Wiring diagrams 12•57
12
Key to wiring diagrams for 1992 and later models (continued)
NoDescriptionTrackNoDescriptionTrack
S20.2High pressure compressor switch925
S20.3High pressure blower compressor switch939
S21Fog lamps switch555 to 557
S22Rear fog lamp switch549 to 551
S24Air conditioning blower switch904 to 911
S29Coolant temperature switch118, 137, 357, 942, 957, 972
S30Left front heating mat switch660 to 662
S31Rear left door contact switch591
S32Rear right door contact switch592
S33Traction control switch1130, 1131
S37Window lifter switch868 to 894
S37.1Left window lifter switch868 to 870
S37.2Right window lifter switch886 to 888
S37.3Left rear window lifter switch874 to 876
S37.4Right rear window lifter switch892 to 894
S37.5Safety switch872, 873
S37.6Window anti-jam off switch890
S37.7Automatic window lifter control877 to 882
S39Left rear door window lifter switch878 to 880
S40Right rear door window lifter switch896 to 898
S41Driver door burglary locking switch800 to 802
S42Passenger door central locking switch805
S44Throttle valve switch316, 317
S47Driver door contact switch593, 594
S52Hazard warning switch569 to 573
S53First gear identification switch372
S55Right front heating mat switch664 to 666
S57Sun roof switch1170 to 1183
S63Computer switch
S63.1Function reset switch856
S63.2Clock hours adjustment switch857
S63.3Function select switch858
S63.4Clock minute adjustment switch859
S64Horn switch672
S68Outside mirror switch assy
S68.1Outside mirror adjustment switch638 to 640, 758 to 762
S68.3Left/right outside mirror switch637 to 641, 759 to 763
S68.4Parking position switch765
S82Washer fluid minimum capacity control switch736
S882 stage coolant temperature switch120, 121, 137, 138, 430, 431
S89Seat belt switch998
S93Coolant minimum capacity control switch737
S95Engine oil minuimum capacity control switch738
S98Headlamps levelling switch691 to 693
S99ZV driver door window lifter switch865
S100ZV passenger door window lifter switch883
S101Compressor switch926 to 928
S102Circulation switch918 to 920
S103Transmission temperature switch350
S104Kickdown switch493
S105Start-up assistance switch495 to 497
S106Economy power program switch492
S109Acceleration revolution pressure switch921
S115Coolant temperature switch487, 488
S116Stop lamp switch564, 565
S117Hydraulic pressure switch346
S120Engine compartment hood (anti-theft warning unit) switch835
S127Calibra tail gate central locking switch831
S128Coolant temperature switch936,937S131Defroster lever limit switch918
U2Computer851 to 862
U4ABS hydroaggregate1102 to 1122, 1146 to 1164
U4.1Pump motor relay1102, 1103, 1146, 1147
U4.2Solenoid valves relay1104, 1105, 1148, 1149
U4.3Pump motor1102,1146
U4.4Diode1105,1149
U4.5Left front solenoid valve1109,1153
U4.6Right front solenoid valve1111,1155
U4.7Rear axle solenoid valve1113,1157
U4.8ABS control unit1106 to 1122, 1150 to 1164
U4.9Solenoid valves plug1109 to 1113, 1153 to 1157
U5Check control display
U5.1Washer fluid minimum capacity telltale741
U5.2Oil minimum capacity telltale740
U5.3Coolant minimum capacity telltale739
U5.4Tail light & low beam telltale738
U5.5Stop light failure telltale737
U5.6Front brake lining telltale736
U12Filter heater
U12.1Temperature switch426, 452
U12.2Filter heater427, 453
U13Automatic transmission
U13.1Solenoid valve (shift 1)481
U13.2Solenoid valve (shift 2)482
U13.3Solenoid valve (lock up control)483
U13.4Solenoid valve (pressure control)484
U17Roof antenna amplifier795
V1Brake fluid test bulb diode712
V8Air conditioning compressor diode926
X1 onWiring connectorsVarious
X10Anti theft warning unit code837
X13Diagnostic link164, 165, 189, 190, 226, 270, 271, 258, 259,
309, 310, 370, 371, 343, 344, 473, 474, 573, 725, 836, 837, 860,
861, 1012, 1013, 1069, 1070, 1118, 1119, 1136, 1162, 1163
X15Octane number plug157, 158, 182, 183, 225, 226,
257, 258, 284, 285
X54Ignition coding plug310, 311, 1014, 1070, 1071
Y1Air conditioning compressor clutch925
Y4Headlamps washer solenoid valve620
Y5Fuel solenoid valve410, 445
Y7Fuel injection valves287 to 294,320 to 327,
384 to 391,1025 to 1032,1078 to 1089
Y10Hall sensor ignition distributor153 to 158
Y11Hot start solenoid valve375, 376
Y12Charging pressure control changeover valve377, 378
Y18Exhaust gas recirculation valve1093
Y23Inductive sensor distributor201 to 208
Y24Distributor (inductive discharge)
Y25Acceleration revolution solenoid valve155, 177
Y30Cold start acceleration solenoid valve 448
Y32Fuel injection valve212, 245
Y33Ignition distributor175 to 177, 268 to 270, 238 to 240,
301 to 303, 360 to 362
Y34Tank ventilation valve293, 331, 332, 379, 380,
1092, 1016, 1017,
Y35Circulation solenoid valve918
Y44Four wheel drive solenoid valve350
Y47Park brake shift lock lifting magnet469
MOTTest Checks REF•9
Seat belts and seats
Note: The following checks are applicable to
all seat belts, front and rear.
MExamine the webbing of all the belts
(including rear belts if fitted) for cuts, serious
fraying or deterioration. Fasten and unfasten
each belt to check the buckles. If applicable,
check the retracting mechanism. Check the
security of all seat belt mountings accessible
from inside the vehicle.
MThe front seats themselves must be
securely attached and the backrests must
lock in the upright position.
Doors
MBoth front doors must be able to be opened
and closed from outside and inside, and must
latch securely when closed.
Vehicle identification
MNumber plates must be in good condition,
secure and legible, with letters and numbers
correctly spaced – spacing at (A) should be
twice that at (B).
MThe VIN plate and/or homologation plate
must be legible.
Electrical equipment
MSwitch on the ignition and check the
operation of the horn.
MCheck the windscreen washers and wipers,
examining the wiper blades; renew damaged
or perished blades. Also check the operation
of the stop-lights.
MCheck the operation of the sidelights and
number plate lights. The lenses and reflectors
must be secure, clean and undamaged.
MCheck the operation and alignment of the
headlights. The headlight reflectors must not
be tarnished and the lenses must be
undamaged.
MSwitch on the ignition and check the
operation of the direction indicators (including
the instrument panel tell-tale) and the hazard
warning lights. Operation of the sidelights and
stop-lights must not affect the indicators - if it
does, the cause is usually a bad earth at the
rear light cluster.
MCheck the operation of the rear foglight(s),
including the warning light on the instrument
panel or in the switch.
Footbrake
MExamine the master cylinder, brake pipes
and servo unit for leaks, loose mountings,
corrosion or other damage.
MThe fluid reservoir must be secure and the
fluid level must be between the upper (A) and
lower (B) markings.MInspect both front brake flexible hoses for
cracks or deterioration of the rubber. Turn the
steering from lock to lock, and ensure that the
hoses do not contact the wheel, tyre, or any
part of the steering or suspension mechanism.
With the brake pedal firmly depressed, check
the hoses for bulges or leaks under pressure.
Steering and suspension
MHave your assistant turn the steering wheel
from side to side slightly, up to the point where
the steering gear just begins to transmit this
movement to the roadwheels. Check for
excessive free play between the steering
wheel and the steering gear, indicating wear or
insecurity of the steering column joints, the
column-to-steering gear coupling, or the
steering gear itself.
MHave your assistant turn the steering wheel
more vigorously in each direction, so that the
roadwheels just begin to turn. As this is done,
examine all the steering joints, linkages,
fittings and attachments. Renew any
component that shows signs of wear or
damage. On vehicles with power steering,
check the security and condition of the
steering pump, drivebelt and hoses.
MCheck that the vehicle is standing level,
and at approximately the correct ride height.
Shock absorbers
MDepress each corner of the vehicle in turn,
then release it. The vehicle should rise and
then settle in its normal position. If the vehicle
continues to rise and fall, the shock absorber
is defective. A shock absorber which has
seized will also cause the vehicle to fail.
2Checks carried out
WITH THE VEHICLE ON THE
GROUND
REF
oil and filter renewal - 0•17, 1•2, 1•9
oil cooler - 2B•10
oil level - 0•12
oil pump - 2A•28, 2B•9
piston rings - 2A•30
piston/connecting rod - 2A•29
removal - 2A•8, 2B•3
SOHC - 2A•1 et seq
sump - 2A•27, 2B•9
timing belt - 2A•13, 2B•3, 2B•6
undershield - 11•13
valve lifters - 2A•24, 2B•9
valves - 2A•5, 2B•2
Environmental considerations- REF•4
Exhaust manifold- 4C•5
Exhaust system check- 1•11, 4C•5
Expansion tank- 3•5
FFan (radiator)- 3•5
Fault diagnosis- REF•12 et seq
automatic transmission - REF•12, REF•16
braking system - REF•12, REF•17
clutch - REF•12, REF•15
cooling system - REF•12, REF•15
driveshafts - REF•12, REF•16
electrical system - REF•12, REF•18
engine - REF•12, REF•13
fuel and exhaust systems - REF•12, REF•15
manual transmission - REF•12, REF•16
steering - REF•12, REF•17
suspension - REF•12, REF•17
Flexplate (automatic transmission)- 2A•26
Flushing (cooling system)- 3•2
Flywheel- 2A•26
Foglamp- 12•11
Fuel and exhaust (carburettor) systems-
4A•1 et seq
Fuel and exhaust (fuel injection) systems-
4B•1 et seq
Fuel and exhaust systems - emissions-
4C•1 et seq
Fuel and exhaust systems:
accelerator cable - 4A•5
accelerator pedal - 4A•5
air box - 4B•5
air cleaner - 1•3, 1•13, 4A•3, 4B•4
air pump/cut off valve - 4C•2
air temperature control - 4B•5
airflow meters - 4B•12
automatic choke - 4A•9
carbon canister - 4C•4
carburettor - 4A•5, 4A•11
catalytic converter - 4C•3
control unit - 4B•16
depressurising fuel system - 4B•5
EGR components - 4C•2
exhaust manifold - 4C•5
exhaust system check - 1•11, 4C•5
fault diagnosis - REF•12, REF•15
filler cap - 11•13
fuel filters - 1•3, 1•14, 4B•6
fuel flow damper - 4B•8
fuel injector(s) - 4B•13
fuel level sender unit - 4A•4, 4B•8
fuel pressure regulator - 4B•10
fuel pump - 4A•3, 4B•6fuel tank - 4A•4, 4B•7
fuel vapour separator - 4A•4
idle speed/mixture adjustment - 4A•7,
4A•12, 4B•9, 4B•11
inlet manifold - 4A•12, 4B•17
knock sensor - 4B•17
lambda sensor - 4C•4
manifolds - 4A•12, 4B•17, 4C•5
mixture (CO) - 4A•7, 4A•12, 4B•9
oxygen sensor - 4C•4
Pierburg 2E3 - 4A•5
potentiometer - 4B•12, 4B•16
throttle cable - 4A•5
throttle pedal - 4A•5
Fuses- 12•1, 12•3
GGear selector linkage- 7A•2
Gearbox - see Manual or Automatic
transmission
Gearbox oil- 0•17, 1•2, 1•15
Gearchange lever- 7A•3
Glass- 11•9
Glossary of technical terms- REF•20
Glove compartment- 11•18
HHandbrake adjustment- 9•18
Handbrake cables- 9•19
Handbrake lever- 9•20
Handles (door)- 11•7
Hazard warning switch- 12•4
Headlamp alignment- 12•10
Headlamp unit- 12•9
Headlining- 11•19
Heater blower motor switch- 12•4
Heater control panel- 3•6
Heater matrix- 3•7
Heating systems- 3•1 et seq
Horn- 12•8
Hose and fluid leak check- 0•9, 1•9
Hoses brake- 9•18
IIdle speed/mixture/adjustment- 4A•7,
4A•12, 4B•9, 4B•11
Ignition coil- 5•9
Ignition switch- 12•3
Ignition system- 5•2
Igniton timing- 5•2, 5•13
Indicator lamps- 12•11
Indicator switch- 12•4
Injector(s)- 4B•13
Inlet manifold- 4A•12, 4B•17
Input shaft (clutch) oil seal- 7A•4
Instrument panel- 12•6
Interior lamps- 12•8
Interior trim panels- 11•14
Introduction to the Vauxhall Cavalier- 0•4
JJacking and vehicle support- REF•5
Jump starting- 0•7
KKickdown switch - 7B•3
Knock sensor- 4B•17
LLambda sensor- 4C•4
Lamps- 12•8, 12•9
Leaks- 0•9, 1•9
Light switch- 12•4
Locks bonnet- 11•4
Locks door- 11•8
Locks tailgate- 11•6
Lubricants and fluids- 0•17
MMain and big-end bearings- 2A•31
Maintenance - see Routine maintenance
Maintenance schedule- 1•4
Manifolds- 4A•12, 4B•17, 4C•5
Manual transmission- 7A•1 et seq
differential bearing oil seals - 7A•3
fault diagnosis - REF•12, REF•16
gear selector linkage - 7A•2
gearbox oil - 0•17, 1•2, 1•15
gearchange lever - 7A•3
input shaft (clutch) oil seal - 7A•4
overhaul -7A•5
removal and refitting - 7A•4
reversing lamp switch - 7A•6
speedometer drive - 7A•6
Master cylinder (brake)- 9•13
Mirrors- 11•11
Mixture (CO)- 4A•7, 4B•9
MOT test checks- REF•8
Mountings (engine/transmission)- 2A•12,
2B•3
NNumber plate lamp- 12•11
OOil change- 0•17, 1•2, 1•9
Oil cooler- 2B•10
Oil filter- 1•2, 1•9
Oil pressure warning lamp switch- 12•5
Oil pump- 2A•28, 2B•9
Oil seals:
differential bearing - 7A•3
general - REF •4
camshaft - 2A•18, 2B•6
crankshaft - 2A•26, 2B•6, 2B•9
Oils- 0•17, 1•2
Open-circuit, finding - 12•2
Oxygen sensor- 4C•4
PPads (brake)- 9•4
Paintwork damage- 11•2
Parts- REF•3
Pedals
brake - 9•21
clutch - 6•3
throttle - 4A•5
REF•26Index