1988 OPEL CALIBRA battery location

12•38Wiring diagrams
Key to wiring diagrams for 1991 models
NoDescriptionTrackNoDescriptionTrack Wiring diagrams for 1991 models
Location of applicable circuitsTrackLocation of applicable circuitsTrack
Air conditioning system800 to 850
Alternator111
Anti-lock braking system (ABS)701 to 722
Anti-theft alarm system633 to 647
Automatic transmission control system773 to 799
Battery100
Brake lamps461 to 462
Carburettor118 to 121
Central locking system600 to 627
Check control system347 to 371
Cigarette lighter597 to 598
Clock661 to 663
Courtesy lamps - front487 to 494
Courtesy lamps - rear569 to 573
Direction indicator and hazard warning lamps467 to 482
Door mirrors536 to 548
Electric windows665 to 699
Engine compartment lamp415
Foglamps - front444 to 452
Foglamps - rear444 to 457
Fuel injection and ignition (Multec) - C16NZ engine129 to 164
Fuel injection and ignition (Multec) - C18NZ engine972 to 997
Fuel injection/ignition (Motronic M1.5) - 2.0litre sohc 168 to 199
Fuel injection/ignition (Motronic M2.5) - 2.0litre dohc 261 to 299
Glovebox lamp599Headlamp aim adjustment system758 to 766
Headlamp dim-dip427 to 431
Headlamp washers519 to 532
Headlamps437 to 442
Headlamps “ON” warning buzzer493 to 495
Heated front seats560 to 566
Heated rear window549 to 556
Heater blower motor853 to 862
Horn(s)592 to 596
Ignition (HEI) - 14NV engine121 to 128
Ignition (MSTS/EZ+) - 16SV, 18 SV engines236 to 256
Instruments301 to 344
Luggage compartment lamp485
Radiator cooling fan113, 115
Radio/cassette player586 to 591
Rear number plate lamp413
Reversing lamps496 to 498
Side and tail lamps401 to 410
Starter motor102 to 110
Sunroof863 to 870
Tailgate wiper510 to 516
Trip computer650 to 662
Windscreen and tailgate washers511 to 529
Windscreen wipers501 to 506
E1Side lamp - left406
E2Tail lamp - left356, 374, 407
E3Number plate lamp413
E4Side lamp - right409
E5Tail lamp - right358, 376, 410
E6Engine compartment lamp415
E7Headlamp main beam - left437
E8Headlamp main beam - right438
E9Headlamp dipped beam - left360, 378, 439
E10Headlamp dipped beam - right362, 380, 440
E11Instrument illumination lamps328 to 329
E12Selector lever illumination lamp (automatic transmission)799
E13Luggage compartment lamp485
E14Courtesy lamp487
E15Glovebox lamp599
E16Cigarette lighter illumination lamp596
E17Reversing lamp - left497
E18Reversing lamp - right498
E19Heated rear window552
E20Front foglamp - left448
E21Front foglamp - right447
E24Rear foglamp - left454
E25Driver’s seat heater580
E27Courtesy lamp - rear left569 to 570
E28Courtesy lamp - rear right572 to 573
E30Passenger front seat heater564
E32Clock illumination lamp663
E38Trip computer illumination lamp654
E39Rear foglamp - right455
E41Courtesy lamp (with delay)488 to 490
E50Kerb lamp - driver’s door666
E51Kerb lamp - passenger door684
F1 onFusesVarious
G1Battery101
G2Alternator111
G3Battery - (Diesel models)882, 901
G6Alternator - (Diesel models)884 to 886, 909 to 911H1Radio/cassette player589 to 590, 634
H2Horn592
H3Direction indicator warning lamp315 to 320
H4Oil pressure warning lamp310
H5Brake fluid level warning lamp313
H6Hazard warning flasher lamp470
H7Alternator charge warning lamp310
H8Headlamp main beam warning lamp322
H9Brake lamp - left364, 382, 461
H10Brake lamp - right366, 384, 462
H11Direction indicator lamp - front left472
H12Direction indicator lamp - rear left473
H13Direction indicator lamp - front right461
H14Direction indicator lamp - rear right482
H15Fuel level warning lamp305
H16Glow plug warning lamp (Diesel models)323
H17Trailer direction indicator warning lamp321
H18Horn593
H19Headlamps-on warning buzzer494 to 495
H21Handbrake-on warning lamp315
H25Door mirror warning lamp542, 952
H26ABS warning lamp319
H30Engine fault warning lamp324
H33Direction indicator side repeater lamp - left476
H34Direction indicator side repeater lamp - right478
H42Automatic transmission warning lamp325
H45Four-wheel-drive warning lamp327
H46Catalytic converter temperature warning lamp329
H47Anti-theft alarm horn638
H48Horn594
K3Relay - starter motor (anti-theft alarm)109 to 110
K5Relay - front foglamps448 to 450
K6Relay - air conditioning801 to 802
K7Relay - air conditioning blower804 to 805
K8Relay - intermittent windscreen wipe503 to 506
K9Relay - headlamp wash519 to 520
K10Relay - direction indicator/hazard warning flashers467 to 469

5If the engine turns over at normal speed but
will not start, check the HT circuit by
connecting a timing light and turning the
engine over on the starter motor. If the light
flashes, voltage is reaching the spark plugs,
so these should be checked first. If the light
does not flash, check the HT leads
themselves followed by the distributor cap,
carbon brush and rotor arm.
6If there is a spark, check the fuel system for
faults as far as possible (Chapters 4A or 4B).
7If there is still no spark, check the voltage at
the ignition coil “+” or “15” terminal; it should
be the same as the battery voltage (i.e., at
least 11.7 volts). If the voltage at the coil is
more than 1 volt less than that at the battery,
check the connections back through the
ignition switch to the battery and its earth until
the fault is found. Note, however, that the
ECU controls the coil’s feed; do not attempt
to “test” the ECU with anything other than the
correct test equipment, which will be available
only to a Vauxhall dealer. If any of the wires
are to be checked which lead to the ECU,
always first unplug the relevant connector
from the ECU so that there is no risk of the
ECU being damaged by the application of
incorrect voltages from test equipment.
8If the feed to the ignition coil is sound,
check the coil’s primary and secondary
windings (refer to Section 16). Renew the coil
if faulty, but check the condition of the LT
connections themselves before doing so, to
ensure that the fault is not due to dirty or
poorly fastened connectors.
9If the ignition coil is in good condition, the
fault may be within the amplifier module or the
distributor on the C16 NZ and C16 NZ2
engines, or the amplifier or the crankshaft
speed/position sensor on the C18 NZ engine.
A quick check of these components can be
made by connecting a low-wattage bulb
across the ignition coil’s (disconnected) LT
terminals. If the bulb flickers or flashes when
the engine is turned over, the amplifier and
distributor (C16 NZ and C16 NZ2 engines), or
amplifier and crankshaft speed/position
sensor (C18 NZ engine), are sound.
10If this is the case, the entire LT circuit is in
good condition; the fault, if it lies in the
ignition system, must be in the HT circuit
components. These should be checked
carefully, as outlined above.
11If the indicator or bulb does not flash, the
fault is in either the amplifier or the distributor
(C16 NZ and C16 NZ2 engines), or the
amplifier or crankshaft speed/position sensor
(C18 NZ engine). Owners should note,
however, that by far the commonest cause of
“failure” of either of these is a poor
connection, either between the components
themselves or in the LT circuit wiring
connections. If such a fault is suspected, the
vehicle must be taken to a suitably equipped
Vauxhall dealer for testing; no information is
available to eliminate these components by
other means.12An irregular misfire suggests either a
loose connection or intermittent fault on the
primary circuit, or a HT fault on the coil side of
the rotor arm.
13With the ignition switched off, check
carefully through the system ensuring that all
connections are clean and securely fastened.
If the equipment is available, check the LT
circuit as described in paragraphs 7 to 11
above.
14Check that the HT coil, the distributor cap
and the HT leads are clean and dry. Check the
leads and the spark plugs (by substitution, if
necessary), then check the distributor cap,
carbon brush and rotor arm.
15Regular misfiring is almost certainly due to
a fault in the distributor cap, HT leads or spark
plugs. Use a timing light (paragraph 5, above)
to check whether HT voltage is present at all
leads.
16If HT voltage is not present on any
particular lead, the fault will be in that lead or
in the distributor cap. If HT is present on all
leads, the fault will be in the spark plugs;
check and renew them if there is any doubt
about their condition.
17If no HT voltage is present, check the
ignition coil; its secondary windings may be
breaking down under load.
18If all components have been checked for
signs of obvious faults but the system is still
thought to be faulty, take the vehicle to a
Vauxhall dealer for testing on special
equipment.
5Battery - testing and charging
2
Note: Refer to Section 3 before proceeding.
Testing
1Topping-up and testing of the electrolyte in
each cell is not possible. The condition of the
battery can therefore only be tested by
observing the battery condition indicator.
2The battery condition indicator is fitted in
the top of the battery casing, and indicates
the condition of the battery from its colour. If
the indicator shows green, then the battery is
in a good state of charge. If the indicator turns
darker, eventually to black, then the battery
requires charging, as described later in this
Section. If the indicator shows clear/yellow,
then the electrolyte level in the battery is too
low to allow further use, and the battery
should be renewed.
Charging
3Do not attempt to charge, load or jump start
a battery when the indicator shows
clear/yellow. If the battery is to be charged,
remove it from the vehicle and charge it as
follows.
4The maintenance-free type battery takes
considerably longer to fully recharge than the
standard type, the time taken being
dependent on the extent of discharge.5A constant-voltage type charger is required,
to be set, when connected, to 13.9 to 14.9
volts with a charger current below 25 amps.
6If the battery is to be charged from a fully
discharged state (less than 12.2 volts output),
have it recharged by a Vauxhall dealer or
battery specialist, as the charge rate will be
high and constant supervision during charging
is necessary.
6Battery - removal and refitting
2
Note: Refer to Section 3 before proceeding.
Removal
1The battery is located at the left-hand front
corner of the engine compartment.
2Disconnect the lead(s) at the negative
(earth) terminal by unscrewing the retaining
nut and removing the terminal clamp.
3Disconnect the positive terminal lead(s) in
the same way.
4Unscrew the clamp bolt sufficiently to
enable the battery to be lifted from its
location. Keep the battery in an upright
position, to avoid spilling electrolyte on the
bodywork.
Refitting
5Refitting is a reversal of removal, but smear
petroleum jelly on the terminals when
reconnecting the leads, and always connect
the positive lead first and the negative lead
last.
7Alternator - description
1A Delco-Remy or Bosch alternator may be
fitted, depending on model and engine
capacity. The maximum output of the
alternator varies accordingly.
2The alternator is belt-driven from the
crankshaft pulley. Cooling is provided by a
fan, mounted outside the casing on the end of
the rotor shaft. An integral voltage regulator is
incorporated, to control the output voltage.
3The alternator provides a charge to the
battery even at very low engine speed, and
consists of a coil-wound stator in which a
rotor rotates. The rotor shaft is supported in
ball-bearings, and slip rings are used to
conduct current to and from the field coils
through the carbon brushes.
4The alternator generates ac (alternating
current), which is rectified by an internal diode
circuit to dc (direct current) for supply to the
battery.
5Later models are fitted with a Delco-Remy,
‘compact’ series alternators (see illustration).
They use a ribbed V-belt type drivebelt with
automatic tensioner. They are rigidly mounted
to the engine.
Engine electrical systems 5•5
5

9Alternator-removal and
refitting
3
Note: Refer to Section 3 before proceeding
Except ‘compact’ series
alternators
Removal
1Disconnect the battery leads.
2Disconnect the air trunking from the air
cleaner, and the air box or throttle body, as
applicable, and remove it for improved
access.
3Disconnect the wiring plug, or disconnect
the wires from their terminals on the rear of
the alternator, noting their locations (see
illustration).
4Remove the drivebelt, (Section 8).
5Unscrew the two mounting bolts and nuts
and recover any washers and insulating
bushes, noting their locations. Note the earth
strap attached to the top mounting bolt (see
illustration).
6Withdraw the alternator, taking care not to
knock or drop it, as this can cause irreparable
damage.
Refitting
7Refitting is a reversal of removal,
remembering the following points.
8Ensure that the earth lead is in place on the
top mounting bolt.
9Refit and tension the drivebelt, (Section 8).
‘Compact’ series alternators
Removal
10Disconnect the battery negative lead.
11Remove the air inlet trunking and, if
necessary for improved access, the air
cleaner assembly.
12Mark the rotational direction on the
alternator drivebelt with chalk.
13Using 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 alternator
pulley, then allow the tensioner to return to its
original position.14Disconnect the electrical cable
connections at the rear of the alternator.
15Undo and remove the alternator lower
mounting bolt, and slacken both upper bolts
that secure the alternator mounting brackets
to the engine.
16Undo and remove both bolts that secure
the alternator to its mounting brackets, noting
the location of the different length bolts.
Swing the brackets clear and remove the
alternator from the engine.
Refitting
17Refitting is a reversal of removal. Tighten
the mounting bolts to the specified torque,
and refit the drivebelt as described in
Section 8.
10Alternator -testing
5
Due to the specialist knowledge and
equipment required to test or service an
alternator, it is recommended that if a fault is
suspected, the vehicle is taken to a dealer or a
specialist. Information is limited to the
inspection and renewal of the brushes.
Should the alternator not charge, or the
system be suspect, the following points may
be checked before seeking further assistance:
a)Check the drivebelt tension, as described
in Section 8
b)Check the condition of the battery and its
connections -see Section 5c)Inspect all electrical cables and
connections for condition and security
Note that if the alternator is found to be
faulty, it may prove more economical to buy a
factory-reconditioned unit, rather than having
the existing unit overhauled.
11Alternator brushes -removal,
inspection and refitting
3
Removal
Delco-Remy type (except ‘compact’
series)
1Remove the alternator, as described in
Section 9
2Scribe a line across the drive end housing
and the slip ring end housing, to ensure
correct alignment when reassembling.
3Unscrew the three through-bolts, and prise
the drive end housing and rotor away from the
slip ring end housing and stator (see
illustration).
4Check the condition of the slip rings, and if
necessary clean with a rag or very fine glass
paper (see illustration).
5Remove the three nuts and washers
securing the stator leads to the rectifier, and
lift away the stator assembly (see
illustration).
Engine electrical systems 5•7
11.3 Separating the drive end housing
from the slip ring end housing - Delco-
Remy alternator
11.4 Alternator slip rings (arrowed) -
Delco-Remy alternator
11.5 Delco-Remy alternator
A Stator lead securing nuts
B Brush holder/voltage regulator
securing screws
9.5 Disconnecting the earth lead from the
top alternator mounting bolt9.3 Disconnecting the wires from the
terminals on the rear of the alternator -
Delco-Remy alternator
5

in a clip at the left-hand rear of the engine
compartment (see illustration).
4The plug is reversible in its connector, and
is marked either “A” or “98” on one side,
which corresponds to the position for use with
98 RON leaded petrol. On the other side either
“B” or “95”, which corresponds to the position
to use with 95 RON unleaded petrol. All
vehicles are set for use with 95 RON unleaded
petrol before they leave the factory.
5To change the coding for use with a
different type of petrol, first allow the fuel tank
to become practically empty.
6Fill the fuel tank with the required type of
petrol.
7Ensure that the ignition is switched off, then
remove the coding plug from its clip and
disconnect the wiring connector.
8Rotate the plug through 180°, so that the
appropriate octane mark is uppermost (see
paragraph 4), then reconnect the wiring
connector and refit the plug to its clip.
9Note that using petrol with a higher octane
rating than that set will not cause damage, but
petrol with a lower octane rating than that set
must not be used.
20 XE, C20 XE and X20 XEV
models
10The ignition coding plug found on these
models is not an octane coding plug
(although its method of operation is similar)
and must not be altered from its factory
setting. Its purpose is to ensure that the
Motronic module uses the correct information,
pre-programmed (or “mapped”) into its
memory, to enable the vehicle to comply with
the relevant national noise and exhaust
emission legislation.
11On these models, the knock sensor circuit
allows the Motronic module to compensate
for differences in the octane value of the
petrol used, without the need for manual
intervention. Remember, however, that all
catalytic converter-equipped vehicles must
use unleaded petrol only. This means that
these models can use any grade of unleaded
petrol on sale in the UK without the need for
adjustment.
23Electronic modules - removal
and refitting
3
Note: Refer to Section 3 for precautions to be
observed when working with electronic
modules. Heat sink compound must be used
when refitting the module.
HEI module (14 NV models)
Removal
1The module is mounted on a metal plate,
beneath the ignition coil, on the left-hand side
of the engine compartment.
2Remove the ignition coil as described in
Section 16, and slide the coil from its clamp.
3The module can be removed from the
mounting plate by unscrewing the two
securing screws.
4Before refitting the module, heat sink
compound should be applied to the mounting
plate to improve heat dissipation. If a new
module is being fitted, it should be supplied
with heat sink compound. Similar compounds
can be bought from DIY electrical shops.
Refitting
5Refitting is a reversal of removal.
MSTS-i module (1.6 and 1.8 litre
models)
Removal
6The module is mounted on the engine
compartment bulkhead, above the steering
rack (see illustration).
7Disconnect the battery negative lead.
8If desired, for improved access, remove the
air box from the top of the carburettor.
9Disconnect the wiring plug from the
module.
10Unscrew the two securing nuts, and
withdraw the module from the bulkhead.
Refitting
11Refitting is a reversal of removal.
Motronic module
Removal
12The module is mounted in the driver’s
footwell, behind the side trim panel.13Disconnect the battery negative lead.
14Remove the driver’s footwell side trim
panel, as described in Chapter 11.
15Unscrew the three module securing
screws, two at the top of the module, and a
single screw at the bottom, and lower the
module from the footwell (see illustration).
16Release the retaining clip, and disconnect
the module wiring plug (see illustration).
17Withdraw the module, noting the plastic
insulating sheet on its rear face.
Refitting
18Refitting is a reversal of removal, but
ensure that the insulating sheet is in place on
the rear face of the module.
24MSTS-i components -
removal and refitting
3
Note: Refer to Section 3 before proceeding.
Procedures for removal and refitting of the
ignition system components and electronic
module are given elsewhere in the relevant
Sections of this Chapter
Manifold pressure sensor
Removal
1The sensor is located on the engine
compartment bulkhead, to the left of the
MSTS-i module, under the edge of the
windscreen cowl panel (see illustration).
2Disconnect the battery negative lead.
5•14Engine electrical systems
22.3 Octane coding plug (arrowed) -
2.0 litre model
23.15 Lowering the Motronic module from
the footwell - 2.0 litre model23.16 Releasing the Motronic module
wiring plug clip - 2.0 litre model
23.6 MSTS-i module location -
1.6 litre model

3Lift up the edge of the windscreen cowl
panel for access to the sensor.
4Disconnect the sensor wiring plug, and the
vacuum pipe.
5Pull the pressure sensor upwards to release
it from its bracket, and withdraw it from the
vehicle.
Refitting
6Refitting is a reversal of removal. However,
on Multec models no fuel vapour trap is fitted.
It is therefore essential that the sensor
vacuum hose is routed so that it falls steadily
from the sensor to the throttle body. This
precaution prevents any fuel droplets being
trapped in the sensor or hose, and allows
them to drain into the inlet port.
Oil temperature sensor
Removal
7The sensor is screwed into the inlet
manifold side of the cylinder block, next to the
starter motor’s right-hand end.
8The sensor can be reached quite easily
from above, but if it is to be removed from
beneath, ensure that the handbrake is
applied, and that the vehicle is securely
supported on axle stands (see “Jacking and
Vehicle Support”).
9Disconnect the battery negative lead.
10Disconnect the sensor wiring plug.
11Using a spanner, unscrew the sensor and
remove it (see illustration). Be prepared for
oil spillage, and plug the hole in the cylinder
block to prevent dirt ingress and further oil
loss.
Refitting
12Refitting is a reversal of removal.
Crankshaft speed/position
sensor (1.8 litre models)
Removal
13The sensor is located on the exhaust
manifold side of the engine, in the lower
cylinder block behind the oil pump.
14Disconnect the battery negative lead.
15Release the relevant outer timing belt
cover securing clips, and unclip the sensor
wiring from the timing belt cover.
16Disconnect the sensor wiring connector,
noting its location.
17Unscrew the securing bolt, and withdraw
the sensor from the cylinder block (see
illustration).
18Examine the sensor sealing ring, and
renew if necessary (see illustration).
Refitting
19Refitting is a reversal of removal, ensuring
that the sensor wiring is correctly located on
the timing belt cover, and that the wiring
connector is correctly located.
25Motronic system
components - removal and
refitting
3
Note: Refer to Section 3 before proceeding.
Procedures for removal and refitting of the
ignition system components and electronic
module are given elsewhere in the relevant
Sections of this Chapter. Removal and
refitting procedures for all fuel injection
system components are given in Chapter 4B
Coolant temperature sensor
Removal
1On all except 20 XEJ models, the sensor is
located in the end of the thermostat housing,
on the inlet manifold side of the engine.
2On 20 XEJ models, the sensor is located in
the thermostat housing, on the exhaust
manifold side of the engine.
3Disconnect the battery negative lead.
4Partially drain the cooling system, as
described in Chapter 3. 5Disconnect the sensor wiring plug (see
illustration).
6Using a spanner, unscrew the sensor and
withdraw it from the thermostat housing.
Refitting
7Refitting is a reversal of removal.
8On completion, top-up the cooling system,
as described in Chapter 3.
Knock sensor (DOHC models)
Removal
9The sensor is located at the lower inlet
manifold side of the cylinder block, below the
idle speed adjuster, and is only accessible
from below the vehicle.
10Disconnect the battery negative lead.
11Apply the handbrake, then jack up the
front of the vehicle, and support securely on
axle stands (see “Jacking and Vehicle
Support”) placed under the body side
members.
12Remove the engine undershield, as
described in Chapter 11.
13Disconnect the sensor wiring plug.
14Unscrew the securing bolt, and withdraw
the sensor from the cylinder block.
Refitting
15Refitting is a reversal of removal, but note
that the mating faces of the sensor and
cylinder block must be cleaned thoroughly
before fitting the sensor.
Engine electrical systems 5•15
24.17 Unscrewing the crankshaft
speed/position sensor securing bolt -
1.8 litre model
25.5 Disconnecting the coolant
temperature sensor wiring plug - 2.0 litre
model (alternator removed)24.18 Examine the crankshaft
speed/position sensor sealing ring -
1.8 litre model
24.11 Unscrewing the MSTS-i oil
temperature sensor - 1.6 litre model
(engine removed)24.1 MSTS-i manifold pressure sensor -
1.6 litre model
5

26DIS module - removal and
refitting
3
Note: Refer to Section 3 before proceeding.
Removal
1Disconnect the battery negative lead.
2Disconnect the HT leads from the module
terminals noting their locations to ensure
correct refitting. Note that the HT lead cylinder
numbers are stamped on the module, next to
each terminal, and similar numbers appear on
each HT lead.
3Disconnect the module wiring plug.
4On X16 SZ engines, undo the three screws
and remove the module from the camshaft
housing. On C20 XE engines, undo the bolts
securing the DIS module mounting bracket tothe cylinder head and remove the module and
bracket. Note the installed position of DIS
module on its mounting bracket, undo the four
securing screws and separate the module
from the bracket.
Refitting
5Refitting is a reversal of removal.
27Camshaft phase sensor (C20
XE engine) -removal and
refitting
3
Note: Refer to Section 3 before proceeding.
Removal
1The camshaft phase sensor is mounted on
the end of the cylinder head in the position
normally occupied by the distributor.2Disconnect the battery negative lead.
3Disconnect the wiring plug then undo the
phase sensor securing bolts.
4Withdraw the phase sensor from the
cylinder head, then undo the bolt and remove
the phase sensor disc from the end of the
camshaft.
Refitting
5Refitting is a reversal of removal.
5•16Engine electrical systems

to be refitted, tie a length of string to the end
of the wiring. Then feed the wiring through the
boot lid and untie the string, leaving it in
position in the boot lid to assist refitting.
3Mark the position of the hinges on the boot
lid.
4With the help of an assistant, support the
weight of the boot lid, then unscrew the
securing bolts from the hinges, and lift the
boot lid from the vehicle. If the boot lid is to be
refitted, rest it carefully on rags or cardboard,
to avoid damaging the paint.
5If a new boot lid is to be fitted, transfer all
the serviceable fittings (rubber buffers, lock
mechanism, etc.), to it.
6If desired, the boot lid hinge counter-
balance springs can be removed, but before
unhooking them from the vehicle body, note
their position so that they can be refitted in
their original positions (see illustration). Use
a lever to unhook the springs.
Refitting
7Refitting is a reversal of removal,
remembering the following points.
8Align the hinges with the precisely made
marks on the boot lid.
9Where applicable, draw the central locking
solenoid wiring through the boot lid, using the
string.
10If necessary, adjust the hinge bolts and
the rubber buffer until a good fit is obtained
with the boot lid shut.
11If necessary, adjust the position of the
lock striker on the body, to achieve
satisfactory lock operation.
10Boot lid lock (Saloon
models) - removal and
refitting
2
Removal
1Open the boot lid fully.
2Unscrew the two securing screws, then
withdraw the lock and disconnect the
operating rod.
Refitting
3Refitting is a reversal of removal, but if
necessary adjust the position of the lock
striker on the body, to achieve satisfactory
lock operation.
11Boot lid lock cylinder
(Saloon models) - removal
and refitting
2
Removal
1Open the boot lid fully.
2Unscrew the two securing nuts, then
withdraw the lock cylinder complete with the
housing, and disconnect the operating rods(s).
3To remove the lock cylinder from the
housing, insert the key into the lock, then
extract the circlip and the operating lever
assembly from the end of the lock cylinder,
and withdraw the cylinder from the housing.
Refitting
4Refitting is a reversal of removal, but check
the operations of the lock on completion (see
illustration).
12Tailgate (Hatchback models)
-removal and refitting
2
Removal
1Open the tailgate fully.
2Disconnect the battery negative lead.
3Remove the securing screws, and withdraw
the tailgate trim panels.
4Disconnect all the relevant wiring now
exposed, and disconnect the washer fluid
hose.5If the original tailgate is to be refitted, tie
string to the ends of all the relevant wires, and
if necessary the washer fluid hose, then feed
the wiring and the hose through the top edge
of the tailgate. Untie the string, leaving it in
position in the tailgate to assist refitting.
6Prise off the rear roof trim panel, taking care
not to break the securing clips, and lower the
rear of the headlining slightly for access to the
tailgate hinge securing screws (see
illustrations). Mark the hinge positions on the
body.
7Have an assistant support the weight of the
tailgate, then disconnect the tailgate struts
from their mounting balljoints, with reference
to Section 15.
8Ensure that the tailgate is adequately
supported, then remove the hinge securing
screws and withdraw the tailgate from the
vehicle. If the tailgate is to be refitted, rest it
carefully on rags or cardboard, to avoid
damaging the paint.
9If desired, the hinges can be removed from
the tailgate by driving out the hinge pins.
10If the tailgate can be moved up and down
on its hinges due to wear in the hinge pins or
their holes, it may be possible to drill out the
holes and fit slightly oversize pins. Consult a
Vauxhall dealer for further advice.
11If a new tailgate is to be fitted, transfer all
serviceable components to it.
Refitting
12Refitting is a reversal of removal,
remembering the following points.
13Align the hinges with the previously made
marks on the body.
Bodywork and fittings 11•5
12.6B . . . for access to the tailgate hinge
screws12.6A Prise off the rear roof trim panel . . .
11.4 Boot lid/tailgate lock cylinder
components
1 Lock cylinder
2 Housing
3 Operating lever assembly
4 Circlip
9.6 Boot lid hinge counterbalance spring
locations - Saloon models
1 Position for basic boot lid
2 Position for boot lid with outer plastic
trim panel or spoiler
3 Position for boot lid with outer plastic
trim panel and spoiler
11

9Where applicable, ensure that the glass
panel securing screw lockwashers engage
with the locating pins on the guide rails.
10Before fully tightening the glass panel
securing screws, close the panel, and adjust
its position to give the dimensions shown (see
illustration).
11If a new glass panel has been fitted, peel
off the protective foil on completion of
adjustment.
12Take care when refitting the guide rail
plastic surround, as it is fragile. Adjust the
open position of the glass panel as required to
fit the surround without damaging it.
Gutter
Removal
13Remove the glass panel, as described
previously in this Section.
14Extract the two securing screws (Allen or
Torx type), then lift the gutter from the roof
aperture.
Refitting
15Refit the gutter to the roof aperture at an
angle, pushing it up to the stop on both sides
until the retaining lugs engage with the gutter
guides.
16Refit and tighten the securing screws,
then refit and adjust the glass panel as
described earlier in this Section.
Sunshade
Removal
17Remove the glass panel and the gutter, as
described previously in this Section. 18Carefully prise the four sunshade spring
clips out of the roof guides using a plastic or
wooden implement to avoid damage, then
withdraw the sunshade from the guides (see
illustration).
Refitting
19Refitting is a reversal of removal, but
ensure that the spring clips engage correctly
with the roof guides.
Crank drive
Removal
20Prise out the trim and unscrew the crank
handle securing screw. Prise the crank from
the drive spindle.
21Disconnect the battery negative lead, then
prise the courtesy lamp from the roof trim
panel, and disconnect the wiring.
22Remove the two trim panel securing
screws, and withdraw the trim panel from the
roof (see illustrations).
23Extract the two securing screws, and
remove the crank drive assembly (see
illustration).
Refitting
24Refitting is a reversal of removal,
remembering the following points.
25Before finally refitting the crank handle,
the crank drive must be adjusted as follows.
26Temporarily refit the crank handle, and
position it so that it faces forwards, then
depress the locking button.
27Remove the crank handle and turn the
crank drive pinion anti-clockwise by hand as
far as the stop.
28Refit the crank handle so that it faces
directly forwards, then tighten the securing
screw and refit the trim.
35Interior trim panels -general
2
1The various interior trim panels are secured
by a variety of screws and plastic clips.
2Where press-fit plastic fasteners are used,
it is advisable to use a forked tool similar to
that shown to remove them, to avoid damage
to the clips and the trim panel (see
illustration).
3Removal and refitting of most of the trim
panels is self-explanatory but in all cases,
care must be taken, as the panels are easily
damaged by careless handling and the use of
sharp instruments to release clips.
36Interior trim panels -removal
and refitting
2
Sill trim panel
Removal
1When working on the passenger side of
models fitted with ABS, extract the three
securing screws and remove the cover from
the ABS control module. Note that two of the
screws are covered by plastic caps, which
must be prised out to expose the screws.
11•14Bodywork and fittings
34.22A Extract the securing screws . . .
35.2 Forked tool being used to remove clip
from rear seat back trim34.23 . . . to expose the crank drive -
securing screws arrowed34.22B . . . then withdraw the trim panel
from the roof . . .
34.18 Sunshade spring clip locations
(arrowed)
34.10 Sunroof glass panel fitting position