1988 OPEL CALIBRA Service Repair Manual

b)Check the throttle cable operation and
adjustment (see above).
c)When reconnecting the vacuum hoses
and pipes, ensure that they are connected
to the front unions as shown in the
accompanying photograph.
d)As no fuel vapour trap is fitted, it is
essential that the manifold absolute
pressure sensor vacuum hose is routed
so that it falls steadily from the sensor to
the throttle body. This precaution will
prevent any fuel droplets being trapped in
the sensor or hose and allowing them to
drain into the inlet port.
e)Ensure that the fuel hoses are correctly
reconnected; the feed hose is on the
injector end of the throttle body.
f)Switch on the ignition and check for signs
of fuel leaks from all disturbed unions; if
any signs of leakage are detected, the
problem must be rectified before the
engine is started.
33Idle air control stepper
motor - removal and refitting
3
Removal
1Remove the air box (see Section 5).
2Disconnect the battery earth lead.3Disconnect the wiring plug from the stepper
motor (see illustration).
4Undo its two screws, then withdraw the
stepper motor. Remove and discard the
sealing ring (see illustrations).
Refitting
5Refitting is the reverse of the removal
procedure, noting the following points.
a)Fit a new sealing ring, greasing it lightly to
ease installation.
b)To prevent the risk of damage, either to
the throttle body or to the stepper motor,
if the motor’s plunger tip projects more
than 28 mm (1.1 in) beyond the motor’s
mating surface, carefully press the
plunger in until its stop is reached. The
stepper motor will then be reset by the
ECU when the engine is restarted.
c)Apply a few drops of a thread-locking
compound to their threads, then carefully
tighten the screws to the specified torque
wrench setting.
34Throttle potentiometer -
removal and refitting
3
Removal
1Disconnect the battery negative lead.
2Disconnect the wiring plug from the
potentiometer (see illustration).
3Unscrew the two Torx-type securing
screws (size TX 25) and withdraw the
potentiometer.
Refitting
4Refitting is the reverse of the removal
procedure, noting the following points.
a)Install the potentiometer when the throttle
valve is fully closed, and ensure that its
adapter seats correctly on the throttle
valve spindle.
b)Tighten the screws carefully to the
specified torque.
35Electronic Control Unit
(ECU) - removal and refitting
3
Removal
1Disconnect the battery negative lead.
2Remove the driver’s footwell side trim panel
(Chapter 11).
3Release the unit from its mountings and
withdraw it until the wiring plugs’ locking lugs
can be released and the plugs can be
disconnected (see illustration).
4Note that the unit consists of two parts the
basic control unit and the Programmable
Read Only Memory (PROM). While it is
possible to renew them separately, do not
attempt to separate them. Faults requiring this
degree of attention can be diagnosed only by
an experienced mechanic using the special
Vauxhall test equipment. A previously sound
ECU could be seriously damaged by careless
handling of the contacts between the two
sub-units.
4B•16Fuel and exhaust systems - fuel injection models
32.10 Intake air temperature control -
Multec systems
A Vacuum pipe
B Exhaust gas recirculation valve hose
C Charcoal canister control pipe
D Fuel return hose
33.4A Unscrew retaining screws (second
screw arrowed) . . .
35.3 Withdrawing the fuel
injection/ignition system ECU34.2 Disconnecting the throttle
potentiometer wiring plug - note the
mounting screws (arrowed)
33.4B . . . to remove the stepper motor -
renew sealing ring (arrowed)
33.3 Disconnecting the idle air control
stepper motor wiring plug

Refitting
5Refitting is a reversal of the removal
procedure, ensuring that the wiring plugs are
correctly reconnected and that the unit is
located securely.
36Knock sensor and module
(X16 SZ models) - removal
and refitting
3
Removal
1The knock sensor fitted to the X16 SZ
engine is located on the cylinder block below
the inlet manifold, between cylinders 2 and 3.
2Disconnect the battery negative lead.
3Remove the wiring and unscrew the unit
from the block.
4The module and control unit are located on
the left-hand side of the engine compartment
behind the battery. To remove, disconnect the
wiring multiplug and remove the retaining
bolts (see illustration).
5There is no provision for testing the knock
sensor or module without dedicated Vauxhall
test equipment. Check for external damage
and replace if necessary.
Refitting
6Refitting is a reversal of the removal
procedure, ensuring that the wiring plugs are
correctly reconnected and that the units are
located securely.
37Knock sensor (Simtec
system) - removal and refitting
3
Removal
1Disconnect the battery negative lead.
2Disconnect wiring harness plug, from inlet
air temperature sensor and wiring harness
plug, from hot mass air flow meter.
3Remove crankcase ventilation hoses.
4Remove coolant hoses from air inlet hoses,
hot film mass air flow meter complete with air
inlet hoses, from upper part of air cleaner and
throttle body.5Press retaining clip for 1st and 4th cylinder
injectors in plug strip (with screwdriver)
towards fuel distributor pipe - lifting plug strip
at the same time. On the underside of the plug
strip there are a total of 6 plug connections, 4
of which are for the injectors.
6Disconnect wiring harness plug for knock
sensor from the plug strip.
7Connect a 1 metre length of separate cable
to knock sensor wiring harness plug (note
routing).
8Remove knock sensor from cylinder block
(see illustration).
9Disconnect knock sensor cable from
separately attached cable, separate cable
remains in engine compartment.
Refitting
10Refitting is a reversal of removal, but note
the following.
11Before refitting ensure that the sensor is
spotlessly clean. Clean the entire contact
surface of the sensor must lie directly on the
cylinder block. Do not use any form of
washers.
12Carefully refit sensor into the block.
Tighten to the correct torque.
13Guide knock sensor cable between ridges
on inlet manifold using separate cable -
ensure correct routing.
14Remove the cable.
15Insert the wiring harness plug for the
knock sensor, into the plug strip.
16Correctly align the spring clips for theinjectors as they may prevent engagement of
the plug strip. Correct contact between the
plug strip and the injector is essential.
17When connecting plug strip, an audible
‘click’ should be heard.
18Ensure that hoses are in good condition
and installed securely with the two clamps.
38Inlet manifold (SOHC without
Multec) - removal and refitting
3
Note:Refer to warning in Section 2, before
proceeding. Use a new gaskets when refitting.
Removal
1Disconnect the battery negative lead.
2Remove the idle speed adjuster and its
hoses, referring to Section 22, if necessary.
3Release the securing clip, then disconnect
the throttle cable and balljoint from the throttle
valve lever. Slide the throttle cable grommet
from the bracket on the inlet manifold, and
move the throttle cable to one side out of the
way.
4Loosen the clamp screw and disconnect
the air trunking from the throttle body.
5Unscrew the union nut and disconnect the
brake servo vacuum hose from the inlet
manifold(see illustration).
6Disconnect the camshaft cover breather
hose from the throttle body.
7Disconnect the coolant hoses from the
throttle body. Be prepared for coolant
spillage, and clamp or plug the open ends of
the hoses, to prevent further coolant loss.
8Disconnect the wiring plug from the throttle
position sensor.
9Disconnect the vacuum pipe from the top
of the fuel pressure regulator.
10Disconnect the wiring harness housing
from the fuel injectors and move it to one side,
taking care not to strain the wiring. Pull up on
the wiring harness housing, and compress the
wiring plug retaining clips to release the
harness housing from the injectors.
11Disconnect the fuel hoses from the fuel
rail. Be prepared for fuel spillage, and take
adequate fire precautions. Clamp or plug the
open ends of the hoses, to prevent dirt
ingress and further fuel leakage.
Fuel and exhaust systems - fuel injection models 4B•17
38.5 Disconnecting the brake servo
vacuum hose -
SOHC models37.8 Knock sensor and wiring
(Simtec system)
1 Sensor2 Securing bolt
36.4 Knock sensor and module (X16 SZ models)
1 Sensor2 Module3 Sensor securing bolt
4B

12Unscrew and remove the top alternator
mounting nut and bolt.
13Make a final check to ensure that all
relevant hoses, pipes and wires have been
disconnected.
14Unscrew the securing nuts, and withdraw
the manifold from the cylinder head. Recover
the gasket (see illustrations).
15It is possible that some of the manifold
studs may be unscrewed from the cylinder
head when the manifold securing nuts are
unscrewed. In this event, the studs should be
screwed back into the cylinder head once the
manifold has been removed, using two
manifold nuts locked together.
16If desired, the ancillary components can
be removed from the manifold, referring to the
relevant Chapter.
Refitting
17Refitting is a reversal of removal,
remembering the following points.
18Where applicable refit any ancillary
components to the manifold, with reference to
relevant Sections of Chapters 4A or 4B.
19If the alternator mounting bracket has
been unbolted from the manifold, refit it
before refitting the manifold, as access to the
securing bolt is extremely limited once the
manifold is in place.
20Refit the manifold using a new gasket,
and tighten the securing nuts to the specified
torque.
21Ensure that all relevant hoses, pipes and
wires are correctly reconnected.
22On completion, check and if necessary
top-up the coolant level, (Chapter 3).
23Check and if necessary adjust the throttle
cable free play, as described in Chapters 4A
or 4B, as applicable.
24If any of the fuel system components have
been disturbed or renewed, check and if
necessary adjust the idle mixture, as
described in Chapters 4A or 4B, as applicable.
39Inlet manifold (SOHCwith
Multec) - removal and refitting
3
Removal
1Depressurise the fuel system Section 8).
2Remove the air box (see Section 5).
3Disconnect the battery negative lead.
4Either remove the throttle body assembly
(see Section 32), or disconnect the throttle
cable, wiring, fuel and vacuum hoses and
pipes to allow the manifold to be removed
with the throttle body.
5Drain the cooling system (see Chapter 3).
6Continue as described in Chapter 4A,
Section 26, paragraph 4 onwards.
Refitting
7Refitting is the reverse of the removal
procedure; renew all gaskets and seals
disturbed.
40Inlet manifold (DOHC
models) - removal and
refitting
3
Removal
1Disconnect the battery negative lead.
2Disconnect the wiring plug from the air
mass meter. Recover the sealing ring.
3Loosen the clamp screw securing the air
trunking to the right-hand end of the air mass
meter.
4Using an Allen key or hexagon bit, unscrew
the four bolts securing the air box to the
throttle body. Lift the air box from the throttle
body, and disconnect the hose from the base
of the air box then withdraw the air box/air
mass meter assembly.
5Disconnect the wiring plug from the throttle
position sensor.
6Slide the throttle cable end from the throttle
valve lever. Then pull the cable end grommet
from the bracket on the inlet manifold and
move the throttle cable to one side out of the
way.
7Disconnect the two breather hoses from the
rear of the camshaft cover. Disconnect the
larger hose from the throttle body, and
remove the hose completely.
8Position a wad of rag beneath one of the
fuel hose unions on the fuel rail, to absorb the
fuel that will be released as the union is
disconnected.
9Slowly loosen the fuel hose union, to
gradually relieve the pressure in the fuel feed
line, then disconnect the hose from the fuel
rail. Be prepared for fuel spillage, and take
adequate fire precautions. Plug the end of the
fuel hose, to prevent dirt ingress and further
fuel leakage.
10Repeat paragraphs 9 and 10 for the
remaining fuel hose-to-fuel rail union.
11Disconnect the vacuum pipe from the top
of the fuel pressure regulator.
12Disconnect the wiring harness housing
from the fuel injectors and move it to one side,
taking care not to strain the wiring. Pull up on
the wiring harness housing, and compress the
wiring plug retaining clips to release the
housing from the injectors.
13Unscrew the union nut, and disconnectthe brake servo vacuum hose from the left-
hand side of the inlet manifold (see
illustration).
14Unscrew the retaining nut, and remove
the fuel hose bracket from the left-hand side
of the throttle body.
15Unscrew the securing nuts, and
disconnect the earth leads from the fuel rail
securing studs at either end of the fuel rail.
16Unscrew the securing bolt, and remove
the cable/hose bracket from the left-hand end
of the inlet manifold.
17Remove the idle speed adjuster, as
described in Section 22.
18Unscrew and remove the top alternator
mounting nut and bolt.
19Make a final check to ensure that all
relevant hoses, pipes and wires have been
disconnected.
20Unscrew the securing nuts, and withdraw
the manifold from the cylinder head. Recover
the gasket.
21It is possible that some of the manifold
studs may be unscrewed from the cylinder
head when the manifold securing nuts are
unscrewed. In this event, the studs should be
screwed back into the cylinder head once the
manifold has been removed, using two
manifold nuts locked together.
22If desired, the ancillary components can
be removed from the manifold, with reference
to the relevant Sections of Chapters 4A or 4B.
Refitting
23Refitting is a reversal of the removal
procedure.
4B•18Fuel and exhaust systems - fuel injection models
38.14A Unscrew the securing nuts
40.13 Brake servo vacuum hose
connection at inlet manifold (arrowed) -
DOHC models
38.14B ...and withdraw the inlet manifold -
SOHC models

1
Chapter 1
Routine maintenance and servicing
Air cleaner element - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Air inlet temperature control check . . . . . . . . . . . . . . . . . . . . . . . . . .28
Alternator V-belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Automatic transmission check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . . .7
Automatic transmission fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . .38
Bodywork check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Brake pad check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Brake shoe check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Clutch cable check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Distributor and HT lead check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Door lock key battery - replacement . . . . . . . . . . . . . . . . . . . . . . . . .24
Driveshaft gaiter check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Engine oil and filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Handbrake linkage check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Headlamp alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Hose and fluid leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Idle speed and mixture - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .9
Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Intensive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Lock and hinge check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Manual transmission fluid check . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Power steering fluid check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Power steering pump drivebelt check . . . . . . . . . . . . . . . . . . . . . . . .18
Radiator inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Rear suspension level control system check . . . . . . . . . . . . . . . . . . .19
Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Spark plug renewal (SOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Spark plug renewal (DOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Steering and suspension check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Throttle linkage maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1•1
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

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

Idle mixture CO content:
All carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5 to 1.5%
20 NE and 20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 max.
20 XEJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.7 to 1.2%
All other injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.3 % (at 2800 to 3200 rpm)
Air filter element:
1.4 and 1.6 litre ‘round type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion W103
1.6 and 1.8 litre ‘square type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion U512
1.8 litre ‘round type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion type not available
2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion U554
Fuel filter:
1.6, 1.8 and 2.0 litre ‘in-line’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion L201
Ignition system:
Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refer to Chapter 5
Spark plugs
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion RN9YCC or RN9YC
DOHC models:
except C20 XE and X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion RC9MCC *
C20 XE and X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vauxhall P/N 90444724 (FR8LDC)
Plug gap:
RN9YCC and RC9MCC * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.8 mm
RN9YC * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.7 mm
FR8LDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.7 to 0.8 mm
* Information on spark plug types and electrode gaps is as recommended by Champion Spark Plug. Where alternative types are used, refer to the
manufacturer’s recommendations
Brakes
Minimum pad friction material thickness (including backing plate):
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.0 mm
Minimum shoe friction material thickness:
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5 mm above rivet heads
Tyres
Tyre size:
51/2 J x 13 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 R13-82T
51/2 J x 14 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175/70 R14-82T, 195/60 R14-85H, or 195/60 R14-85V
6J x 15 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195/60 R15-87V or 205/55 R15-87V
PressuresSee “Weekly checks”
Torque wrench settingsNmlbf ft
Automatic transmission drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4533
Roadwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11081
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Engine oil (sump) drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5541
Servicing Specifications 1•3
1
The maintenance intervals in this manual
are provided with the assumption that you,
not the dealer, will be carrying out the work.
These are the minimum maintenance intervals
recommended by the manufacturer for
vehicles driven daily. If you wish to keep your
vehicle in peak condition at all times, you may
wish to perform some of these procedures
more often. We encourage frequent
maintenance, because it enhances the
efficiency, performance and resale value of
your vehicle.
If the vehicle is driven in dusty areas, used
to tow a trailer, or driven frequently at slow
speeds (idling in traffic) or on short journeys,more frequent maintenance intervals are
recommended. Vauxhall recommend that the
service intervals are halved for vehicles that
are used under these conditions.
When the vehicle is new, it should be
serviced by a factory-authorised dealer
service department, to preserve the factory
warranty.
Maintenance is essential for ensuring safety
and for getting the best in terms of
performance and economy from your vehicle.
Over the years, the need for periodic
lubrication -oiling, greasing, and so on -has
been drastically reduced, if not eliminated.
This has unfortunately tended to lead someowners to think that because no action is
required, components either no longer exist,
or will last for ever. This is certainly not the
case; it is essential to carry out regular visual
examination comprehensively to spot any
possible defects at an early stage before they
develop into major expensive repairs.
The following service schedules are a list of
the maintenance requirements, and the
intervals at which they should be carried out,
as recommended by the manufacturers.
Where applicable, these procedures are
covered in greater detail near the beginning of
each relevant Chapter.
Maintenance schedule

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