
1Disconnect the battery negative lead.
2Disconnect the wiring plug at the hot film
mass airflow meter and at the inlet air
temperature sensor.
3Remove the upper part of the air cleaner
together with the inlet air trunking and air flow
meter.
4Release the hose clamps and separate the
airflow meter from the inlet air trunking, noting
the position of the trunking with the air flow
meter. If there is any external damage replace
the unit.
Refitting
5Refitting is a reversal of removal but ensure
that the air trunking is connected to the
airflow meter as shown (see illustration). Also
ensure that the marks on the air trunking and
air box are aligned as shown (see
illustration).
4B•12Fuel and exhaust systems - fuel injection models
25.2 Airflow meter securing bolt (arrowed)
- SOHC model
26.2 Recover the sealing ring from the air
mass meter wiring plug - DOHC model
27.5B Correct attachment of air trunking to
hot film mass airflow meter - Motronic M2.8
Arrows indicate air trunking to airflow meter
alignment notches
27.5A Hot film mass airflow meter
attachments - Motronic M2.8
1 Hot film mass airflow meter wiring plug
2 Inlet air temperature sensor wiring plug
25.3 Airflow meter securing bolts and
reinforcing plates, and air funnel

28Fuel injectors (except Multec
system) - removal and refitting
3
Note:Refer to Section 2 before proceeding.
New O-rings must be used when refitting the
injectors. Where applicable, a tachometer and
an exhaust gas analyser will be required to
check the idle mixture on completion
Removal
SOHC models
1Disconnect the battery negative lead.
2Unscrew the union nut, and disconnect the
brake servo vacuum hose from the inlet
manifold.
3Remove the idle speed adjuster, complete
with hoses, referring to Section 22 if
necessary.4Disconnect the vacuum pipe from the top
of the fuel pressure regulator.
5Disconnect the wiring harness housing from
the fuel injectors, and move it to one side,
taking care not to strain the wiring. Pull up on
the wiring harness housing, and compress the
wiring plug retaining clips to release the
harness housing from the injectors.
6Remove the four bolts from the brackets
securing the fuel rail to the inlet manifold, then
lift the fuel rail complete with fuel injectors
sufficiently to enable the injector(s) to be
removed (see illustrations). Take care not to
strain the fuel hoses.
7To remove an injector from the fuel rail,
prise out the metal securing clip using a
screwdriver, then pull the injector from the fuel
rail (see illustrations).
Refitting
8Overhaul of the fuel injectors is notpossible, as no spares are available. If faulty,
an injector must be renewed.
9Begin refitting by fitting new seals to both
ends of each fuel injector (see illustration).
Even if only one injector has been removed,
new seals should be fitted to all four injectors.
10Refitting is a reversal of removal, ensuring
that all hoses, pipes and wires are correctly
reconnected.
11On completion, where applicable, check
and if necessary adjust the idle mixture, as
described in Section 20.
DOHC models
Removal
12Disconnect the battery negative lead.
13Loosen the clamp screw securing the air
trunking to the left-hand end of the air mass
meter.
14Using an Allen key or hexagon bit, unscrew
the four bolts securing the air box to the throttle
body. Lift the air box from the throttle body,
and disconnect the hose from the base of the
air box, then withdraw the air box.
15Position a wad of rag beneath one of the
fuel hose unions on the fuel rail, to absorb the
fuel that will be released as the union is
disconnected.
16Slowly loosen the fuel hose union to
relieve the pressure in the fuel line, then
disconnect the hose from the fuel rail. Be
prepared for fuel spillage, and take adequate
fire precautions. Plug the end of the fuel hose,
to prevent dirt ingress and further fuel leakage.
17Repeat paragraphs 15 and 16 for the
remaining fuel hose-to-fuel rail union.
18Disconnect the two breather hoses from
the rear of the camshaft cover. Disconnect the
larger hose from the throttle body, and
remove the hose completely.
19Disconnect the vacuum pipe from the top
of the fuel pressure regulator.
20Disconnect the wiring plug from the air
mass meter. Recover the sealing ring.
21Disconnect the wiring plug from the
throttle position sensor.
22Slide the end of the throttle cable from the
throttle valve lever on the throttle body, then
unbolt the cable bracket from the inlet
manifold, and move it to one side (see
illustration).
Fuel and exhaust systems - fuel injection models 4B•13
28.6C . . . and lift the fuel rail from the inlet
manifold (inlet manifold removed for
clarity) - SOHC model
28.22 Throttle cable bracket securing
bolts (arrowed) - DOHC model28.9 Fit new seals to the injectors
28.7B . . . then pull the injector from the
fuel rail - SOHC model28.7A Withdraw the securing clip . . .
28.6B . . . and inner fuel rail securing
bolts . . .28.6A Remove the outer . . .
4B

4B
10Unscrew the four securing nuts, and
withdraw the throttle body from the inlet
manifold (see illustrations). Access to the
lower nuts is difficult and it may be necessary
to move the two fuel hoses to one side for
improved access. Take care not to strain the
hoses.
11Recover the gasket.
12If desired, the throttle position sensor can
be removed from the throttle body, with
reference to Section 23.
Refitting
13Refitting is a reversal of removal,
remembering the following points.
14Where applicable, refit the throttle
position sensor, as described in Section 23.
15Refit the throttle body, using a new gasket
(see illustration).
16Ensure that all hoses and wires are
correctly reconnected and routed.
17Check and if necessary top-up the
coolant level, as described in Chapter 3.
18Check and if necessary adjust the throttle
cable free play, as described in Section 19.
DOHC
Removal
19Disconnect the battery negative lead.
20Loosen the clamp screw securing the air
trunking to the left-hand side of the air mass
meter.
21Using an Allen key or hexagon bit,
unscrew the four bolts securing the air box tothe throttle body. Lift the air box from the
throttle body, and disconnect the hose from
the base of the air box, then withdraw the air
box.
22Disconnect the wiring plug from the
throttle position sensor.
23Unscrew the retaining nut, and remove
the fuel hose bracket from the left-hand side
of the throttle body (see illustration).
24Slide the throttle cable end from the
throttle valve lever.
25Disconnect the breather hose from the
front of the throttle body.
26Disconnect the vacuum pipe from the top
of the fuel pressure regulator.
27Make a final check to ensure that all
relevant hoses, pipes and wires have been
disconnected and moved clear of the throttle
body.
28Unscrew the four securing nuts, and
withdraw the throttle body from the inlet
manifold. Recover the gasket.
29If desired, the throttle position sensor can
be removed from the throttle body, referring
to Section 31, if necessary.
30Do not under any circumstances attempt
to adjust the throttle valve linkage. If the
throttle valve linkage is faulty, refer the
problem to a Vauxhall dealer.Refitting
31Refitting is a reversal of removal,
remembering the following points.
32Where applicable, refit the throttle
position sensor, as described in Section 23. 33Refit the throttle body, using a new
gasket.
34Ensure that all hoses, pipes and wires are
correctly reconnected and routed.
35On completion, check and if necessary
adjust the throttle cable free play, as
described in Section 19.
32Throttle body (Multec
system) - removal and refitting
3
Removal
1Depressurise the fuel system (Section 8).
2Remove the air box (see above).
3Disconnect the battery negative lead.
4Disconnect the wiring plugs from the fuel
injector (pressing out the wiring rubber
grommet), from the idle air control stepper
motor and from the potentiometer.
5Disconnect the fuel hoses from their unions
and plug them to prevent loss of fuel and the
entry of dirt; label them to ensure correct
refitting. Be prepared for fuel spillage and take
safety precautions.
6Disconnect the vacuum hoses and pipes
from the body unions.
7Disconnect the throttle valve operating
linkage at the throttle body.
8Undo the two nuts securing the throttle
body to the inlet manifold and withdraw the
body assembly; peel off and discard the
gasket (see illustration).
9If required, the throttle body’s upper and
lower sections may be separated by removing
the two Torx-type securing screws; note that
a new gasket must be fitted on reassembly.
The fuel inlet and return unions may also be
unscrewed, but note that new sealing rings
must be fitted on reassembly, and the unions
must be tightened securely.
Refitting
10Refitting is the reverse of the removal
procedure, noting the following points (see
illustration).
a)Renew all gaskets and seals, and use
thread-locking compound where
applicable.
Fuel and exhaust systems - fuel injection models 4B•15
31.15 Refit the throttle body, using a new
gasket32.8 Throttle body - Multec systems
A Mounting nuts
B Upper-to-lower section Torx screws31.23 Remove the fuel hose bracket
(arrowed) from the throttle body -
DOHC models
31.10B. . . and withdraw the throttle body
(inlet manifold removed for clarity) -
SOHC models31.10A Unscrew the securing nuts . . .

b)Check the throttle cable operation and
adjustment (see above).
c)When reconnecting the vacuum hoses
and pipes, ensure that they are connected
to the front unions as shown in the
accompanying photograph.
d)As no fuel vapour trap is fitted, it is
essential that the manifold absolute
pressure sensor vacuum hose is routed
so that it falls steadily from the sensor to
the throttle body. This precaution will
prevent any fuel droplets being trapped in
the sensor or hose and allowing them to
drain into the inlet port.
e)Ensure that the fuel hoses are correctly
reconnected; the feed hose is on the
injector end of the throttle body.
f)Switch on the ignition and check for signs
of fuel leaks from all disturbed unions; if
any signs of leakage are detected, the
problem must be rectified before the
engine is started.
33Idle air control stepper
motor - removal and refitting
3
Removal
1Remove the air box (see Section 5).
2Disconnect the battery earth lead.3Disconnect the wiring plug from the stepper
motor (see illustration).
4Undo its two screws, then withdraw the
stepper motor. Remove and discard the
sealing ring (see illustrations).
Refitting
5Refitting is the reverse of the removal
procedure, noting the following points.
a)Fit a new sealing ring, greasing it lightly to
ease installation.
b)To prevent the risk of damage, either to
the throttle body or to the stepper motor,
if the motor’s plunger tip projects more
than 28 mm (1.1 in) beyond the motor’s
mating surface, carefully press the
plunger in until its stop is reached. The
stepper motor will then be reset by the
ECU when the engine is restarted.
c)Apply a few drops of a thread-locking
compound to their threads, then carefully
tighten the screws to the specified torque
wrench setting.
34Throttle potentiometer -
removal and refitting
3
Removal
1Disconnect the battery negative lead.
2Disconnect the wiring plug from the
potentiometer (see illustration).
3Unscrew the two Torx-type securing
screws (size TX 25) and withdraw the
potentiometer.
Refitting
4Refitting is the reverse of the removal
procedure, noting the following points.
a)Install the potentiometer when the throttle
valve is fully closed, and ensure that its
adapter seats correctly on the throttle
valve spindle.
b)Tighten the screws carefully to the
specified torque.
35Electronic Control Unit
(ECU) - removal and refitting
3
Removal
1Disconnect the battery negative lead.
2Remove the driver’s footwell side trim panel
(Chapter 11).
3Release the unit from its mountings and
withdraw it until the wiring plugs’ locking lugs
can be released and the plugs can be
disconnected (see illustration).
4Note that the unit consists of two parts the
basic control unit and the Programmable
Read Only Memory (PROM). While it is
possible to renew them separately, do not
attempt to separate them. Faults requiring this
degree of attention can be diagnosed only by
an experienced mechanic using the special
Vauxhall test equipment. A previously sound
ECU could be seriously damaged by careless
handling of the contacts between the two
sub-units.
4B•16Fuel and exhaust systems - fuel injection models
32.10 Intake air temperature control -
Multec systems
A Vacuum pipe
B Exhaust gas recirculation valve hose
C Charcoal canister control pipe
D Fuel return hose
33.4A Unscrew retaining screws (second
screw arrowed) . . .
35.3 Withdrawing the fuel
injection/ignition system ECU34.2 Disconnecting the throttle
potentiometer wiring plug - note the
mounting screws (arrowed)
33.4B . . . to remove the stepper motor -
renew sealing ring (arrowed)
33.3 Disconnecting the idle air control
stepper motor wiring plug

Refitting
5Refitting is a reversal of the removal
procedure, ensuring that the wiring plugs are
correctly reconnected and that the unit is
located securely.
36Knock sensor and module
(X16 SZ models) - removal
and refitting
3
Removal
1The knock sensor fitted to the X16 SZ
engine is located on the cylinder block below
the inlet manifold, between cylinders 2 and 3.
2Disconnect the battery negative lead.
3Remove the wiring and unscrew the unit
from the block.
4The module and control unit are located on
the left-hand side of the engine compartment
behind the battery. To remove, disconnect the
wiring multiplug and remove the retaining
bolts (see illustration).
5There is no provision for testing the knock
sensor or module without dedicated Vauxhall
test equipment. Check for external damage
and replace if necessary.
Refitting
6Refitting is a reversal of the removal
procedure, ensuring that the wiring plugs are
correctly reconnected and that the units are
located securely.
37Knock sensor (Simtec
system) - removal and refitting
3
Removal
1Disconnect the battery negative lead.
2Disconnect wiring harness plug, from inlet
air temperature sensor and wiring harness
plug, from hot mass air flow meter.
3Remove crankcase ventilation hoses.
4Remove coolant hoses from air inlet hoses,
hot film mass air flow meter complete with air
inlet hoses, from upper part of air cleaner and
throttle body.5Press retaining clip for 1st and 4th cylinder
injectors in plug strip (with screwdriver)
towards fuel distributor pipe - lifting plug strip
at the same time. On the underside of the plug
strip there are a total of 6 plug connections, 4
of which are for the injectors.
6Disconnect wiring harness plug for knock
sensor from the plug strip.
7Connect a 1 metre length of separate cable
to knock sensor wiring harness plug (note
routing).
8Remove knock sensor from cylinder block
(see illustration).
9Disconnect knock sensor cable from
separately attached cable, separate cable
remains in engine compartment.
Refitting
10Refitting is a reversal of removal, but note
the following.
11Before refitting ensure that the sensor is
spotlessly clean. Clean the entire contact
surface of the sensor must lie directly on the
cylinder block. Do not use any form of
washers.
12Carefully refit sensor into the block.
Tighten to the correct torque.
13Guide knock sensor cable between ridges
on inlet manifold using separate cable -
ensure correct routing.
14Remove the cable.
15Insert the wiring harness plug for the
knock sensor, into the plug strip.
16Correctly align the spring clips for theinjectors as they may prevent engagement of
the plug strip. Correct contact between the
plug strip and the injector is essential.
17When connecting plug strip, an audible
‘click’ should be heard.
18Ensure that hoses are in good condition
and installed securely with the two clamps.
38Inlet manifold (SOHC without
Multec) - removal and refitting
3
Note:Refer to warning in Section 2, before
proceeding. Use a new gaskets when refitting.
Removal
1Disconnect the battery negative lead.
2Remove the idle speed adjuster and its
hoses, referring to Section 22, if necessary.
3Release the securing clip, then disconnect
the throttle cable and balljoint from the throttle
valve lever. Slide the throttle cable grommet
from the bracket on the inlet manifold, and
move the throttle cable to one side out of the
way.
4Loosen the clamp screw and disconnect
the air trunking from the throttle body.
5Unscrew the union nut and disconnect the
brake servo vacuum hose from the inlet
manifold(see illustration).
6Disconnect the camshaft cover breather
hose from the throttle body.
7Disconnect the coolant hoses from the
throttle body. Be prepared for coolant
spillage, and clamp or plug the open ends of
the hoses, to prevent further coolant loss.
8Disconnect the wiring plug from the throttle
position sensor.
9Disconnect the vacuum pipe from the top
of the fuel pressure regulator.
10Disconnect the wiring harness housing
from the fuel injectors and move it to one side,
taking care not to strain the wiring. Pull up on
the wiring harness housing, and compress the
wiring plug retaining clips to release the
harness housing from the injectors.
11Disconnect the fuel hoses from the fuel
rail. Be prepared for fuel spillage, and take
adequate fire precautions. Clamp or plug the
open ends of the hoses, to prevent dirt
ingress and further fuel leakage.
Fuel and exhaust systems - fuel injection models 4B•17
38.5 Disconnecting the brake servo
vacuum hose -
SOHC models37.8 Knock sensor and wiring
(Simtec system)
1 Sensor2 Securing bolt
36.4 Knock sensor and module (X16 SZ models)
1 Sensor2 Module3 Sensor securing bolt
4B

12Unscrew and remove the top alternator
mounting nut and bolt.
13Make a final check to ensure that all
relevant hoses, pipes and wires have been
disconnected.
14Unscrew the securing nuts, and withdraw
the manifold from the cylinder head. Recover
the gasket (see illustrations).
15It is possible that some of the manifold
studs may be unscrewed from the cylinder
head when the manifold securing nuts are
unscrewed. In this event, the studs should be
screwed back into the cylinder head once the
manifold has been removed, using two
manifold nuts locked together.
16If desired, the ancillary components can
be removed from the manifold, referring to the
relevant Chapter.
Refitting
17Refitting is a reversal of removal,
remembering the following points.
18Where applicable refit any ancillary
components to the manifold, with reference to
relevant Sections of Chapters 4A or 4B.
19If the alternator mounting bracket has
been unbolted from the manifold, refit it
before refitting the manifold, as access to the
securing bolt is extremely limited once the
manifold is in place.
20Refit the manifold using a new gasket,
and tighten the securing nuts to the specified
torque.
21Ensure that all relevant hoses, pipes and
wires are correctly reconnected.
22On completion, check and if necessary
top-up the coolant level, (Chapter 3).
23Check and if necessary adjust the throttle
cable free play, as described in Chapters 4A
or 4B, as applicable.
24If any of the fuel system components have
been disturbed or renewed, check and if
necessary adjust the idle mixture, as
described in Chapters 4A or 4B, as applicable.
39Inlet manifold (SOHCwith
Multec) - removal and refitting
3
Removal
1Depressurise the fuel system Section 8).
2Remove the air box (see Section 5).
3Disconnect the battery negative lead.
4Either remove the throttle body assembly
(see Section 32), or disconnect the throttle
cable, wiring, fuel and vacuum hoses and
pipes to allow the manifold to be removed
with the throttle body.
5Drain the cooling system (see Chapter 3).
6Continue as described in Chapter 4A,
Section 26, paragraph 4 onwards.
Refitting
7Refitting is the reverse of the removal
procedure; renew all gaskets and seals
disturbed.
40Inlet manifold (DOHC
models) - removal and
refitting
3
Removal
1Disconnect the battery negative lead.
2Disconnect the wiring plug from the air
mass meter. Recover the sealing ring.
3Loosen the clamp screw securing the air
trunking to the right-hand end of the air mass
meter.
4Using an Allen key or hexagon bit, unscrew
the four bolts securing the air box to the
throttle body. Lift the air box from the throttle
body, and disconnect the hose from the base
of the air box then withdraw the air box/air
mass meter assembly.
5Disconnect the wiring plug from the throttle
position sensor.
6Slide the throttle cable end from the throttle
valve lever. Then pull the cable end grommet
from the bracket on the inlet manifold and
move the throttle cable to one side out of the
way.
7Disconnect the two breather hoses from the
rear of the camshaft cover. Disconnect the
larger hose from the throttle body, and
remove the hose completely.
8Position a wad of rag beneath one of the
fuel hose unions on the fuel rail, to absorb the
fuel that will be released as the union is
disconnected.
9Slowly loosen the fuel hose union, to
gradually relieve the pressure in the fuel feed
line, then disconnect the hose from the fuel
rail. Be prepared for fuel spillage, and take
adequate fire precautions. Plug the end of the
fuel hose, to prevent dirt ingress and further
fuel leakage.
10Repeat paragraphs 9 and 10 for the
remaining fuel hose-to-fuel rail union.
11Disconnect the vacuum pipe from the top
of the fuel pressure regulator.
12Disconnect the wiring harness housing
from the fuel injectors and move it to one side,
taking care not to strain the wiring. Pull up on
the wiring harness housing, and compress the
wiring plug retaining clips to release the
housing from the injectors.
13Unscrew the union nut, and disconnectthe brake servo vacuum hose from the left-
hand side of the inlet manifold (see
illustration).
14Unscrew the retaining nut, and remove
the fuel hose bracket from the left-hand side
of the throttle body.
15Unscrew the securing nuts, and
disconnect the earth leads from the fuel rail
securing studs at either end of the fuel rail.
16Unscrew the securing bolt, and remove
the cable/hose bracket from the left-hand end
of the inlet manifold.
17Remove the idle speed adjuster, as
described in Section 22.
18Unscrew and remove the top alternator
mounting nut and bolt.
19Make a final check to ensure that all
relevant hoses, pipes and wires have been
disconnected.
20Unscrew the securing nuts, and withdraw
the manifold from the cylinder head. Recover
the gasket.
21It is possible that some of the manifold
studs may be unscrewed from the cylinder
head when the manifold securing nuts are
unscrewed. In this event, the studs should be
screwed back into the cylinder head once the
manifold has been removed, using two
manifold nuts locked together.
22If desired, the ancillary components can
be removed from the manifold, with reference
to the relevant Sections of Chapters 4A or 4B.
Refitting
23Refitting is a reversal of the removal
procedure.
4B•18Fuel and exhaust systems - fuel injection models
38.14A Unscrew the securing nuts
40.13 Brake servo vacuum hose
connection at inlet manifold (arrowed) -
DOHC models
38.14B ...and withdraw the inlet manifold -
SOHC models

Lubricants and fluids
Refer to “Weekly Checks”
Capacities
Engine oil
Including filter:
1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.0 litres
1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 litres
1.8 and 2.0 litre SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.0 litres
20 XEJ and C 20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 litres
X 20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.0 litres
Quantity of oil required to raise level on dipstick from “MIN” to “MAX”:
1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.8 litre
All other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 litre
Cooling system (approx.)
1.4 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6 litres
1.6 litre models (except C 16 NZ2) - manual transmission . . . . . . . . . .5.8 litres
1.6 litre models (except C 16 NZ2) - automatic transmission . . . . . . . .5.6 litres
C 16 NZ2, 1.8 and 2.0 litre SOHC models - manual transmission . . . . .7.2 litres
C 16 NZ2, 1.8 and 2.0 litre SOHC models - automatic transmission . . .7.1 litres
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2 litres
Transmission
Manual transmission codes:
F10 and F13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6 litres
F16, F18 and F20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9 litres
Automatic - at fluid change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.0 to 3.5 litres
Difference between dipstick MAX and MIN marks -approximate:
+ 20°C side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.25 litre
+ 80°C side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.40 litre
Power steering fluid
Approximately . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 litre
Fuel tank
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63.0 ±2 litres
Washer fluid
Without headlamp washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6 litres
With headlamp washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 litres
Engine
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion G102
Cooling system
Antifreeze mixture:
28% antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Protection down to -15°C (5°F)
50% antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Protection down to -30°C (-22°F)
Note:
Refer to antifreeze manufacturer for latest recommendations.
Fuel system
Note:Ignition timing adjustment is not possible on some models, shown for information only.
For further details refer to Chapters 4A or 4B, as applicable.
Idle speed:
14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .925 ±25 rpm
16 SV
Manual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .925 ±25 rpm
Automatic transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . .825 ±25 rpm
18 SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .925 ±25 rpm
C 16 NZ and X 16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .850 ±80 rpm
C 16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .880 ±80 rpm
C 18 NZ
Manual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .880 ±80 rpm
Automatic transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . .830 ±80 rpm
20 NE, C 20 NE and 20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 ±80 rpm
20 XEJ and C 20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .940 ±80 rpm
X 20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .850 ±160 rpm
1•2Servicing Specifications

Idle mixture CO content:
All carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5 to 1.5%
20 NE and 20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 max.
20 XEJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.7 to 1.2%
All other injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.3 % (at 2800 to 3200 rpm)
Air filter element:
1.4 and 1.6 litre ‘round type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion W103
1.6 and 1.8 litre ‘square type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion U512
1.8 litre ‘round type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion type not available
2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion U554
Fuel filter:
1.6, 1.8 and 2.0 litre ‘in-line’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion L201
Ignition system:
Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refer to Chapter 5
Spark plugs
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion RN9YCC or RN9YC
DOHC models:
except C20 XE and X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion RC9MCC *
C20 XE and X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vauxhall P/N 90444724 (FR8LDC)
Plug gap:
RN9YCC and RC9MCC * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.8 mm
RN9YC * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.7 mm
FR8LDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.7 to 0.8 mm
* Information on spark plug types and electrode gaps is as recommended by Champion Spark Plug. Where alternative types are used, refer to the
manufacturer’s recommendations
Brakes
Minimum pad friction material thickness (including backing plate):
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.0 mm
Minimum shoe friction material thickness:
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5 mm above rivet heads
Tyres
Tyre size:
51/2 J x 13 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 R13-82T
51/2 J x 14 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175/70 R14-82T, 195/60 R14-85H, or 195/60 R14-85V
6J x 15 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195/60 R15-87V or 205/55 R15-87V
PressuresSee “Weekly checks”
Torque wrench settingsNmlbf ft
Automatic transmission drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4533
Roadwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11081
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Engine oil (sump) drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5541
Servicing Specifications 1•3
1
The maintenance intervals in this manual
are provided with the assumption that you,
not the dealer, will be carrying out the work.
These are the minimum maintenance intervals
recommended by the manufacturer for
vehicles driven daily. If you wish to keep your
vehicle in peak condition at all times, you may
wish to perform some of these procedures
more often. We encourage frequent
maintenance, because it enhances the
efficiency, performance and resale value of
your vehicle.
If the vehicle is driven in dusty areas, used
to tow a trailer, or driven frequently at slow
speeds (idling in traffic) or on short journeys,more frequent maintenance intervals are
recommended. Vauxhall recommend that the
service intervals are halved for vehicles that
are used under these conditions.
When the vehicle is new, it should be
serviced by a factory-authorised dealer
service department, to preserve the factory
warranty.
Maintenance is essential for ensuring safety
and for getting the best in terms of
performance and economy from your vehicle.
Over the years, the need for periodic
lubrication -oiling, greasing, and so on -has
been drastically reduced, if not eliminated.
This has unfortunately tended to lead someowners to think that because no action is
required, components either no longer exist,
or will last for ever. This is certainly not the
case; it is essential to carry out regular visual
examination comprehensively to spot any
possible defects at an early stage before they
develop into major expensive repairs.
The following service schedules are a list of
the maintenance requirements, and the
intervals at which they should be carried out,
as recommended by the manufacturers.
Where applicable, these procedures are
covered in greater detail near the beginning of
each relevant Chapter.
Maintenance schedule