1988 OPEL CALIBRA height

C16 NZ2, 1.8 and 2.0 litre models, remove the
timing belt. Details are as described in
Chapter 2A.
3Remove timing belt tension roller from oil
pump, where applicable.
4Unscrew and remove the coolant pump
securing bolts (see illustration).
5Withdraw the coolant pump from the
cylinder block, and recover the O-ring (see
illustrations). It may be necessary to tap the
pump lightly with a plastic-faced hammer to
free it from the cylinder block.
6If desired, the rear timing belt cover can be
removed from the pump by rotating the cover
to release it from the flange on the pump.
7No overhaul of the coolant pump is
possible, and if faulty, the unit must be
renewed.
Refitting
8Refitting is a reversal of removal, bearing in
mind the following points.
9Use a new O-ring when refitting the pump.
Before refitting the pump, smear the pump
mounting face in the cylinder block and the O-
ring with a silicone grease or petroleum jelly.
10Do not fully tighten the pump securing
bolts until the timing belt has been fitted and
tensioned.
11Refit and tension the timing belt, as
described in Chapter 2A.
12If the engine is in the vehicle, refill the
cooling system, as described in Section 4.
DOHC models
Removal
13Remove the engine undershield.
14If the engine is in the vehicle, drain the
cooling system, as described in Section 2.
15Remove the timing belt, camshaft
sprockets, crankshaft sprocket, timing belt
tensioner and idler rollers, and the timing belt
rear cover, as described in Chapter 2B.
16Proceed as described in paragraphs 4
and 5.
17No overhaul of the coolant pump is
possible, and if faulty, the unit must be
renewed.
Refitting
18Refitting is a reversal of removal, bearing
in mind the following points.19Always use a new O-ring. Before fitting
the pump, smear the pump mating face in the
cylinder block and the O-ring with a silicone
grease or petroleum jelly.
20Refit the pump, and ensure that the lugs
on the pump and the cylinder block are
aligned before tightening the pump securing
bolts (see illustration).
21Refit the remaining components, and
tension the timing belt, as described in
Chapter 2B.
22If the engine is in the vehicle, refill the
cooling system, as described in Section 4.
Replace the undershield.
12Cooling fan - removal and
refitting
3
Removal
1Disconnect the battery negative lead.
2Disconnect the wiring from the cooling fan,
noting the location of the wiring connector for
use when refitting.
3Unscrew the two upper fan shroud securing
bolts from the top corners of the shroud, then
tilt the assembly back slightly towards the
engine, and withdraw it upwards away from
the radiator (see illustration).
4To separate the fan motor from the shroud,
unscrew the three securing nuts. If desired,
the fan blades can be separated from the
motor by removing the securing spring clip
from the end of the motor shaft.5No spare parts are available for the motor,
and if the unit is faulty, it must be renewed.
Refitting
6Reassembly (where applicable), and
refitting are reversals of the dismantling and
removal procedures, but ensure that the lower
end of the fan shroud locates correctly on the
radiator.
7On completion, start the engine and run it
until it reaches normal operating temperature,
then continue to run the engine and check
that the cooling fan cuts in and functions
correctly.
13Expansion tank and coolant
level sensor -removal and
refitting
3
Expansion tank
Removal
1The expansion tank is secured by a single
screw at its front edge. If the tank is to be
moved for access purposes, it should be
possible to move it sufficiently within the
confines of the hoses once the securing
screw has been removed. If the tank is to be
removed completely, continue as follows.
2Disconnect the two hoses from the top of
the expansion tank, and suspend them above
the height of the engine to prevent coolant loss.
3Remove the tank securing screw, then
manipulate the tank from its location, holding
it as high as possible above the engine.
Cooling, heating and ventilation systems 3•5
11.5B . . .and recover the O-ring -
2.0 litre SOHC model
12.3 Withdrawing the fan shroud assembly
- 2.0 litre SOHC model11.20 Lugs (arrowed) on coolant pump
and cylinder block must be aligned -
DOHC models
11.5A Withdraw the coolant pump . . .11.4 Coolant pump securing bolt
(arrowed) - 2.0 litre SOHC model
3

REF
Overall length: *
Saloon models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4432 mm
Hatchback models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4352 mm
Overall width: *
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1876 mm
Overall height (unladen): *
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1400 mm
Wheelbase: *
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2600 mm
Track:
Front: *
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1426 mm
Rear: *
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1423 mm
Ground clearance (minimum): *
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 mm
Weights
Kerb weight: *
Dependent on model . . . . . . . . . . . . . . . . . . . . . . . . . .1098 ± 101 kg
Maximum gross vehicle weight: *
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refer to VIN plate
Maximum roof rack load: *
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 kg
Maximum towing hitch downward load: *
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 kg
Maximum towing weight: *
Trailer with brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . .1175 ± 175 kg
Trailer without brakes . . . . . . . . . . . . . . . . . . . . . . . . . . .550 ± 50 kg
* Exact details depend upon model and specification.
Refer to owners handbook.
Dimensions and Weights . . . . . . . . . . . . . . . . . .REF•1
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . .REF•2
Buying Spare Parts . . . . . . . . . . . . . . . . . . . . . . .REF•3
Vehicle Identification . . . . . . . . . . . . . . . . . . . . . .REF•3
General Repair Procedures . . . . . . . . . . . . . . . . .REF•4
Jacking and Vehicle Support . . . . . . . . . . . . . . .REF•5Radio/cassette unit Anti-theft System . . . . . . . .REF•5
Tools and Working Facilities . . . . . . . . . . . . . . . .REF•6
MOT Test Checks . . . . . . . . . . . . . . . . . . . . . . . .REF•8
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . .REF•12
Glossary of Technical Terms . . . . . . . . . . . . . . .REF•20
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .REF•25
Reference REF•1
Dimensions and Weights

Tools and Working Facilities REF•7
REF
Special tools
The tools in this list are those which are not
used regularly, are expensive to buy, or which
need to be used in accordance with their
manufacturers’ instructions. Unless relatively
difficult mechanical jobs are undertaken
frequently, it will not be economic to buy
many of these tools. Where this is the case,
you could consider clubbing together with
friends (or joining a motorists’ club) to make a
joint purchase, or borrowing the tools against
a deposit from a local garage or tool hire
specialist. It is worth noting that many of the
larger DIY superstores now carry a large
range of special tools for hire at modest rates.
The following list contains only those tools
and instruments freely available to the public,
and not those special tools produced by the
vehicle manufacturer specifically for its dealer
network. You will find occasional references
to these manufacturers’ special tools in the
text of this manual. Generally, an alternative
method of doing the job without the vehicle
manufacturers’ special tool is given. However,
sometimes there is no alternative to using
them. Where this is the case and the relevant
tool cannot be bought or borrowed, you will
have to entrust the work to a dealer.
MValve spring compressor
MValve grinding tool
MPiston ring compressor
MPiston ring removal/installation tool
MCylinder bore hone
MBalljoint separator
MCoil spring compressors (where applicable)
MTwo/three-legged hub and bearing puller
MImpact screwdriver
MMicrometer and/or vernier calipers
MDial gauge
MStroboscopic timing light
MDwell angle meter/tachometer
MUniversal electrical multi-meter
MCylinder compression gauge
MHand-operated vacuum pump and gauge
MClutch plate alignment set
MBrake shoe steady spring cup removal tool
MBush and bearing removal/installation set
MStud extractors
MTap and die set
MLifting tackle
MTrolley jack
Buying tools
Reputable motor accessory shops and
superstores often offer excellent quality tools
at discount prices, so it pays to shop around.
Remember, you don’t have to buy the most
expensive items on the shelf, but it is always
advisable to steer clear of the very cheap
tools. Beware of ‘bargains’ offered on market
stalls or at car boot sales. There are plenty of
good tools around at reasonable prices, but
always aim to purchase items which meet the
relevant national safety standards. If in doubt,
ask the proprietor or manager of the shop for
advice before making a purchase.
Care and maintenance of tools
Having purchased a reasonable tool kit, it is
necessary to keep the tools in a clean and
serviceable condition. After use, always wipe
off any dirt, grease and metal particles using a
clean, dry cloth, before putting the tools away.
Never leave them lying around after they have
been used. A simple tool rack on the garage
or workshop wall for items such as
screwdrivers and pliers is a good idea. Store
all normal spanners and sockets in a metal
box. Any measuring instruments, gauges,
meters, etc, must be carefully stored where
they cannot be damaged or become rusty.
Take a little care when tools are used.
Hammer heads inevitably become marked,
and screwdrivers lose the keen edge on their
blades from time to time. A little timely
attention with emery cloth or a file will soon
restore items like this to a good finish.
Working facilities
Not to be forgotten when discussing tools
is the workshop itself. If anything more than
routine maintenance is to be carried out, a
suitable working area becomes essential.
It is appreciated that many an owner-
mechanic is forced by circumstances to
remove an engine or similar item without the
benefit of a garage or workshop. Having done
this, any repairs should always be done under
the cover of a roof.
Wherever possible, any dismantling should
be done on a clean, flat workbench or table at
a suitable working height.
Any workbench needs a vice; one with a jaw
opening of 100 mm is suitable for most jobs.
As mentioned previously, some clean dry
storage space is also required for tools, as well
as for any lubricants, cleaning fluids, touch-up
paints etc, which become necessary.
Another item which may be required, and
which has a much more general usage, is an
electric drill with a chuck capacity of at least 8
mm. This, together with a good range of twist
drills, is virtually essential for fitting
accessories.
Last, but not least, always keep a supply of
old newspapers and clean, lint-free rags
available, and try to keep any working area as
clean as possible.
Stroboscopic timing light Stud extractor setCompression tester
Dial test indicator (“dial gauge”)Micrometer set

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

Excessive fuel consumption
MAir filter element dirty or clogged (Chapter 1).
MChoke cable incorrectly adjusted, or choke sticking - carburettor
models (Chapter 4A).
MFuel injection system fault - fuel-injected models (Chapter 4B).
MIgnition timing incorrect/ignition system fault (Chapters 1 and 5).
MTyres under-inflated (Chapter 1).
Fuel leakage and/or fuel odour
MDamaged or corroded fuel tank, pipes or connections (Chapter 4A
or 4B).
MCarburettor float chamber flooding (float height incorrect) -
carburettor models (Chapter 4A).
Excessive noise or fumes from exhaust system
MLeaking exhaust system or manifold joints (Chapters 1 and 4C).
MLeaking, corroded or damaged silencers or pipe (Chapters 1 and 4C).
MBroken mountings causing body or suspension contact (Chapter 1).
Pedal travels to floor - no pressure or very little
resistance
MBroken clutch cable (Chapter 6).
MIncorrect clutch cable adjustment (Chapter 6).
MBroken clutch release bearing or fork (Chapter 6).
MBroken diaphragm spring in clutch pressure plate (Chapter 6).
Clutch fails to disengage (unable to select gears).
MIncorrect clutch cable adjustment (Chapter 6).
MClutch disc sticking on transmission input shaft splines (Chapter 6).
MClutch disc sticking to flywheel or pressure plate (Chapter 6).
MFaulty pressure plate assembly (Chapter 6).
MClutch release mechanism worn or incorrectly assembled (Chapter 6).
Clutch slips (engine speed increases, with no
increase in vehicle speed).
MIncorrect clutch cable adjustment (Chapter 6).
MClutch disc linings excessively worn (Chapter 6).MClutch disc linings contaminated with oil or grease (Chapter 6).
MFaulty pressure plate or weak diaphragm spring (Chapter 6).
Judder as clutch is engaged
MClutch disc linings contaminated with oil or grease (Chapter 6).
MClutch disc linings excessively worn (Chapter 6).
MClutch cable sticking or frayed (Chapter 6).
MFaulty or distorted pressure plate or diaphragm spring (Chapter 6).
MWorn or loose engine or transmission mountings (Chapter 2A or 2B).
MClutch disc hub or transmission input shaft splines worn (Chapter 6).
Noise when depressing or releasing clutch pedal
MWorn clutch release bearing (Chapter 6).
MWorn or dry clutch pedal bushes (Chapter 6).
MFaulty pressure plate assembly (Chapter 6).
MPressure plate diaphragm spring broken (Chapter 6).
MBroken clutch disc cushioning springs (Chapter 6).
Fault Finding REF•15
REF
Overheating
MInsufficient coolant in system (Chapter 1).
MThermostat faulty (Chapter 3).
MRadiator core blocked, or grille restricted (Chapter 3).
MElectric cooling fan or thermoswitch faulty (Chapter 3).
MPressure cap faulty (Chapter 3).
MIgnition timing incorrect/ignition system fault (Chapters 1 and 5).
MInaccurate temperature gauge sender unit (Chapter 3).
MAirlock in cooling system (Chapter 1).
Overcooling
MThermostat faulty (Chapter 3).
MInaccurate temperature gauge sender unit (Chapter 3).
External coolant leakage
MDeteriorated or damaged hoses or hose clips (Chapter 1).
MRadiator core or heater matrix leaking (Chapter 3).
MPressure cap faulty (Chapter 3).
MWater pump seal leaking (Chapter 3).
MBoiling due to overheating (Chapter 3).
MCore plug leaking (Chapter 2A).
Internal coolant leakage
MLeaking cylinder head gasket (Chapter 2A or 2B).
MCracked cylinder head or cylinder bore (Chapter 2A or 2B).
Corrosion
MInfrequent draining and flushing (Chapter 1).
MIncorrect coolant mixture or inappropriate coolant type (Chapter 1).
Cooling system
Clutch
Fuel and exhaust systems