1988 OPEL CALIBRA wiper fluid

16If adjustment is necessary, slacken the
locknut, turn the fork to give the specified
dimension, then tighten the locknut.
17Where applicable, coat the contact faces
of the servo and the mounting bracket with
sealing compound, then refit the bracket to
the servo, and tighten the securing nuts to the
specified torque.
18Coat the threads of the servo securing
bolts with locking fluid, then fit the servo to
the bulkhead and tighten the securing bolts.
19Refit the securing bolt cover plugs to the
cowl panel.
20Refit the master cylinder to the servo, and
tighten the securing nuts to the specified
torque.
21Reconnect the vacuum pipe to the servo.
22Refit the coolant expansion tank, as
described in Chapter 3.
23Refit the windscreen wiper motor and
linkage as described in Chapter 12, then refit
the windscreen cowl panel.
24Further refitting is a reversal of removal.
On completion, test the operation of the
servo, as described in Section 18.
20ABS hydraulic modulator -
removal and refitting
4
Note: Refer to Section 2, and the note at the
beginning of Section 3, before proceeding
Removal
1Disconnect the battery negative lead.
2Remove the brake fluid reservoir cap, and
secure a piece of polythene over the filler
neck with a rubber band, or by refitting the
cap. This will reduce the loss of fluid during
the following procedure.
3Remove the securing screw, and withdraw
the plastic cover from the hydraulic
modulator.
4Remove the two clamp screws, and lift off
the modulator wiring harness clamp (see
illustration).
5Disconnect the modulator wiring plug,
levering it from the socket with a screwdriver if
necessary.6Unscrew the brake fluid pipe union nuts,
and disconnect the pipes from the modulator.
Be prepared for fluid spillage, and plug the
open ends to prevent dirt ingress and further
fluid loss. Move the pipes just clear of the
modulator, taking care not to strain them.
7Unscrew the three modulator securing nuts
(see illustration), then tilt the modulator
slightly, and withdraw it upwards from its
bracket, sufficiently to gain access to the
earth lead securing nut at the front lower edge
of the modulator.
8Unscrew the securing nut and disconnect
the earth lead, then withdraw the modulator
from the vehicle, taking care not to spill brake
fluid on the vehicle paintwork.
9If a new modulator is to be fitted, pull the
two relays from the top of the old modulator,
and transfer them to the new unit. No attempt
must be made to dismantle the modulator.
Refitting
10Before refitting the modulator, check that
the bolts securing the mounting bracket to the
body panel are tight, and that the modulator
rubber mountings are in good condition.
Renew the rubber mountings if necessary.
11Refitting is a reversal of removal,
remembering the following points.
12Make sure that the earth lead is
reconnected before fitting the modulator to its
mounting bracket.13On completion, remove the polythene
sheet from the brake fluid reservoir filler neck,
and bleed the complete brake hydraulic
system, as described in Section 3.
14Check that the ABS warning lamp
extinguishes when first starting the engine
after the modulator has been removed. At the
earliest opportunity, take the vehicle to a
Vauxhall dealer, and have the complete
system tested, using the dedicated ABS test
equipment.
21ABS wheel sensors - removal
and refitting
3
Note: Refer to Section 2 before proceeding
Front wheel sensor
Removal
1Disconnect the battery negative lead.
2Where applicable, remove the wheel trim,
then loosen the relevant front roadwheel bolts
and apply the handbrake. Jack up the front of
the vehicle, and support on axle stands (see
“Jacking and Vehicle Support”) positioned
under the body side members. Remove the
roadwheel.
3Unclip the sensor wiring connector from the
retaining clip under the wheel arch, then
separate the two halves of the wiring
connector, prising them apart with a
screwdriver if necessary (see illustration).
4Using a Allen key or hexagon bit, unscrew
the bolt securing the wheel sensor to its
mounting bracket, then carefully lever the
sensor from the bracket using a screwdriver
(see illustration). Recover the seal ring.
Refitting
5Examine the condition of the seal ring, and
renew if necessary.
6Refitting is a reversal of removal,
remembering the following points.
7Smear a little grease on the sensor casing
before fitting it to the bracket.
8Do not fully tighten the roadwheel bolts until
the vehicle is resting on its wheels.
9Check that the ABS warning lamp
extinguishes when first starting the engine
after a wheel sensor has been removed. At
9•16Braking system
20.4 ABS hydraulic modulator (cover
removed)
1 Wiring harness
clamp screws2 Earth lead
3 Relays
21.3 Front wheel sensor wiring under
wheelarch - DOHC model
1 ABS sensor connector
2 Disc pad wear sensor wiring connector
21.4 ABS front wheel sensor securing bolt
(arrowed) - DOHC model20.7 ABS hydraulic modulator securing
screws (arrowed)

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

Engine
m mEngine fails to rotate when attempting to start
m mEngine rotates, but will not start
m mEngine difficult to start when cold
m mEngine difficult to start when hot
m mStarter motor noisy or excessively rough in engagement
m mEngine starts, but stops immediately
m mEngine idles erratically
m mEngine misfires at idle speed
m mEngine misfires throughout the driving speed range
m mEngine hesitates on acceleration
m mEngine stalls
m mEngine lacks power
m mEngine backfires
m mOil pressure warning light illuminated with engine running
m mEngine runs-on after switching off
m mEngine noises
Cooling system
m
mOverheating
m mOvercooling
m mExternal coolant leakage
m mInternal coolant leakage
m mCorrosion
Fuel and exhaust systems
m
mExcessive fuel consumption
m mFuel leakage and/or fuel odour
m mExcessive noise or fumes from exhaust system
Clutch
m
mPedal travels to floor - no pressure or very little resistance
m mClutch fails to disengage (unable to select gears)
m mClutch slips (engine speed increases, with no increase in vehicle
speed)
m mJudder as clutch is engaged
m mNoise when depressing or releasing clutch pedal
Manual transmission
m
mNoisy in neutral with engine running
m mNoisy in one particular gear
m mDifficulty engaging gears
m mJumps out of gear
m mVibration
m mLubricant leaks
Automatic transmission
m
mFluid leakage
m mTransmission fluid brown, or has burned smell
m mGeneral gear selection problems
m mTransmission will not downshift (kickdown) with accelerator fully
depressed
m mEngine will not start in any gear, or starts in gears other than Park
or Neutral
m mTransmission slips, shifts roughly, is noisy, or has no drive in
forward or reverse gears
Driveshafts
m mClicking or knocking noise on turns (at slow speed on full-lock)
m mVibration when accelerating or decelerating
Braking system
m
mVehicle pulls to one side under braking
m mNoise (grinding or high-pitched squeal) when brakes applied
m mExcessive brake pedal travel
m mBrake pedal feels spongy when depressed
m mExcessive brake pedal effort required to stop vehicle
m mJudder felt through brake pedal or steering wheel when braking
m mBrakes binding
m mRear wheels locking under normal braking
Suspension and steering systems
m
mVehicle pulls to one side
m mWheel wobble and vibration
m mExcessive pitching and/or rolling around corners, or during
braking
m mWandering or general instability
m mExcessively stiff steering
m mExcessive play in steering
m mLack of power assistance
m mTyre wear excessive
Electrical system
m
mBattery will not hold a charge for more than a few days
m mIgnition/no-charge warning light remains illuminated with engine
running
m mIgnition/no-charge warning light fails to come on
m mLights inoperative
m mInstrument readings inaccurate or erratic
m mHorn inoperative, or unsatisfactory in operation
m mWindscreen/tailgate wipers inoperative, or unsatisfactory in
operation
m mWindscreen/tailgate washers inoperative, or unsatisfactory in
operation
m mElectric windows inoperative, or unsatisfactory in operation
m mCentral locking system inoperative, or unsatisfactory in operation
The vehicle owner who does his or her own maintenance according to
the recommended service schedules should not have to use this section
of the manual very often. Modern component reliability is such that,
provided those items subject to wear or deterioration are inspected or
renewed at the specified intervals, sudden failure is comparatively rare.
Faults do not usually just happen as a result of sudden failure, but
develop over a period of time. Major mechanical failures in particular are
usually preceded by characteristic symptoms over hundreds or even
thousands of miles. Those components that do occasionally fail without
warning are often small and easily carried in the vehicle.
With any fault-finding, the first step is to decide where to begininvestigations. Sometimes this is obvious, but on other occasions, a
little detective work will be necessary. The owner who makes half a
dozen haphazard adjustments or replacements may be successful in
curing a fault (or its symptoms). However, will be none the wiser if the
fault recurs, and ultimately may have spent more time and money than
was necessary. A calm and logical approach will be found to be more
satisfactory in the long run. Always take into account any warning
signs or abnormalities that may have been noticed in the period
preceding the fault - power loss, high or low gauge readings, unusual
smells, etc. - and remember that failure of components such as fuses
or spark plugs may only be pointers to some underlying fault.
REF•12Fault Finding
Introduction

Horn inoperative, or unsatisfactory in operation
Horn operates all the time
MHorn push either earthed or stuck down (Chapter 12).
MHorn cable-to-horn push earthed (Chapter 12).
Horn fails to operate
MBlown fuse (Chapter 12).
MCable or cable connections loose, broken or disconnected
(Chapter 12).
MFaulty horn (Chapter 12).
Horn emits intermittent or unsatisfactory sound
MCable connections loose (Chapter 12).
MHorn mountings loose (Chapter 12).
MFaulty horn (Chapter 12).
Windscreen/tailgate wipers inoperative, or unsat-
isfactory in operation
Wipers fail to operate, or operate very slowly
MWiper blades stuck to screen, or linkage seized or binding
(Chapters 1 and 12).
MBlown fuse (Chapter 12).
MCable or cable connections loose, broken or disconnected
(Chapter 12).
MFaulty relay (Chapter 12).
MFaulty wiper motor (Chapter 12).
Wiper blades sweep over too large or too small an area of
the glass
MWiper arms incorrectly positioned on spindles (Chapter 1).
MExcessive wear of wiper linkage (Chapter 12).
MWiper motor or linkage mountings loose or insecure (Chapter 12).
Wiper blades fail to clean the glass effectively
MWiper blade rubbers worn or perished (Chapter 1).
MWiper arm tension springs broken, or arm pivots seized
(Chapter 12).
MInsufficient windscreen washer additive to adequately remove
road film (Chapter 1).
Windscreen/tailgate washers inoperative, or
unsatisfactory in operation
One or more washer jets inoperative
MBlocked washer jet (Chapter 1).
MDisconnected, kinked or restricted fluid hose (Chapter 12).
MInsufficient fluid in washer reservoir (Chapter 1).
Washer pump fails to operate
MBroken or disconnected wiring or connections (Chapter 12).
MBlown fuse (Chapter 12).
MFaulty washer switch (Chapter 12).
MFaulty washer pump (Chapter 12).
Washer pump runs for some time before fluid is emitted
from jets
MFaulty one-way valve in fluid supply hose (Chapter 12).
Electric windows inoperative, or unsatisfactory in
operation
Window glass will only move in one direction
MFaulty switch (Chapter 12).
Window glass slow to move
MRegulator seized or damaged, or in need of lubrication
(Chapter 11).
MDoor internal components or trim fouling regulator (Chapter 11).
MFaulty motor (Chapter 12).
Window glass fails to move
MBlown fuse (Chapter 12).
MFaulty relay (Chapter 12).
MBroken or disconnected wiring or connections (Chapter 12).
MFaulty motor (Chapter 12).
Central locking system inoperative, or unsatis-
factory in operation
Complete system failure
MBlown fuse (Chapter 12).
MFaulty relay (Chapter 12).
MBroken or disconnected wiring or connections (Chapter 12).
MFaulty control module (Chapter 12).
Latch locks but will not unlock, or unlocks but will not lock
MFaulty master switch (Chapter 12).
MBroken or disconnected latch operating rods or levers
(Chapter 11).
MFaulty relay (Chapter 12).
MFaulty control module (Chapter 12).
One solenoid/motor fails to operate
MBroken or disconnected wiring or connections (Chapter 12).
MFaulty solenoid/motor (Chapter 12).
MBroken, binding or disconnected latch operating rods or levers
(Chapter 11).
MFault in door latch (Chapter 11).
Fault Finding REF•19
REF
Electrical system (continued)

Pierburg 2E3 carburettor- 4A•5
Piston rings- 2A•30
Piston/connecting rod- 2A•29
Plastic components- 11•3
Potentiometer- 4B•12, 4B•16
Power steering fluid - 0•14, 0•17, 1•2, 1•12
Power steering pump- 10•22
Power steering system bleeding- 10•22
Punctures- 0•8
RRadiator- 3•3
Radiator cooling fan- 3•5
Radiator grille- 11•12
Radio/cassette anti theft system- REF•5
Radio/cassette player- 12•18
Rear hub- 10•10, 10•15
Rear lamps- 12•11
Rear suspension assembly- 10•15
Relays- 12•3
Release bearing (clutch)- 6•6
Repair procedures- REF •4
Respraying- 11•2
Reversing lamp switch- 7A•6
Road test- 1•13
Roll bars- 10•8, 10•13, 10•17
Routine maintenance - 1•1 et seq
SSafety first!- 0•5
Scratches- 11•2
Seat belts- 11•21
Seats- 11•20, 11•22
Seats heated- 12•6
Selector cable (automatics)- 7B•4
Selector lever- 7B•4
Sender unit fuel level- 4A•4, 4B•8
Sender units (temperature gauge)- 3•6
Servicing - see Routine maintenance
Servo unit (braking system)- 9•15
Shock absorber- 10•11
Shoes (brake)- 9•6
Short-circuit finding- 12•2
Spark plugs- 1•3, 1•14, 1•16
Speakers- 12•17
Speedometer cable- 12•18
Speedometer drive- 7A•6
Starter inhibitor switch- 7B•3
Starter motor- 5•8
Starting problems- 0•6
Steering wheel alignment- 10•1, 10•24
Steering- 10•1 et seq
camber - 10•1 10•24
castor - 10•1, 10•24
column - 10•18
damper - 10•21
fault diagnosis - REF•12, REF•17gear - 10•21
power steering system bleeding - 10•22
power steering fluid - 0•17, 1•2
power steering pump - 10•22
shaft rubber coupling - 10•18
tie-rod end - 10•23
toe setting - 10•1, 10•24
wheel - 10•17
wheel bearing - 10•4, 10•9, 10•14
wheel with airbag - 12•20
Stub axle- 10•13
Subframe- 10•5
Sump- 2A•27, 2B•9
Sunroof- 11•13
Sunroof motor- 12•18
Sunroof switch- 12•5
Suspension- 10•1 et seq
anti-roll bars - 10•8, 10•13, 10•17
assembly (rear) - 10•15
coil spring (rear) - 10•12, 10•15
fault diagnosis - REF•12, REF•17
level control system - 10•14
lower arm (front) - 10•7
rear hub - 10•10, 10•15
shock absorber - 10•11
strut (front) - 10•6
stub axle - 10•13
sub frame - 10•5
trailing arms - 10•12, 10•16
wheel bearing - 10•4, 10•9, 10•14
Suspension/steering checks- 1•10
Switches:
brake lamp - 12•5
cooling fan - 3•6
courtesy lamp - 12•5
electric door mirror - 12•5
handbrake warning lamp - 12•5
hazard warning - 12•4
heater blower motor - 12•4
ignition - 12•3
indicator - 12•4
kickdown - 7B•3
lights - 12•4
luggage compartment - 12•5
oil pressure warning lamp - 12•5
push button - 12•4
reversing lamp - 7A•6
starter inhibitor - 7B•3
sunroof - 12•5
TTailgate- 11•5
Temperature gauge sender- 3•6
Temperature sensor (automatics)- 7B•5
Thermostat- 3•4
Throttle cable- 4A•5, 4B•9
Throttle pedal- 4A•5Tie-rod end- 10•23
Timing- 5•2, 5•13
Timing belt- 1•16, 2A•13, 2B•3, 2B•6
Toe setting- 10•1, 10•24
Tools and working facilities- REF•4, REF•6,
REF•7
Towing- 0•9
Trim panel (door)- 11•6
Tyre checks- 0•16, 0•17
Tyre pressures- 0•17
UUnderbody- 11•1
Underbody views- 1•7
Underbonnet views- 0•10, 1•5
Upholstery and carpets- 11•2
VVacuum servo unit (braking system)- 9•15
Valve lifters- 2A•24, 2B•9
Valves- 2A•5, 2B•2
Vehicle identification numbers- REF•3
Ventilation system- 3•1 et seq
Vents- 3•8
WWasher fluid- 0•13, 1•2
Washers- 12•13, 12•15
Water pump- 3•4
Weekly checks- 0•10et seq
Wheelalignment- 10•1, 10•24
Wheel arch liners- 11•12
Wheel bearing- 10•4, 10•9, 10•14
Wheel changing- 0•8
Wheel cylinder- 9•11
Window glass- 11•9
Window regulator- 11•10
Windscreen- 11•9, 11•12
Wiper blades- 0•15, 12•13
Wiper motors- 12•14
Wiring diagrams- 12•22 et seq
Index REF•27
REF