1988 OPEL CALIBRA fuel cap

4C
Torque wrench settingsNm lbf ft
AIR non-return valve to pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
AIR pipe support bracket to manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
AIR pipe to manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
AIR pipe to support bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
AIR pump bracket to protective shield . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
AIR pump to wheel arch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
AIR pump to insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
AIR valves to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3
Carbon canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3
EGR valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
Oxygen sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Chapter 4 Part C:
Fuel and exhaust systems - exhaust and emissions
AIR cut-off valve - removal, testing and refitting . . . . . . . . . . . . . . . . .7
AIR pipe and non-return valve - removal and refitting . . . . . . . . . . . . .9
AIR pump assembly (Simtec system) - removal and refitting . . . . . . . .6
AIR switchover valve - removal and refitting . . . . . . . . . . . . . . . . . . . .8
Carbon canister - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .11
Catalytic converter - description, general and precautions . . . . . . . .10
EGR module (X 16 SZ models) - removal and refitting . . . . . . . . . . . . .5EGR valve (Multec system models) - testing, removal and refitting . . .3
EGR valve (Simtec system) - testing, removal and refitting . . . . . . . . .4
Emissions control systems - general . . . . . . . . . . . . . . . . . . . . . . . . . .1
Exhaust gas recirculation (EGR) system - general . . . . . . . . . . . . . . . .2
Exhaust manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . .13
Exhaust system - checking, removal and refitting . . . . . . . . . . . . . . .14
Oxygen sensor (catalytic converter models) - removal and refitting .12
4C•1
Specifications Contents
1 Emissions control systems -
general
General
Multec system
1An evaporative emissions control system is
fitted to minimise the escape into the
atmosphere of unburned hydrocarbons.
2The fuel tank filler cap is sealed and a
charcoal canister is mounted under the
right-hand front wing to collect the petrol
vapours generated in the tank when the
vehicle is parked. It stores them until they can
be purged from the canister into the inlet tract
to be burned by the engine during normal
combustion. The canister’s control valve (on
the top of the canister) is opened by a vacuum
pipe from the front of the throttle body on C16
NZ, C16 NZ2 and C18 NZ engines. On X16 SZ
it’s opened by an electronically activated
purge valve, mounted on the camshaft
housing.
Motronic system
3The system is as described in Chapter 4B,
except that the charcoal canister is purged
under the control of the fuel injection/ignition
system module through the fuel tank vent
valve. To ensure that the engine runs correctly
when it is cold and/or idling, and to protect
the catalytic converter from the effects of an
over-rich mixture, the valve is not opened by
the module until the engine is under partial or
full load. The valve solenoid is then modulated
on and off to allow the stored vapour to pass
into the inlet tract.
4Canister removal and refitting is as
described in Section 11.
5On C20 NE engines, the vent valve is
mounted above the injectors for cylinders 2
and 4. To remove it, disconnect the battery
negative lead and the valve wiring plug, then
disconnect the two vent hoses having made
note of their connections. Either remove the
valve from its mounting bracket, or unbolt the
bracket, as required.
6On C20 XE engines, the vent valve is
mounted on the left-hand end of the engine,underneath the end of the fuel injector wiring
harness housing (see illustration). Removal
and refitting is as described in the previous
paragraph.
Simtec system
7For information refer to “General
description”, in Chapter 4B. Note that “AIR”,
is an abbreviation for the secondary Air
Injection Reactor system used on this model.
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
1.6 Disconnecting the fuel tank vent valve
wiring

4B
General
Injection system type:
C16 NZ, C16 NZ2, X16 SZ and C18 NZ . . . . . . . . . . . . . . . . . . . . . . . Multec Central Fuel Injection
20 NE, C20 NE and 20 SEH, (up to 1990) . . . . . . . . . . . . . . . . . . . . . Motronic M4.1
20 NE, C20 NE and 20 SEH, (from 1990) . . . . . . . . . . . . . . . . . . . . . . Motronic M1.5
20 XEJ and C20 XE, (up to 1993) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motronic M2.5
C20 XE (from 1993) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motronic M2.8
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simtec 56.1
Fuel tank capacity:
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.0 ± 2 litres
Fuel octane rating *
Leaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 RON (4-star)
Unleaded (refer to Chapter 5) * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 RON (Premium)
* Note
: Models fitted with a catalytic converter (engine code prefixed by ‘C’ or ‘X’), must only be operated on unleadedfuel.
Idle settings
Idle speed:
C16 NZ and X16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 ± 80 rpm
C16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 880 ± 80 rpm
C18 NZ
Manual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 880 ± 80 rpm
Automatic transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . 830 ± 80 rpm
20 NE, C20 NE and 20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 80 rpm
20 XEJ and C20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 940 ± 80 rpm
X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 ± 160 rpm
Note:Idle speed adjustment is not possible on these models, for information only
Chapter 4 Part B:
Fuel and exhaust systems - fuel injection models
Air box - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Air cleaner - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Air filter element - renewal . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Airflow meter (if fitted) - removal and refitting . . . . . . . . . . . . . . . . . .25
Air mass meter (if fitted) - removal and refitting . . . . . . . . . . . . . . . . .26
Air temperature sensor (later models) - removal and refitting . . . . . . .7
Air temperature control - description and testing . . . . . . . . . . . . . . . .6
Depressurising the fuel system - general . . . . . . . . . . . . . . . . . . . . . . .8
Electronic Control Unit (ECU) - removal and refitting . . . . . . . . . . . . .35
Fuel filter (‘In-tank’ fuel pump models) - removal and refitting . . . . . .10
Fuel filter (‘Out-of-tank’ fuel pump models) - removal and refitting . . .9
Fuel flow damper - removal and refitting . . . . . . . . . . . . . . . . . . . . . .18
Fuel injection system - precautions . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Fuel injector (Multec system) - removal and refitting . . . . . . . . . . . . .29
Fuel injector (Multec system) - testing . . . . . . . . . . . . . . . . . . . . . . . .30
Fuel injectors (except Multec system) - removal and refitting . . . . . .28
Fuel pressure regulator - removal and refitting . . . . . . . . . . . . . . . . .21
Fuel pump - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Fuel pump (‘In-tank’ fuel pump models) - removal and refitting . . . .13
Fuel pump (‘Out-of-tank’ fuel pump models) - removal and refitting .12
Fuel pump relay - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Fuel tank - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Fuel tank filler pipe - removal and refitting . . . . . . . . . . . . . . . . . . . . .15
Fuel tank sender unit - removal and refitting . . . . . . . . . . . . . . . . . . .17
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Hot film mass airflow meter - removal and refitting . . . . . . . . . . . . . .27
Idle air control stepper motor - removal and refitting . . . . . . . . . . . . .33
Idle mixture - checking and adjustment . . . . . . . . . . . . . . . . . . . . . . .20
Idle speed adjuster - removal and refitting . . . . . . . . . . . . . . . . . . . . .22
Inlet manifold (DOHC models) - removal and refitting . . . . . . . . . . . .40
Inlet manifold (SOHC with Multec) - removal and refitting . . . . . . . . .39
Inlet manifold (SOHC without Multec) - removal and refitting . . . . . .38
Knock sensor and module (X16 SZ models) - removal and refitting .36
Knock sensor (Simtec system) - removal and refitting . . . . . . . . . . . .37
System testing - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Throttle body (except Multec system) - removal and refitting . . . . . .31
Throttle body (Multec system) - removal and refitting . . . . . . . . . . . .32
Throttle cable - removal, refitting and adjustment . . . . . . . . . . . . . . .19
Throttle pedal - removal and refitting . . . . . . . . . . . . . .See Chapter 4A
Throttle position sensor - removal and refitting . . . . . . . . . . . . . . . . .23
Throttle potentiometer - removal and refitting . . . . . . . . . . . . . . . . . .34
Throttle valve potentiometer - removal and refitting . . . . . . . . . . . . .24
4B•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

4B
cruising and accelerating. The injector earth is
also switched off on the overrun to improve
fuel economy and reduce exhaust emissions.
Additionally, on the X16 SZ engine, the ECU
also controls the operation of the charcoal
canister purge valve in the evaporative
emission control system.
10The oxygen sensor screwed into the
exhaust manifold provides the ECU with a
constant feedback signal. This enables it to
adjust the mixture (closed-loop control) to
provide the best possible conditions for the
catalytic converter to operate effectively.
11Until the oxygen sensor is fully warmed up
it gives no feedback so the ECU uses
pre-programmed values (open-loop control) to
determine the correct injector pulse width.
When the sensor reaches its normal operating
temperature, its tip (which is sensitive to
oxygen) sends the ECU a varying voltage
depending on the amount of oxygen in the
exhaust gases. If the inlet air/fuel mixture is too
rich, the exhaust gases are low in oxygen so the
sensor sends a low-voltage signal. The voltage
rises as the mixture weakens and the amount of
oxygen rises in the exhaust gases. Peak
conversion efficiency of all major pollutants
occurs if the inlet air/fuel mixture is maintained
at the chemically correct ratio for the complete
combustion of petrol of 14.7 parts (by weight) of
air to 1 part of fuel (the “stoichiometric” ratio).
The sensor output voltage alters in a large step
at this point, the ECU using the signal change
as a reference point and correcting the inlet
air/fuel mixture accordingly by altering the fuel
injector pulse width.
12In addition, the ECU senses battery
voltage, incorporates diagnostic capabilities,
and can both receive and transmit information
by way of the diagnostic connector, thus
permitting engine diagnosis and tuning by
Vauxhall’s TECH1, test equipment.
Motronic system
13The Motronic type is available in several
different versions, depending on model. The
system is under the overall control of the
Motronic engine management system (Chapter
5), which also controls the ignition timing.
14Fuel is supplied from the rear-mounted
fuel tank by an electric fuel pump mounted
under the rear of the vehicle, through a
pressure regulator, to the fuel rail. The fuel rail
acts as a reservoir for the four fuel injectors,
which inject fuel into the cylinder inlet tracts,
upstream of the inlet valves. On SOHC
engines, the fuel injectors receive an electrical
pulse once per crankshaft revolution, which
operates all four injectors simultaneously. On
DOHC engines, sequential fuel injection is
used, whereby each injector receives an
individual electrical pulse allowing the four
injectors to operate independently, which
enables finer control of the fuel supply to each
cylinder. The duration of the electrical pulse
determines the quantity of fuel-injected, and
pulse duration is computed by the Motronic
module, based on the information received
from the various sensors.15On SOHC engines, inlet air passes from
the air cleaner through a vane type airflow
meter, before passing to the cylinder inlet
tracts through the throttle valve. A flap in the
vane airflow meter is deflected in proportion
to the airflow; this deflection is converted into
an electrical signal, and passed to the
Motronic module. A potentiometer screw
located on the airflow meter provides the
means of idle mixture adjustment, by altering
the reference voltage supplied to the Motronic
module.
16On DOHC engines, inlet air passes from
the air cleaner through a hot wire type air
mass meter, before passing to the cylinder
inlet tracts through a two-stage throttle body
assembly. The electrical current required to
maintain the temperature of the hot wire in the
air mass meter is directly proportional to the
mass flow rate of the air trying to cool it. The
current is converted into a signal, which is
passed to the Motronic module. The throttle
body contains two throttle valves that open
progressively, allowing high torque at part
throttle, and full-throttle, high-speed
“breathing” capacity. A potentiometer screw
located on the air mass meter provides the
means of idle mixture adjustment, by altering
the reference voltage supplied to the Motronic
module.
17A throttle position sensor enables the
Motronic module to compute the throttle
position, and on certain models, its rate of
change. Extra fuel can thus be provided for
acceleration when the throttle is opened
suddenly. Information from the throttle
position sensor is also used to cut off the fuel
supply on the overrun, thus improving fuel
economy and reducing exhaust gas
emissions.
18Idle speed is controlled by a variable-
orifice solenoid valve, which regulates the
amount of air bypassing the throttle valve. The
valve is controlled by the Motronic module;
there is no provision for direct adjustment of
the idle speed.
19Additional sensors inform the Motronic
module of engine coolant temperature, air
temperature, and on models fitted with a
catalytic converter, exhaust gas oxygen
content.
20A fuel filter is incorporated in the fuel
supply line, to ensure that the fuel supplied to
the injectors is clean.
21A fuel pump cut-off relay is controlled by
the Motronic module, which cuts the power to
the fuel pump should the engine stop with the
ignition switched on, if there is an accident. All
1993-onwards models equipped with
Motronic systems, have their fuel pump
located inside the fuel tank.
22The later M2.8 system is basically the
same as the earlier M2.5 system apart from
the following:
a)Hot Film Mass Airflow Meter - The hot
wire type unit used previously is replaced
on the M2.8 system by a hot film mass
airflow meter. The operation is the sameexcept that a thin, electrically heated plate
rather than a wire is used. The plate is
maintained at a constant temperature by
electric current as the inlet air mass
passing over the plate tries to cool it. The
current required to maintain the
temperature of the plate is directly
proportional to the mass flow rate of the
inlet air. The current is converted to a
signal that is passed to the Motronic
module.
b)Inlet Air Temperature Sensor -The sensor
is located in the hose between the hot
film mass airflow meter and the air cleaner
for precise monitoring of inlet air
temperature. Signals from the sensor are
used in conjunction with other sensors to
indicate the occurrence of a hot start
condition. The Motronic module then
interprets these signals to alter injector
duration accordingly.
c)Throttle Valve Potentiometer -On the
M2.8 system a throttle valve
potentiometer replaces the throttle valve
switch used previously.
Simtec system
23An increased amount of electronic
components are used instead of mechanical
parts as sensors and actuators with the
Simtec engine management system. This
provides more precise operating data as well
as greater problem free motoring.
24The control unit is equipped with
electronic ignition control. Called ‘Micropro-
cessor Spark Timing System, inductive
triggered’, (or MSTS-i), and means that the
mechanical high voltage distributor is no
longer needed. It is located behind the trim
panel, on the right-hand side footwell (door
pillar).
25The ignition coil is replaced by a dual
spark ignition coil, which is switched directly
by the output stages in the control unit.
26A camshaft sensor will maintain
emergency operation, should the crankshaft
inductive pulse pick-up, malfunction. These
sense TDC (‘Top Dead Centre’), crankshaft
angle and engine speed. The signals are used
by the control unit to calculate ignition point
and for fuel injection.
27The ‘hot film airflow meter’ determines the
mass of air taken in by the engine. The system
uses this information to calculate the correct
amount of fuel needed for injection in the
engine.
28The air inlet temperature sensor (NTC), is
fitted in the air inlet duct between the air
cleaner and the hot mass air flow meter.
29A controlled canister purge valve is
actuated by the system. The tank ventilation is
monitored closely with the Lambda control (or
oxygen sensor) and adaptation by the
computer within the control unit.
30A knock control system is also fitted. This
eliminates the need for octane number
adjustment, as it is performed automatically
through the control unit.
Fuel and exhaust systems - fuel injection models 4B•3

31This engine is also fitted with an EGR
(exhaust gas recirculation) valve and
secondary air injection (AIR - Air Injection
Reactor), to conform to the latest European
exhaust emission limits (as from 1996). The
EGR returns a specific amount of exhaust gas
into the combustion process. This in turn
reduces the formation of nitrogen oxides
(No
x). The secondary air injection system has
an electrically driven air pump that injects air
into the exhaust manifold, reducing the
amount of CO and HC emissions.
2Fuel injection system -
precautions
The fuel injection system is pressurised,
therefore extra care must be taken when
disconnecting fuel lines. When disconnecting
a fuel line union, loosen the union slowly, to
avoid a sudden release of pressure that may
cause fuel to spray out.
Fuel pressure checking must be entrusted
to a Vauxhall dealer, or other specialist, who
has the necessary special equipment.
3System testing - general
3
General
1Apart from basic electrical tests, there is
nothing that can be done by the owner to test
individual fuel system components.2If a fault arises, check first that it is not due
to poor maintenance. Check that the air
cleaner filter element is clean, the spark plugs
are in good condition and correctly gapped.
Check also that the engine breather hoses are
clear and undamaged and that the throttle
cable is correctly adjusted. If the engine is
running very roughly, check the compression
pressures (Chapter 1) and remember the
possibility that one of the hydraulic tappets
might be faulty, producing an incorrect valve
clearance.
3If the fault is thought to be due to a dirty
injector, it is worth trying one of the
established injector-cleaning treatments
before renewing, perhaps unnecessarily, the
injector.
4If the fault persists, check the ignition
system components (as far as possible).
5If the fault is still not eliminated, work
methodically through the system, checking all
fuses, wiring connectors and wiring, looking
for any signs of poor connections, dampness,
corrosion, dirt or other faults.
6Once the system components have been
checked for signs of obvious faults, take the
vehicle to a Vauxhall dealer for the full system
to be tested on special equipment.
7Do not attempt to “test” any component,
but particularly the ECU, with anything other
than the correct test equipment, available at a
Vauxhall dealer. If any of the wires to be
checked lead to a component such as the
ECU, always first unplug the relevant
connector from the system components so
that there is no risk of the component being
damaged by the application of incorrect
voltages from test equipment.
4Air cleaner - removal and
refitting
2
Note:If ‘round type’ air filter is fitted, follow
procedure in Chapter 4A.
Removal
1Unclip the coolant expansion tank hose
from the air cleaner cover, and move it to one
side out of the way.2Loosen the clamp screw and disconnect
the air trunking from the airflow meter (see
illustration).
3Disconnect the battery negative lead, then
disconnect the wiring plug from the airflow
meter.
4Release the two securing clips from the left-
hand side of the air cleaner cover, and
unscrew the two captive securing screws
from the right-hand side, then lift off the
cover.
5Lift out the filter element.
6Loosen the preheat hoses, fastening nuts.
7Undo the nuts securing the 2 rubber block
studs which are secured through the lower
half of the air cleaner housing.
8Some models are fitted with an inlet air
resonance box, to reduce induction noise.
This box is located under the wheel arch, and
connects to a pipe on the air inlet tube.
9The resonance box must be removed
before the air inlet tube can be removed. To
do this, first apply the handbrake, then jack up
the front of the vehicle, and support securely
on axle stands placed under the body side
members.
10Remove the securing screws, and
withdraw the lower splash shield from the
wing to expose the resonance box.
11Unscrew the single securing screw, and
pull the resonance box from the connector
tube (see illustrations).
12If desired, the air inlet tube can be
removed after pulling off the connector tube
from under the wing (see illustration).
4B•4Fuel and exhaust systems - fuel injection models
4.12 Removing the resonance box
connector tube4.11B . . . and withdraw the resonance box4.11A Remove the securing screw . . .
4.2 Loosening the air trunking clamp
screw at the airflow meter
Warning: Many of the
procedures in this sub-Section
require the removal of fuel lines
and connections that may result
in some fuel spillage. Before carrying out
any operation on the fuel system refer to
the precautions given in Safety first! at
the beginning of this Manual and follow
them implicitly. Petrol is a highly
dangerous and volatile liquid, and the
precautions necessary when handling it
cannot be overstressed.

4B
9Run the engine and check for leaks on
completion. If leakage is evident, stop the
engine immediately, and rectify the problem
without delay.
13Fuel pump (‘In-tank’ fuel
pump models) - removal and
refitting
3
Removal
1Depressurise the fuel system (Section 8),
then remove and refit the fuel filler cap to
ensure that the pressure is equalised inside
and outside the tank.
2Disconnect the battery negative terminal.
3Fold forwards the rear seat cushion. Peel
back the floor covering beneath it, then
remove the cover plug from the vehicle floor
to reach the pump mountings (see
illustration).
4Noting exactly how it is connected, and
making your own marks or notes to ensure
that it can be reconnected the same way
round, disconnect the wiring plug from the
pump.
5Release the securing clip and disconnect
the fuel hose from the pump. Clamp or plug
the hose to prevent the loss of fuel and the
entry of dirt.
6Undo the pump mounting bracket screws,
then withdraw the mounting bracket and
pump assembly from the tank. Note the
position of the sealing ring and discard it, then
cover the tank opening as a safety measure
and to prevent the entry of dirt.
7If the pump is to be renewed, first move it to
a clean working area and carry out the
following.
8Prise off the filter at the base of the pump
assembly, then release the securing clamp
and disconnect the mounting
bracket-to-pump fuel hose.
9Making your own marks or notes to ensure
that they can be reconnected the same way
round, unsolder the wires connecting the
pump to the mounting bracket.
10Press the pump out of the rubber sleeve.
Refitting
11Reassembly and refitting are the reverse
of the removal and dismantling procedures,
noting the following points.a)Ensure that the pump is seated correctly
in the sleeve and that the hose is securely
fastened.
b)Ensure that the wires are correctly
reconnected and securely soldered.
c)Always renew the pump mounting
bracket’s sealing ring.
d)Apply a few drops of sealing compound
(i.e. Vauxhall part no. 90485251) to the
threads of the screws, then tighten them
securely, but take care not to distort the
sealing ring.
14Fuel pump relay - renewal
2
The relay is mounted in the engine
compartment relay box (Chapter 12). Where
more than one relay is fitted, the fuel pump
relay is the one with the black base.
15Fuel tank filler pipe - removal
and refitting
3
Removal
1Syphon out any remaining fuel in the tank
into a clean container that is designed for
carrying petrol and is clearly marked as such.
2Raise the bottom edge of the seal
surrounding the filler neck and undo the single
securing screw beneath.
3Chock the front wheels, jack up the rear of
the vehicle and support it securely on axle
stands (see “Jacking and Vehicle Support”)
placed under the body side members.
4Unscrew the single filler pipe mounting bolt
from the underbody, then work along the
length of the pipe, cutting or releasing any
clips or ties securing other pipes or hoses to
it. Releasing their clips, disconnect the filler
and vent hoses from the pipe’s lower end and
the small-bore vent hoses from the unions at
its upper end.
5Having ensured that all components have
been removed or disconnected which mightprevent its removal, manoeuvre the pipe away
from the vehicle’s underside.
6To check the operation of the pipe’s
anti-leak valve, invert the filler pipe and fill the
lower union (now uppermost) with petrol. If
the valve is functioning correctly, no petrol will
leak from the other union. If petrol leaks from
the other union the valve is faulty and the
complete filler pipe must be renewed.
Refitting
7Refitting is the reverse of the removal
procedure, noting the following.
a)Check the condition of all hoses and
clips, renewing any components that are
found to be worn or damaged
b)When reconnecting the small-bore vent
hoses to the unions at the pipe’s upper
end, connect the hose from the charcoal
canister to the uppermost union and the
vent hose from the tank itself to the lower
union (see illustration).
c)Replacing any that were cut on removal
use the clips or ties provided to secure
any other pipes or hoses to the filler pipe.
d)Check carefully for signs of leaks on
refilling the tank; if any signs of leakage
are detected, the problem must be
rectified immediately.
16Fuel tank - removal and
refitting
4
Note: Refer to Section 2 before proceeding
Removal
SOHC models
1The procedure is similar as for models with
carburettors. Refer to Chapter 4A, however
note the following:
a)Depressurise the fuel system (Section 8).
b)On models with C16 NZ and X16 SZ
engines, disconnect the exhaust system
from the manifold.
c)When working on the fuel tank sender
unit, note that there is only one hose to be
disconnected.
Fuel and exhaust systems - fuel injection models 4B•7
15.7 Vent hose connections at fuel tank
filler pipe
A Charcoal canister hose
B Tank vent hose
13.3 Fuel pump - ‘in-tank’, fuel pump
model
A Wiring connector
B Fuel hose clampC Mounting bracket
screws
12.8 Fuel pump clamping sleeve should
rest against rim (arrowed)

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

1•4Maintenance schedule
Every 250 miles (400 km) or weekly
MRefer to “Weekly checks”
Basic service, every 9000 miles
(15 000 km) or 12 months -
whichever comes sooner
Along with the items in “Weekly checks”, carry out the
following:
MRenew the engine oil and oil filter (Section 3).
MCheck all hoses and other components for fluid
leaks (Section 4).
MCheck the steering and suspension components
(Section 5).
MCheck the condition of the driveshaft rubber
gaiters (Section 6).
MCheck the automatic transmission fluid level (if
applicable), (Section 7).
MCheck the radiator for blockage (e.g. dead insects)
and clean as necessary (Section 8).
MCheck and adjust the idle speed and mixture (if
applicable), (Section 9).
MCheck the throttle linkage and lubricate if
necessary (Section 10).
MCheck the exhaust system for corrosion, leaks and
security (Section 11).
MCheck all wiring for condition and security
(Section 12).
MCheck and adjust the ignition timing (if applicable),
(Section 13).
MRenew the brake fluid (Section 14).
MCheck the brake pad friction material for wear
(Section 15).
MCheck the handbrake linkage (Section 16).
MCheck the power steering fluid level (if applicable),
(Section 17).
MCheck the power steering pump drivebelt (if
applicable), (Section 18).
MCheck the rear suspension level control system
height, if fitted (Section 19).
MCheck the bodywork (Section 20).
MLubricate all locks and hinges (Section 21).
MCheck the alternator V-belt (Section 22).
MCheck the headlamp alignment (Section 23).
MReplace battery in the door-lock key (if applicable),
(Section 24).
MCarry out a road test (Section 25).
Note: Vauxhall specify that an Exhaust Emissions Test should be
carried out at least annually. However, this requires special
equipment, and is performed as part of the MOT test (refer to the
end of the manual).
Full service, every 18 000 miles
(30 000 km) or 24 months -
whichever comes sooner
Along with the ‘basic service’, carry out the following:
MRenew the coolant (Section 26).
MRenew the air cleaner element (Section 27).
MCheck the operation of the air cleaner air inlet
temperature control (carburettor models only),
(Section 28).
MRenew the fuel filter (Section 29).
MRenew the spark plugs (SOHC only), (Section 30) *.
MInspect and clean the distributor cap and HT leads
(Section 31).
MCheck the clutch cable adjustment (Section 32).
MCheck the manual transmission oil level (Section 33).
MCheck the automatic transmission (Section 34).
MCheck the brake drum shoe for wear (Section 35).
Major service, every 36 000 miles
(60 000 km) or 48 months -
whichever comes sooner
Along with the ‘full service’, carry out the following:
MRenew timing belt (Section 36).
MRenew the spark plugs (DOHC models only),
(Section 37).
MRenew automatic transmission fluid (Section 38) *.
* Note: If a vehicle is used for heavy-duty work (e.g. taxi work,
caravan/trailer towing, mostly short-distance, stop-start city driving)
the fluid must be changed every 36 months or 27 000 miles (45 000
km), whichever occurs first.

Maintenance - component location 1•5
1
Underbonnet view of a 1989 1.6 L model (16 SV engine)
1 VIN plate
2 Air cleaner casing *
3 Suspension strut top
4 Coolant expansion tank
5 Brake fluid reservoir
6 Fuel pump
7 Steering rack
8 Octane rating plug
9 Washer fluid reservoir
10 Battery
11 Ignition coil
12 Distributor (Bosch type)
13 Cooling fan motor
14 Engine oil level dipstick
15 Oil filter
16 Oil filler cap
* Refer to Chapter 4A for
alternative type
Underbonnet view of a 1991 model Cavalier 1.6 L (C16 NZ engine)
1 Air cleaner casing
2 Suspension strut top
3 Coolant expansion tank
4 Brake fluid reservoir
5 Air box
6 Exhaust gas recirculation valve
7 Steering gear
8 Octane coding plug
9 Washer fluid reservoir
10 Battery
11 Ignition coil
12 Distributor
13 Cooling fan motor
14 Engine oil level dipstick
15 Engine oil filter
16 Oxygen sensor
17 Engine oil filler cap