1988 OPEL CALIBRA headlamp

12•40Wiring diagrams
Key to wiring diagrams for 1991 models (continued)
NoDescriptionTrackNoDescriptionTrack
S1.2Key contact switch586
S2.1Lighting switch404 to 407
S2.2Courtesy lamp switch487
S2.3Instrument illumination lamp dimmer328
S3Heater blower switch853 to 860
S4Heated rear window and mirror switch554 to 556
S5.2Dipped beam switch438 to 439
S5.3Direction indicator switch480 to 482
S5.4Sidelamp switch401 to 402
S7Reversing lamp switch497
S8Brake lamp switch462
S9.2Windscreen wiper interval switch501 to 504
S9.5Rear window washer/wiper switch514 to 516
S10Automatic transmission starter inhibitor switch773 to 779
S11Brake fluid level warning sensor31
S13Handbrake-on warning switch315
S14Oil pressure switch310
S15Luggage compartment lamp switch485
S17Passenger door courtesy lamp switch490
S21Front fog lamp switch450 to 452
S22Rear foglamp switch455 to 457
S24Air conditioning blower motor switch804 to 811
S27Air conditioning compressor low-pressure switch821
S28Air conditioning compressor high-pressure switch821
S29Cooling fan switch113
S30Driver’s seat heater switch560 to 562
S31Rear door courtesy lamp switch - left491
S32Rear door courtesy lamp switch - right491
S37Driver’s door electric window switch assembly668 to 694
S37.1Electric window switch - front left668 to 670
S37.2Electric window switch - front right686 to 688
S37.3Electric window switch - rear left674 to 676
S37.4Electric window switch - rear right692 to 694
S37.5Electric window safety cut-out switch672 to 673
S37.6Electric window anti-jam switch690
S37.7Electric window automatic control677 to 682
S39Electric window switch - rear left door678 to 680
S40Electric window switch - rear right door696 to 698
S41Central locking switch - driver’s door601 to 603
S42Central locking switch - passenger door605
S44Throttle position sensor278 to 279
S47Driver’s door courtesy lamp switch493 to 494
S52Hazard warning flasher switch469 to 474
S55Passenger seat heater switch564 to 566
S57Sunroof switch864 to 869, 872 to 877
S63.1Trip computer function reset switch656
S63.2Trip computer clock hours adjustment switch657
S63.3Trip computer function select switch658
S63.5Trip computer clock minutes adjustment switch659
S64Horn switch592, 595
S68.1Door mirror adjustment switch538 to 540, 945 to 950
S68.3Door mirror left/right selector switch537 to 541, 946 to 950
S68.4Door mirror parking position switch952
S76Air conditioning compressor switch - high-pressure fan827
S82Washer pump switch347, 392
S88Cooling fan switch115 to 116, 935 to 936
S93Coolant level sensor348, 393
S95Oil level sensor349, 394
S98Headlamp aim adjustment switch758 to 760
S99Electric window switch - driver’s door685
S100Electric window switch - passenger door683
S101Air conditioning compressor switch822 to 824
S102Air conditioning circulation switch816 to 818
S104Automatic transmission kickdown switch794
S105Automatic transmission “Winter” mode button796 to 798
S106Automatic transmission “Economy/Sport” mode button793S109Air conditioning compressor switch818
S115Automatic transmission coolant temperature switch788 to 789
S116Brake lamp switch464 to 465
S117Four-wheel-drive hydraulic pressure switch729
S119Air conditioning refrigerant temperature switch829, 843
S120Anti-theft alarm bonnet switch635
S127Central locking switch - tailgate (Calibra models)630
S128Air conditioning refrigerant temperature cooling switch825 to 826
S131Air conditioning defroster lever limit switch815
U2Trip computer651 to 662
U4ABS hydraulic modulator assembly705 to 718, 738 to 751
U4.1ABS hydraulic pump relay706 to 709, 739 to 742
U4.2ABS solenoid valves relay715 to 718, 747 to 751
U4.3ABS hydraulic pump705, 738
U4.4ABS diode717
U4.5ABS solenoid valve - front left710, 743
U4.6ABS solenoid valve - front right711, 744
U4.7ABS solenoid valve - rear left712, 745
U4.8ABS solenoid valve - rear right713
U5Check control display347 to 355
U5.1Check control washer fluid level warning lamp352
U5.2Check control oil level warning lamp351
U5.3Check control coolant level warning lamp350
U5.4Check control tail lamp and dipped beam bulb
failure warning lamp349
U5.5Check control brake lamp bulb failure warning lamp348
U5.6Check control brake wear warning lamp347
U6LCD instruments
U6.1Check control washer fluid level warning lamp392
U6.2Check control oil level warning lamp394
U6.3Check control coolant level warning lamp393
U6.4Check control tail lamp and dipped beam bulb
failure warning lamp391
U6.5Check control brake lamp bulb failure warning lamp395
U6.6Check control brake pad wear warning lamp396
U12.1Temperature switch (Diesel models)898, 931
U12.2Fuel filter heater (Diesel models)899, 932
U13AF14/20automatic transmission782 to 786
U13.1Solenoid - 1/2 and 3/4 shift up782
U13.2Solenoid - 2/3 shift up783
U13.3Solenoid - converter lock-up control784
U13.4Solenoid - main fluid pressure control785
V1Brake fluid level warning lamp test diode312
V8Air conditioning compressor diode820
Y1Air conditioning compressor clutch821
Y4Headlamp washer solenoid valve520
Y5Fuel solenoid valve (Diesel models)893, 928
Y7Fuel injectors187 to 194, 280 to 287
Y10Distributor (Hall-effect)246 to 251
Y23Distributor (inductive discharge)123 to 127
Y24Distributor (inductive discharge)129 to 136
Y25Idle-up solenoid valve (automatic transmission)242
Y30Cold start valve (Diesel models)896
Y32Fuel injector140, 979
Y33Distributor170, 262, 972 to 974
Y34Fuel tank vent valve193, 292
Y35Air conditioning circulation solenoid valve816
Y44Four-wheel-drive solenoid valve731
Y47Parking brake lock lifting magnet (automatic transmission)769
X13Diagnostic equipment connector149, 170 to 171, 254 to 255,
269 to 270, 325, 339 to 340,
752 to 753, 774 to 775, 992 to 993
X15Octane coding plug160, 184 to 185, 248 to 249, 990 to 991
X54Ignition coding plug270 to 271
X1 onWiring connectorsVarious

Wiring diagrams 12•55
12
Key to wiring diagrams for 1992 and later models
NoDescriptionTrackNoDescriptionTrack
E1Left parking lamp506
E2Left tail lamp507, 745
E3Licence plate lamp513
E4Right parking lamp509
E5Right tail lamp510, 746
E6Engine compartment lamp515
E7Left high beam 535
E8Right high beam536
E9Left low beam537, 747
E10Right low beam538, 748
E11Instrument lights728, 729
E12Selector lever lamp 498, 499
E13Boot lamp585
E14Passenger compartment lamp587
E15Glove box lamp677
E16Cigarette lighter lamp676
E17Left reversing lamp597
E18Right reversing lamp598
E19Heated back window652
E20Left fog lamp553
E21Right fog lamp554
E24Left rear fog lamp548
E25Left front heating mat660
E27Left rear reading lamp680, 681
E28Right rear reading lamp683, 684
E30Right front heating mat664
E32Clock lamp863
E37Left mirror make-up lamp686
E38Computer lamp854
E39Right rear foglamp549
E40Right mirror make-up lamp688
E41Passenger compartment delay lamp 588 to 590
E50Driver door lamp866
E51Passenger door lamp884
F1 onFusesVarious
F35Voltage stabilizer702
G1Battery101
G2Alternator114
G6Diesel alternator 402 to 405
H1Radio784 to 798
H3Turn signal lamp telltale716, 718
H4Oil pressure telltale710
H5Brake fluid telltale712
H6Telltale hazard warning system570
H7Charging indicator lamp710
H8High beam telltale722
H9Left stop lamp561, 749
H10Right stop lamp562, 750
H11Left front turn signal lamp572
H12Left rear turn signal lamp573
H13Right front turn signal lamp581
H14Right rear turn signal lamp582
H15Fuel telltale705, 706
H16Preheating time telltale715
H17Trailer turn signal lamp telltale717
H18Horn670
H19Headlamps on warning buzzer594, 595
H21Parking brake telltale713
H23Airbag telltale719
H25Heated back window & mirror telltale642, 765
H26ABS telltale721
H27Safety checking warning buzzer996 to 998
H28Seat belt warning telltale723
H30Engine telltale724H33Left auxiliary turn signal lamp576
H34Right auxiliary turn signal lamp578
H36Additional stop lamp563
H37Left front loudspeaker788 to 790
H38Right front loudspeaker794 to 796
H39Left rear loudspeaker788, 789
H40Right rear loudspeaker791, 792
H42Automatic program power telltale725
H45Four wheel drive telltale727
H46Catalytic converter temperature telltale729
H47Anti-theft warning unit horn838
H48Horn671
H51Traction control telltale720
H52Left front tweeter787 to 791
H53Right front tweeter793 to 797
K3Starter relay anti-theft warning unit109, 110
K5Fog lamps relay554 to 555
K6Air conditioning relay901, 902
K7Four stage air conditioning blower relay904, 905
K8Windshield wiper interval relay603 to 606
K9Headlamps washer unit relay619, 620
K10Flasher unit567 to 569
K20Ignition coil module149, 150, 171, 172, 241, 242, 302 to 305,
361 to 364, 1001 to 1005, 1055 to 1061
K22Coolant pump relay133, 134, 969, 970
K25Glow time relay440 to 443
K26Radiator blower relays972 to 974
K27Radiator blower relay137 to 139
K30Back window wiper interval relay613 to 615
K31Airbag control unit1191 to 1198
K34Radiator blower time delay relay356 to 358, 956 to 958
K35Heated back window & mirror time delay relay650 to 652
K37Central locking control unit805 to 812
K51Radiator blower relay430, 431, 942, 943, 956, 957
K52Radiator blower relay145 to 147, 433,435,
982 to 984, 960 to 962
K57Multec unit control211 to 230, 244 to 262
K58Fuel pump relay231, 232, 262, 263
K59Running light relay520 to 525
K60Compressor relay931,932
K61Motronic control unit270 to 294, 307 to 337,
366 to 396, 1007 to 1037, 1063 to 1096
K63Horn relay671, 672
K641 stage air conditioning blower relay913, 914
K67Radiator blower relay142, 143, 436, 437, 948,
949, 964, 965, 986, 987
K68Fuel injection unit relay295 to 299, 393 to 397,
334 to 338, 1093 to 1097, 1034 to 1038
K73High beam relay (Calibra)530, 531
K76Glow time control unit413 to 417
K77Glow plugs relay419, 420
K78Preresistor relay (70A)422, 423
K79Charge indicator relay406 to 408
K80Filter heating relay426, 427, 452, 453
K82Engine revolution relay447, 448
K83Four wheel drive unit control342 to 349
K84EZ Plus control unit155 to 166, 177 to 191
K85Automatic transmission control unit473 to 496
K86Check control unit736 to 752
K87Radiator blower relay945, 946, 953, 954, 977, 978
K88Catalytic converter temperature control unit462 to 464
K89Rear fog lamp relay543 to 545
K90Compressor relay (automatic transmission only)930, 931
K94Anti-theft warning unit control unit833 to 847

12•56Wiring diagrams
Key to wiring diagrams for 1992 and later models (continued)
NoDescriptionTrackNoDescriptionTrack
K95Traction control control unit1125 to 1140
K97Headlamps washer pump time delay relay630 to 632
K101Parking position mirror relay774 to 777
K102Park brake shift lock control unit 469 to 471
L1Ignition coil150, 172, 205, 273, 241, 302, 361
L2Ignition coil1000 to 1004, 1054 to 1059
M1Starter105, 106
M2Windshield wiper motor601 to 604
M3Heating blower motor127 to 129
M4Radiator blower motor118, 120, 140, 356, 431, 948, 954, 980
M6Left headlamp wiper motor622 to 624
M7Right headlamp wiper motor 626 to 628
M8Back window wiper motor611 to 613
M10Air conditioning blower motor905 to 908
M11Radiator blower motor136, 434, 962, 984
M13Vectra/Cavalier sun roof motor1172 to 1175
M13.1Sun roof motor1172, 1174
M13.2Timing box microswitch1172
M13.3Timing box microswitch1174
M18Driver door central locking motor807 to 810
M19Left rear door central locking motor821 to 823
M20Right rear door central locking motor825 to 827
M21Fuel pump232, 263, 297, 339, 399, 834, 1098, 1039
M23Alternator blower motor135, 974
M24Headlamps washer pump632
M26Automatic antenna motor798 to 799
M30Driver side outside mirror638 to 641
M31Passenger side outside mirror644 to 647
M32Passenger door central locking motor813 to 816
M33Idle speed actuator285, 286, 317, 318, 381,
382, 1019, 1020, 1075, 1076
M37Tail gate/boot lid central locking motor818 to 821
M39Left headlamp levelling motor 692 to 695
M40Right headlamp levelling motor696 to 699
M41Fuel filler door central locking motor823, 824
M47Driver door window lifter motor867 to 871
M48Passenger door window lifter motor885 to 889
M49Left rear window lifter motor873 to 877
M50Right rear window lifter motor891 to 895
M55Windshield and back window washer pump617
M57Coolant pump134, 970
M60Calibra tailgate central locking motor827, 828
M61Calibra sun roof motor1178 to 1186
M61.1Sun roof motor1179 to 1182
M61.2Relay 11178, 1179
M61.3Relay 21184 to 1186
M62Driver side outside mirror760 to 767
M63Passenger side outside mirror769 to 776
M65TC throttle valve actuator1130 to 1134
M66Idle air stepper motor215 to 218, 250 to 253
P1Fuel indicator704
P2Coolant temperature indicator706
P3Clock862
P4Fuel sensor704
P5Coolant temperature sensor706
P7Tachometer708
P11Airflow meter 285 to 289
P12Coolant temperature sensor282, 381
P13Outside temperature sensor856
P14Distance sensor412, 413
P17Left front revolution sensor1110, 1154
P18Right front revolution sensor1113, 1157
P19Left rear revolution sensor1116, 1160
P20Right rear revolution sensor1119, 1163P21Distance sensor731
P23Intake manifold absolute pressure sensor160, 161, 185, 186,
217 to 219, 250 to 252
P24Engine oil temperature sensor162, 187
P27Left front brake lining sensor740
P28Right front brake lining sensor740
P29Intake manifold temperature sensor382, 1016, 1072
P30Coolant temperature sensor215, 248, 313, 1017, 1073
P32Heated exhaust oxygen sensor294, 295, 331, 332, 391,
392, 1034, 1035, 1093, 1094
P33Exhaust oxygen sensor229, 257
P34Throttle valve potentiometer221 to 223, 280, 281, 253 to 255,
383 to 385, 478, 479, 1018, 1019, 1074, 1075
P35Crankshaft impulse sensor178 to 180, 289 to 291, 248 to 250,
318 to 320, 373 to 375, 1025 to 1027, 1084 to 1086
P38Transmission oil temperature sensor494
P39Trailer bulb test sensor752 to 754
P43Electronic speedometer733
P44Air mass meter393 to 397, 334 to 338,
1037, 1038, 1096, 1097
P45Transmission input revolution sensor490, 491
P46Knock control sensor322, 323, 377, 378,
1022, 1023, 1078, 1079
P47Cylinder identification hall sensor325 to 327, 385 to 387,
1028 to 1030, 1087, 1089
P48Automatic transmission distance sensor488, 489
P50Catalytic converter temperature sensor463, 464
P53Driver side anti-theft warning unit sensor839 to 847
P54Passenger side anti-theft warning unit sensor839 to 847
P55Engine coolant temperature sensor415
P56Knock control sensor II1080, 1081
P57Antenna797
R3Cigarette lighter675
R5Glow plugs418 to 420, 441 to 443
R13Left heated washer nozzle 626
R14Right heated washer nozzle628
R19Radiator blower preresistor120, 140, 945
R22Glow plugs pre-resistor423
R23Driver airbag squib1194
S1Starter switch103 to 106
S1.2Key contact switch783
S2Light switch assy
S2.1Light switch504 to 507
S2.2Passenger compartment lamp switch587
S2.3Instrument lights dimmer728
S3Heating blower switch123 to 130
S4Heated back window & mirror switch654 to 657
S5Turn signal switch assy
S5.2Low beam switch536, 537
S5.3Turn signal switch580 to 582
S5.4Parking lamp switch501, 502
S7Back up lamp switch597, 599
S8Stop lamp switch562
S9Wiper unit switch
S9.2Interval windshield wiper switch601 to 604
S9.5Back window and washer unit wiper switch614 to 616
S10Automatic transmission switch472 to 478
S11Brake fluid control switch712
S13Parking brake switch713
S14Oil pressure switch710
S15Boot lamp switch585
S17Passenger door contact switch590
S20Pressure switch
S20.1Low pressure compressor switch925

Wiring diagrams 12•57
12
Key to wiring diagrams for 1992 and later models (continued)
NoDescriptionTrackNoDescriptionTrack
S20.2High pressure compressor switch925
S20.3High pressure blower compressor switch939
S21Fog lamps switch555 to 557
S22Rear fog lamp switch549 to 551
S24Air conditioning blower switch904 to 911
S29Coolant temperature switch118, 137, 357, 942, 957, 972
S30Left front heating mat switch660 to 662
S31Rear left door contact switch591
S32Rear right door contact switch592
S33Traction control switch1130, 1131
S37Window lifter switch868 to 894
S37.1Left window lifter switch868 to 870
S37.2Right window lifter switch886 to 888
S37.3Left rear window lifter switch874 to 876
S37.4Right rear window lifter switch892 to 894
S37.5Safety switch872, 873
S37.6Window anti-jam off switch890
S37.7Automatic window lifter control877 to 882
S39Left rear door window lifter switch878 to 880
S40Right rear door window lifter switch896 to 898
S41Driver door burglary locking switch800 to 802
S42Passenger door central locking switch805
S44Throttle valve switch316, 317
S47Driver door contact switch593, 594
S52Hazard warning switch569 to 573
S53First gear identification switch372
S55Right front heating mat switch664 to 666
S57Sun roof switch1170 to 1183
S63Computer switch
S63.1Function reset switch856
S63.2Clock hours adjustment switch857
S63.3Function select switch858
S63.4Clock minute adjustment switch859
S64Horn switch672
S68Outside mirror switch assy
S68.1Outside mirror adjustment switch638 to 640, 758 to 762
S68.3Left/right outside mirror switch637 to 641, 759 to 763
S68.4Parking position switch765
S82Washer fluid minimum capacity control switch736
S882 stage coolant temperature switch120, 121, 137, 138, 430, 431
S89Seat belt switch998
S93Coolant minimum capacity control switch737
S95Engine oil minuimum capacity control switch738
S98Headlamps levelling switch691 to 693
S99ZV driver door window lifter switch865
S100ZV passenger door window lifter switch883
S101Compressor switch926 to 928
S102Circulation switch918 to 920
S103Transmission temperature switch350
S104Kickdown switch493
S105Start-up assistance switch495 to 497
S106Economy power program switch492
S109Acceleration revolution pressure switch921
S115Coolant temperature switch487, 488
S116Stop lamp switch564, 565
S117Hydraulic pressure switch346
S120Engine compartment hood (anti-theft warning unit) switch835
S127Calibra tail gate central locking switch831
S128Coolant temperature switch936,937S131Defroster lever limit switch918
U2Computer851 to 862
U4ABS hydroaggregate1102 to 1122, 1146 to 1164
U4.1Pump motor relay1102, 1103, 1146, 1147
U4.2Solenoid valves relay1104, 1105, 1148, 1149
U4.3Pump motor1102,1146
U4.4Diode1105,1149
U4.5Left front solenoid valve1109,1153
U4.6Right front solenoid valve1111,1155
U4.7Rear axle solenoid valve1113,1157
U4.8ABS control unit1106 to 1122, 1150 to 1164
U4.9Solenoid valves plug1109 to 1113, 1153 to 1157
U5Check control display
U5.1Washer fluid minimum capacity telltale741
U5.2Oil minimum capacity telltale740
U5.3Coolant minimum capacity telltale739
U5.4Tail light & low beam telltale738
U5.5Stop light failure telltale737
U5.6Front brake lining telltale736
U12Filter heater
U12.1Temperature switch426, 452
U12.2Filter heater427, 453
U13Automatic transmission
U13.1Solenoid valve (shift 1)481
U13.2Solenoid valve (shift 2)482
U13.3Solenoid valve (lock up control)483
U13.4Solenoid valve (pressure control)484
U17Roof antenna amplifier795
V1Brake fluid test bulb diode712
V8Air conditioning compressor diode926
X1 onWiring connectorsVarious
X10Anti theft warning unit code837
X13Diagnostic link164, 165, 189, 190, 226, 270, 271, 258, 259,
309, 310, 370, 371, 343, 344, 473, 474, 573, 725, 836, 837, 860,
861, 1012, 1013, 1069, 1070, 1118, 1119, 1136, 1162, 1163
X15Octane number plug157, 158, 182, 183, 225, 226,
257, 258, 284, 285
X54Ignition coding plug310, 311, 1014, 1070, 1071
Y1Air conditioning compressor clutch925
Y4Headlamps washer solenoid valve620
Y5Fuel solenoid valve410, 445
Y7Fuel injection valves287 to 294,320 to 327,
384 to 391,1025 to 1032,1078 to 1089
Y10Hall sensor ignition distributor153 to 158
Y11Hot start solenoid valve375, 376
Y12Charging pressure control changeover valve377, 378
Y18Exhaust gas recirculation valve1093
Y23Inductive sensor distributor201 to 208
Y24Distributor (inductive discharge)
Y25Acceleration revolution solenoid valve155, 177
Y30Cold start acceleration solenoid valve 448
Y32Fuel injection valve212, 245
Y33Ignition distributor175 to 177, 268 to 270, 238 to 240,
301 to 303, 360 to 362
Y34Tank ventilation valve293, 331, 332, 379, 380,
1092, 1016, 1017,
Y35Circulation solenoid valve918
Y44Four wheel drive solenoid valve350
Y47Park brake shift lock lifting magnet469

2When the starter switch is operated, current
flows from the battery to the solenoid that is
mounted on the starter body. The plunger in
the solenoid moves inwards, so causing a
centrally pivoted lever to push the drive pinion
into mesh with the starter ring gear. When the
solenoid plunger reaches the end of its travel,
it closes an internal contact and full starting
current flows to the starter field coils. The
armature is then able to rotate the crankshaft,
so starting the engine.
3A special freewheel clutch is fitted to the
starter driven pinion, so that when the engine
fires and starts to operate on its own it does
not drive the starter motor.
4When the starter switch is released, the
solenoid is de-energised, and a spring moves
the plunger back to its rest position. This
operates the pivoted lever to the withdraw the
drive pinion from engagement with the starter
ring.
13Starter motor - testing
3
Note: Refer to Section 3 before proceeding
Testing
1If the starter motor fails to turn the engine
when the switch is operated, and engine
seizure is not the problem, there are several
other possible reasons:
a)The battery is faulty
b)The electrical connections between the
switch, solenoid battery and starter motor
are somewhere failing to pass the
necessary current from the battery
through the starter to earth
c)The solenoid switch is faulty
d)The starter motor is mechanically or
electrically defective
e)The starter motor pinion and/or flywheel
ring gear is badly worn, and in need of
replacement
2To check the battery, switch on the
headlamps. If they dim after a few seconds,
then the battery is in a discharged state. If the
lamps glow brightly, operate the starter switch
and see what happens to the lamps. If theydim, then power is reaching the motor, but
failing to turn it. If the starter turns slowly, go
on to the next check.
3If, when the starter switch is operated, the
lamps stay bright, then insufficient power is
reaching the motor. Disconnect the battery
and the starter/solenoid power connections,
and the engine earth strap, then thoroughly
clean them and refit them. Smear petroleum
jelly around the battery connections to
prevent corrosion. Corroded connections are
the most frequent cause of electrical system
malfunctions.
4If the preceding checks and cleaning tasks
have been carried out without success, a
clicking noise will probably have been heard
each time the starter switch was operated.
This indicates that the solenoid switch was
operating, but it does not necessarily follow
that the main contacts were closing properly
(if no clicking has been heard from the
solenoid, it is certainly defective). The
solenoid can be checked by connecting a
voltmeter across the main cable connection
on the solenoid and earth. When the switch is
operated, these should be a reading on the
voltmeter. If there is no reading, the solenoid
unit is faulty, and should be renewed.
5If the starter motor operates, but does not
turn the engine, then it is likely that the starter
pinion and/or flywheel ring gear are badly
worn. If this is the case, the starter motor will
normally be noisy in operation.
6Finally, if it is established that the solenoid
is not faulty, and 12 volts are reaching the
starter, then the motor itself is faulty, and
should be removed for inspection.
14Starter motor - removal and
refitting
3
Note: Refer to Section 3 before proceeding
Removal
1Disconnect the battery negative lead.
2Apply the handbrake, then jack up the front
of the vehicle, and support securely on axle
stands (see “Jacking and Vehicle Support”)
positioned under the body side members.3On DOHC models, remove the engine
undershield, as described in Chapter 11.
4Note the wiring connections on the
solenoid, then disconnect them (see
illustration).
5Where applicable, unscrew the bolt
securing the exhaust bracket and the starter
motor mounting bracket to the cylinder block
(see illustration).
6Unscrew the two starter motor mounting
bolts. Note that the top bolt on some models
are fitted from the transmission side, and
secures a wiring harness bracket (see
illustration).
7Withdraw the starter motor.
Refitting
8Refitting is a reversal of removal, but where
applicable, ensure that the wiring harness
bracket is in place on the top mounting bolt,
and tighten all bolts to the specified torque.
15Starter motor - overhaul
5
If the starter motor is thought to be suspect,
it should be removed from the vehicle and
taken to an auto-electrician for testing. Most
auto-electricians will be able to supply and fit
brushes at a reasonable cost. However, check
on the cost of repairs before continuing as it
may prove more economical to obtain a new
or exchange motor.
16Ignition coil - removal, testing
and refitting
3
Note: Refer to Section 3 before proceeding.
An ohmmeter will be required to test the coil
Removal
1The ignition coil is either a cylindrical metal
canister or a moulded plastic unit. It is
clamped or bolted to the left-hand inner wing
panel, near the suspension strut top mounting
(under the power steering fluid reservoir, on
Engine electrical systems 5•9
14.6 Starter motor securing bolts
(arrowed) - 1.6 litre model
(engine removed)14.5 Starter motor mounting
bracket/exhaust bracket securing bolt
(arrowed) - 1.6 litre model14.4 Starter motor and solenoid viewed
from underneath the vehicle. Solenoid
wiring connections arrowed
5

wax-based underbody protective coating, it is
a good idea to have the whole of the
underframe of the vehicle steam cleaned,
engine compartment included, so that a
thorough inspection can be carried out to see
what minor repairs and renovations are
necessary. Steam cleaning is available at
many garages and is necessary for removal of
the accumulation of oily grime that sometimes
is allowed to become thick in certain areas.
The dirt can then be simply hosed off. Note
that these methods should not be used on
vehicles with wax-based underbody
protective coating or the coating will be
removed. Such vehicles should be inspected
annually, preferably just before winter, when
the underbody should be washed down and
any damage to the wax coating repaired.
Ideally, a completely fresh coat should be
applied. It would also be worth considering
the use of such wax-based protection for
injection into door panels, sills, box sections,
etc., as an additional safeguard against rust
damage where such protection is not
provided by the vehicle manufacturer.
After washing paintwork, wipe off with a
chamois leather to give an unspotted clear
finish. A coat of clear protective wax polish,
will give added protection against chemical
pollutants in the air. If the paintwork sheen
has dulled or oxidised, use a cleaner/polisher
combination to restore the brilliance of the
shine. This requires a little effort, but such
dulling is usually caused because regular
washing has been neglected. Care needs to
be taken with metallic paintwork, as special
non-abrasive cleaner/polisher is required to
avoid damage to the finish.
Always check that the door and ventilator
opening drain holes and pipes are completely
clear so that water can be drained out. Bright
work should be treated in the same way as
paint work. Windscreens and windows can be
kept clear of the smeary film that often
appears, by using a glass cleaner. Never use
any form of wax or other body or chromium
polish on glass.
3Upholstery and carpets -
maintenance
1
Mats and carpets should be brushed or
vacuum cleaned regularly to keep them free of
grit. If they are badly stained remove them
from the vehicle for scrubbing or sponging
and make quite sure they are dry before
refitting. Seats and interior trim panels can be
kept clean by wiping with a damp cloth. If they
do become stained (which can be more
apparent on light coloured upholstery) use a
little liquid detergent and a soft nail brush to
scour the grime out of the grain of the
material. Do not forget to keep the headlining
clean in the same way as the upholstery.
When using liquid cleaners inside the vehicle
do not over-wet the surfaces being cleaned.Excessive damp could get into the seams and
padded interior causing stains, offensive
odours or even rot. If the inside of the vehicle
gets wet accidentally it is worthwhile taking
some trouble to dry it out properly, particularly
where carpets are involved. Do not leave oil or
electric heaters inside the vehicle for this
purpose.
4Minor body damage - repair
3
Repairs of minor scratches in
bodywork
If the scratch is very superficial, and does
not penetrate to the metal of the bodywork,
repair is very simple. Lightly rub the area of
the scratch with a paintwork renovator, to
remove loose paint from the scratch and to
clear the surrounding bodywork of wax polish.
Rinse the area with clean water.
Apply touch-up paint to the scratch using a
fine paint brush; continue to apply fine layers
of paint until the surface of the paint in the
scratch is level with the surrounding
paintwork. Allow the new paint at least two
weeks to harden: then blend it into the
surrounding paintwork by rubbing the scratch
area with a paintwork renovator or a very fine
cutting paste and apply wax polish.
Where the scratch has penetrated right
through to the metal of the bodywork, causing
the metal to rust, a different repair technique
is required. Remove any loose rust from the
bottom of the scratch with a penknife, then
apply rust inhibiting paint, to prevent the
formation of rust in the future. Using a rubber
or nylon applicator fill the scratch with
bodystopper paste. If required, this paste can
be mixed with cellulose thinners to provide a
very thin paste that is ideal for filling narrow
scratches. Before the stopper-paste in the
scratch hardens, wrap a piece of smooth
cotton rag around the top of a finger. Dip the
finger in cellulose thinners and then quickly
sweep it across the surface of the
stopper-paste in the scratch; this will ensure
that the surface of the stopper-paste is
slightly hollowed. The scratch can now be
painted over as described earlier in this
Section.
Repair of dents in bodywork
When deep denting of the vehicle’s
bodywork has taken place, the first task is to
pull the dent out, until the affected bodywork
almost attains its original shape. There is little
point in trying to restore the original shape
completely, as the metal in the damaged area
will have stretched on impact and cannot be
reshaped fully to its original contour. It is
better to bring the level of the dent up to a
point that is about 8 in (3 mm) below the level
of the surrounding bodywork. In cases where
the dent is very shallow anyway, it is not worthtrying to pull it out at all. If the underside of the
dent is accessible, it can be hammered out
gently from behind, using a mallet with a
wooden or plastic head. Whilst doing this,
hold a block of wood firmly against the
outside of the panel to absorb the impact
from the hammer blows and thus prevent a
large area of the bodywork from being
“belled-out”.
Should the dent be in a section of the
bodywork that has a double skin or some
other factor making it inaccessible from
behind, a different technique is called for. Drill
several small holes through the metal inside
the area particularly in the deeper section.
Then screw long self-tapping screws into the
holes just sufficiently for them to gain a good
purchase in the metal. Now the dent can be
pulled out by pulling on the protruding heads
of the screws with a pair of pliers.
The next stage of the repair is the removal
of the paint from the damaged area, and from
an inch or so of the surrounding “sound”
bodywork. This is accomplished most easily
by using a wire brush or abrasive pad on a
power drill, although it can be done just as
effectively by hand using sheets of abrasive
paper. To complete the preparation for filling,
score the surface of the bare metal with a
screwdriver or the tang of a file, or
alternatively, drill small holes in the affected
area. This will provide a good “key” for the
filler paste.
To complete the repair see the Section on
filling and re-spraying.
Repair of rust holes or gashes in
bodywork
Remove all paint from the affected area and
from an inch or so of the surrounding “sound”
bodywork, using an abrasive pad or a wire
brush on a power drill. If these are not
available a few sheets of abrasive paper will
do the job just as effectively. With the paint
removed you will be able to gauge the severity
of the corrosion and therefore decide whether
to renew the whole panel (if this is possible) or
to repair the affected area. New body panels
are not as expensive as most people think
and it is often quicker and more satisfactory
to fit a new panel than to attempt to repair
large areas of corrosion.
Remove all fittings from the affected area
except those which will act as a guide to the
original shape of the damaged bodywork (e.g.
headlamp shells, etc.). Then, using tin snips or
a hacksaw blade, remove all loose metal and
any other metal badly affected by corrosion.
Hammer the edges of the hole inwards to
create a slight depression for the filler paste.
Wire brush the affected area to remove the
powdery rust from the surface of the
remaining metal. Paint the affected area with
rust inhibiting paint. If the back of the rusted
area is accessible treat this also.
Before filling can take place it will be
necessary to block the hole in some way. This
can be achieved by using aluminium or plastic
mesh, or aluminium tape.
11•2Bodywork and fittings

27Door mirror - removal,
overhaul and refitting
3
Glass renewal
1If desired, the mirror glass can be removed
for renewal without removing the mirror. On
models with electric mirrors, disconnect the
battery negative lead.
2Carefully prise the glass from its balljoints
using a screwdriver, and where applicable,
disconnect the heater wires from the glass.
Take care, as the glass is easily broken if
forced (see illustration).
3To refit, simply push the glass onto the
balljoints, ensuring that the heater wires are
connected (where applicable).
Mirror -removal and refitting
4On models with electric mirrors, disconnect
the battery negative lead.
5On models with manually adjustable
mirrors, pull off the interior adjuster lever.
6Prise the mirror trim panel from the inside
front edge of the door (see illustration).
7Extract the three now-exposed securing
screws, and withdraw the mirror assembly
from the door. On models with electric
mirrors, disconnect the wiring plug (see
illustrations).
8Refitting is a reversal of removal, but ensure
that the rubber weather seal is correctly
located on the mirror housing (see
illustration).
Electric motor removal and
refitting
Removal
9Remove the mirror glass, as described
previously in this Section.
10Extract the three motor securing screws,
and disconnect the wiring plug, then withdraw
the motor (see illustration).
Refitting
11Refitting is a reversal of removal, but
ensure that the wiring is routed behind the
motor, to avoid interfering with the adjustment
mechanism.
28Bumpers - removal and
refitting
3
Front bumper
Removal
1Remove both headlamps, as described in
Chapter 12.
2The bumper is removed as a complete
assembly with the front trim panel, therefore
on models with front foglamps, disconnect
the foglamp wiring plugs. On DOHC and
1993-on models remove the radiator grille
panel, as described in Section 29. Also
remove the water deflector if fitted.
3The bumper is secured by a single bolt at
each end, and by clips. It is possible to
unscrew the right-hand securing bolt with the
air cleaner assembly in place. Using an
open-ended spanner, but if desired the air
cleaner assembly can be removed for
improved access, as described in Chapters
4A or 4B, as applicable.
4Remove the left and right-hand bumper
securing bolts from the body side panels
behind the headlamp apertures (see
illustration).
5Release the bumper retaining clips from the
body by pushing each end of the bumper
towards the front of the vehicle, then pulling
the end of the bumper out from the wing (see
illustration).
Bodywork and fittings 11•11
27.7A . . . for access to the mirror securing
screws
28.4 Unscrewing the right-hand front
bumper securing bolt (air cleaner removed)27.10 Mirror motor securing screws
(arrowed)
27.8 Locating the weather seal on the
mirror housing27.7B Withdraw the mirror and disconnect
the wiring plug
27.6 Removing the mirror trim panel . . .27.2 Removing the mirror glass - electric
mirror (mirror removed)
11

4B
13Manipulate the air inlet tube to release the
securing lugs from the front body panel. This
is a tricky operation, and patience will be
required. For improved access, the headlamp
can be removed, as described in Chapter 12.
Refitting
14Refitting of all components is a reversal of
removal, noting that the air cleaner element
fits with the rubber locating flange uppermost.
5Air box - removal and refitting
2
Removal
1The air box, if fitted, is secured by two or
three bolts to the top of the throttle body.
Take note of the routing and connections of
the inlet air temperature control system
vacuum pipes.
2Disconnect the engine breather hose from
the air box and the vacuum pipe from the
rearmost of the throttle body’s three unions
(see illustration).
3Do not lose the sealing ring as the air box is
withdrawn.
Refitting
4On refitting, ensure that the sealing ring is
seated correctly in the slot in the underside of
the air box, tighten the screws, and reconnect
the vacuum pipe and breather hose (see
illustrations).
6Air temperature control -
description and testing
3
Description
1Fitted to models with Multec systems, air
temperature is controlled by a thermac switch
(thermostat), mounted in the air box. When
the engine is started from cold, the switch is
closed to allow inlet manifold depression to
act on the air temperature control valve in the
air cleaner assembly. This uses a vacuum
servo in the valve assembly to draw a flap
valve across the cold air inlet thus allowing
only (warmed) air from the exhaust manifold to
enter the air cleaner.2As the temperature of the exhaust warmed
air in the air box rises, a bi-metallic strip in the
thermac switch deforms. This opens the
switch to shut off the depression in the air
temperature control valve. The flap is then
lowered gradually across the hot air inlet. Until
the engine is fully warmed up to normal
operating temperature, only cold air from the
front of the vehicle is entering the air cleaner.
Testing
3To check the system, allow the engine to
cool down completely, then remove the air
cleaner cover; the flap valve should be
securely seated across the hot air inlet. Start
the engine. The flap should immediately rise to
close off the cold air inlet. It should then lower
steadily as the engine warms until it is
eventually seated across the hot air inlet again.
4To check the thermac switch, disconnect
the control valve vacuum pipe from the switch
union (on the rear face of the air box) when the
engine is running. With the engine cold, full
inlet manifold depression should be felt
sucking at the union; none at all should be felt
when the engine is fully warmed up.
5To check the air temperature control valve,
remove the air cleaner cover; the flap valve
should be securely seated across the hot air
inlet. Disconnect the control valve vacuum
pipe from the switch union on the rear face of
the air box and suck hard on its end; the flap
should rise to shut off the cold air inlet.
6If either component is faulty, it must be
renewed. This means renewing the air cleaner
lower casing to obtain a new air temperature
control valve, or renewing the air box in the
case of the thermac switch.
7Air temperature sensor (later
models) - removal and
refitting
2
Removal
1Disconnect the battery negative lead.
2Disconnect the wiring plug at the inlet air
temperature sensor.
3Release the hose clips and remove the air
trunking then remove the inlet air temperature
sensor from the trunking.
Refitting
4Refitting is a reversal of removal but ensure
that the air trunking is connected to the
airflow meter as shown (see illustration).
8Depressurising the fuel
system - general
2
General
1The fuel system consisting of the
tank-mounted fuel pump, the fuel filter, the
fuel injector and the pressure regulator in the
throttle body. Metal pipes and flexible hoses
of the fuel lines connect these components.
All these contain fuel that will be under
pressure while the engine is running and/or
while the ignition is switched on.
2The pressure will remain for some time after
the ignition has been switched off and must
be relieved before any of these components
are disturbed.
3Remove either the fuel pump fuse (num-
ber 11) or the fuel pump relay and start the
engine. Allow the engine to idle until it cuts
out. Turn the engine over once or twice on the
starter to ensure that all pressure is released,
then switch off the ignition.
4Do not forget to refit the fuse or relay when
work is complete.
Fuel and exhaust systems - fuel injection models 4B•5
5.4B Do not overtighten the air box
screws
7.4 Removing the intake air temperature
sensor from the air trunking - later models
5.4A Ensure the sealing ring is located in
the air box groove5.2 Vacuum pipe connections to air box
A To throttle body B To air cleaner
Warning: The following
procedures will merely relieve
the pressure in the fuel system.
Remember that fuel will still be
present in the system components, so
take precautions before disconnecting
any of them. Refer to Section 2.