1988 OPEL CALIBRA suspension

Note:For problems associated with the starting system, refer to the
faults listed under “Engine” earlier in this Section.
Battery will not hold a charge for more than a few
days
MBattery defective internally (Chapter 5).
MBattery terminal connections loose or corroded (Chapter 1).
MAuxiliary drivebelt worn or incorrectly adjusted (Chapter 1).
MAlternator not charging at correct output (Chapter 5).
MAlternator or voltage regulator faulty (Chapter 5).
MShort-circuit causing continual battery drain (Chapters 5 and 12).
Ignition/no-charge warning light remains
illuminated with engine running
MAuxiliary drivebelt broken, worn, or incorrectly adjusted (Chapter 1).
MAlternator brushes worn, sticking, or dirty (Chapter 5).
MAlternator brush springs weak or broken (Chapter 5).
MInternal fault in alternator or voltage regulator (Chapter 5).
MBroken, disconnected, or loose wiring in charging circuit
(Chapter 5).
Ignition/no-charge warning light fails to come on
MWarning light bulb blown (Chapter 12).
MBroken, disconnected, or loose wiring in warning light circuit
(Chapter 12).
MAlternator faulty (Chapter 5).
Lights inoperative
MBulb blown (Chapter 12).
MCorrosion of bulb or bulbholder contacts (Chapter 12).
MBlown fuse (Chapter 12).
MFaulty relay (Chapter 12).
MBroken, loose, or disconnected wiring (Chapter 12).
MFaulty switch (Chapter 12).
Instrument readings inaccurate or erratic
Instrument readings increase with engine speed
MFaulty voltage regulator (Chapter 12).
Fuel or temperature gauges give no reading
MFaulty gauge sender unit (Chapters 3, 4A and 4B).
MWiring open-circuit (Chapter 12).
MFaulty gauge (Chapter 12).
Fuel or temperature gauges give continuous maximum
reading
MFaulty gauge sender unit (Chapters 3, 4A and 4B).
MWiring short-circuit (Chapter 12).
MFaulty gauge (Chapter 12). MIncorrect front wheel alignment (Chapter 10).
MSteering rack or column bent or damaged (Chapter 10).
Excessive play in steering
MWorn steering column intermediate shaft universal joint
(Chapter 10).
MWorn steering track rod end balljoints (Chapters 1 and 10).
MWorn rack-and-pinion steering gear (Chapter 10).
MWorn steering or suspension joints, bushes or components
(Chapters 1 and 10).
Lack of power assistance
MBroken or incorrectly adjusted auxiliary drivebelt (Chapter 1).
MIncorrect power steering fluid level (Chapter 1).
MRestriction in power steering fluid hoses (Chapter 1).
MFaulty power steering pump (Chapter 10).
MFaulty rack-and-pinion steering gear (Chapter 10).
Tyre wear excessive
Tyres worn on inside or outside edges
MTyres under-inflated (wear on both edges), (Chapter 1).
MIncorrect camber or castor angles (wear on one edge only),
(Chapter 10).
MWorn steering or suspension joints, bushes or components
(Chapters 1 and 10).
MExcessively hard cornering.
MAccident damage.
Tyre treads exhibit feathered edges
MIncorrect toe setting (Chapter 10).
Tyres worn in centre of tread
MTyres over-inflated (Chapter 1).
Tyres worn on inside and outside edges
MTyres under-inflated (Chapter 1).
Tyres worn unevenly
MTyres/wheels out of balance (Chapter 1).
MExcessive wheel or tyre run-out (Chapter 1).
MWorn shock absorbers (Chapters 1 and 10).
MFaulty tyre (Chapter 1).
REF•18Fault Finding
Electrical system
Suspension and steering (continued)

Glossary of Technical Terms REF•21
REF
CamshaftA rotating shaft on which a series
of cam lobes operate the valve mechanisms.
The camshaft may be driven by gears, by
sprockets and chain or by sprockets and a
belt.
CanisterA container in an evaporative
emission control system; contains activated
charcoal granules to trap vapours from the
fuel system.
CarburettorA device which mixes fuel with
air in the proper proportions to provide a
desired power output from a spark ignition
internal combustion engine.
CastellatedResembling the parapets along
the top of a castle wall. For example, a
castellated balljoint stud nut.
CastorIn wheel alignment, the backward or
forward tilt of the steering axis. Castor is
positive when the steering axis is inclined
rearward at the top.Catalytic converterA silencer-like device in
the exhaust system which converts certain
pollutants in the exhaust gases into less
harmful substances.
CirclipA ring-shaped clip used to prevent
endwise movement of cylindrical parts and
shafts. An internal circlip is installed in a
groove in a housing; an external circlip fits into
a groove on the outside of a cylindrical piece
such as a shaft.
ClearanceThe amount of space between
two parts. For example, between a piston and
a cylinder, between a bearing and a journal,
etc.
Coil springA spiral of elastic steel found in
various sizes throughout a vehicle, for
example as a springing medium in the
suspension and in the valve train.
CompressionReduction in volume, and
increase in pressure and temperature, of a
gas, caused by squeezing it into a smaller
space.
Compression ratioThe relationship between
cylinder volume when the piston is at top
dead centre and cylinder volume when the
piston is at bottom dead centre.
Constant velocity (CV) jointA type of
universal joint that cancels out vibrations
caused by driving power being transmitted
through an angle.
Core plugA disc or cup-shaped metal device
inserted in a hole in a casting through which
core was removed when the casting was
formed. Also known as a freeze plug or
expansion plug.
CrankcaseThe lower part of the engine
block in which the crankshaft rotates.
CrankshaftThe main rotating member, or
shaft, running the length of the crankcase,
with offset “throws” to which the connecting
rods are attached.Crocodile clipSee Alligator clip
DDiagnostic codeCode numbers obtained by
accessing the diagnostic mode of an engine
management computer. This code can be
used to determine the area in the system
where a malfunction may be located.
Disc brakeA brake design incorporating a
rotating disc onto which brake pads are
squeezed. The resulting friction converts the
energy of a moving vehicle into heat.
Double-overhead cam (DOHC)An engine
that uses two overhead camshafts, usually
one for the intake valves and one for the
exhaust valves.
Drivebelt(s)The belt(s) used to drive
accessories such as the alternator, water
pump, power steering pump, air conditioning
compressor, etc. off the crankshaft pulley.
DriveshaftAny shaft used to transmit
motion. Commonly used when referring to the
axleshafts on a front wheel drive vehicle.
Drum brakeA type of brake using a drum-
shaped metal cylinder attached to the inner
surface of the wheel. When the brake pedal is
pressed, curved brake shoes with friction
linings press against the inside of the drum to
slow or stop the vehicle.
Castellated nut
Catalytic converter
Crankshaft assembly
Carburettor
Canister
Drum brake assembly
Accessory drivebelts
Driveshaft

Glossary of Technical Terms REF•23
JJump startStarting the engine of a vehicle
with a discharged or weak battery by
attaching jump leads from the weak battery to
a charged or helper battery.
LLoad Sensing Proportioning Valve (LSPV)A
brake hydraulic system control valve that
works like a proportioning valve, but also
takes into consideration the amount of weight
carried by the rear axle.
LocknutA nut used to lock an adjustment
nut, or other threaded component, in place.
For example, a locknut is employed to keep
the adjusting nut on the rocker arm in
position.
LockwasherA form of washer designed to
prevent an attaching nut from working loose.
MMacPherson strutA type of front
suspension system devised by Earle
MacPherson at Ford of England. In its original
form, a simple lateral link with the anti-roll bar
creates the lower control arm. A long strut - an
integral coil spring and shock absorber - is
mounted between the body and the steering
knuckle. Many modern so-called MacPherson
strut systems use a conventional lower A-arm
and don’t rely on the anti-roll bar for location.
MultimeterAn electrical test instrument with
the capability to measure voltage, current and
resistance.
NNOxOxides of Nitrogen. A common toxic
pollutant emitted by petrol and diesel engines
at higher temperatures.
OOhmThe unit of electrical resistance. One
volt applied to a resistance of one ohm will
produce a current of one amp.
OhmmeterAn instrument for measuring
electrical resistance.
O-ringA type of sealing ring made of a
special rubber-like material; in use, the O-ring
is compressed into a groove to provide the
sealing action.Overhead cam (ohc) engineAn engine with
the camshaft(s) located on top of the cylinder
head(s).
Overhead valve (ohv) engineAn engine with
the valves located in the cylinder head, but
with the camshaft located in the engine block.
Oxygen sensorA device installed in the
engine exhaust manifold, which senses the
oxygen content in the exhaust and converts
this information into an electric current. Also
called a Lambda sensor.
PPhillips screwA type of screw head having a
cross instead of a slot for a corresponding
type of screwdriver.
PlastigageA thin strip of plastic thread,
available in different sizes, used for measuring
clearances. For example, a strip of Plastigage
is laid across a bearing journal. The parts are
assembled and dismantled; the width of the
crushed strip indicates the clearance between
journal and bearing.
Propeller shaftThe long hollow tube with
universal joints at both ends that carries
power from the transmission to the differential
on front-engined rear wheel drive vehicles.
Proportioning valveA hydraulic control
valve which limits the amount of pressure to
the rear brakes during panic stops to prevent
wheel lock-up.
RRack-and-pinion steeringA steering system
with a pinion gear on the end of the steering
shaft that mates with a rack (think of a geared
wheel opened up and laid flat). When the
steering wheel is turned, the pinion turns,
moving the rack to the left or right. This
movement is transmitted through the track
rods to the steering arms at the wheels.
RadiatorA liquid-to-air heat transfer device
designed to reduce the temperature of the
coolant in an internal combustion engine
cooling system.
RefrigerantAny substance used as a heat
transfer agent in an air-conditioning system.
R-12 has been the principle refrigerant for
many years; recently, however, manufacturers
have begun using R-134a, a non-CFC
substance that is considered less harmful tothe ozone in the upper atmosphere.
Rocker armA lever arm that rocks on a shaft
or pivots on a stud. In an overhead valve
engine, the rocker arm converts the upward
movement of the pushrod into a downward
movement to open a valve.
RotorIn a distributor, the rotating device
inside the cap that connects the centre
electrode and the outer terminals as it turns,
distributing the high voltage from the coil
secondary winding to the proper spark plug.
Also, that part of an alternator which rotates
inside the stator. Also, the rotating assembly
of a turbocharger, including the compressor
wheel, shaft and turbine wheel.
RunoutThe amount of wobble (in-and-out
movement) of a gear or wheel as it’s rotated.
The amount a shaft rotates “out-of-true.” The
out-of-round condition of a rotating part.
SSealantA liquid or paste used to prevent
leakage at a joint. Sometimes used in
conjunction with a gasket.
Sealed beam lampAn older headlight design
which integrates the reflector, lens and
filaments into a hermetically-sealed one-piece
unit. When a filament burns out or the lens
cracks, the entire unit is simply replaced.
Serpentine drivebeltA single, long, wide
accessory drivebelt that’s used on some
newer vehicles to drive all the accessories,
instead of a series of smaller, shorter belts.
Serpentine drivebelts are usually tensioned by
an automatic tensioner.
ShimThin spacer, commonly used to adjust
the clearance or relative positions between
two parts. For example, shims inserted into or
under bucket tappets control valve
clearances. Clearance is adjusted by
changing the thickness of the shim.
Slide hammerA special puller that screws
into or hooks onto a component such as a
shaft or bearing; a heavy sliding handle on the
shaft bottoms against the end of the shaft to
knock the component free.
SprocketA tooth or projection on the
periphery of a wheel, shaped to engage with a
chain or drivebelt. Commonly used to refer to
the sprocket wheel itself.
Starter inhibitor switchOn vehicles with an
O-ring
Serpentine drivebelt
Plastigage
REF

oil and filter renewal - 0•17, 1•2, 1•9
oil cooler - 2B•10
oil level - 0•12
oil pump - 2A•28, 2B•9
piston rings - 2A•30
piston/connecting rod - 2A•29
removal - 2A•8, 2B•3
SOHC - 2A•1 et seq
sump - 2A•27, 2B•9
timing belt - 2A•13, 2B•3, 2B•6
undershield - 11•13
valve lifters - 2A•24, 2B•9
valves - 2A•5, 2B•2
Environmental considerations- REF•4
Exhaust manifold- 4C•5
Exhaust system check- 1•11, 4C•5
Expansion tank- 3•5
FFan (radiator)- 3•5
Fault diagnosis- REF•12 et seq
automatic transmission - REF•12, REF•16
braking system - REF•12, REF•17
clutch - REF•12, REF•15
cooling system - REF•12, REF•15
driveshafts - REF•12, REF•16
electrical system - REF•12, REF•18
engine - REF•12, REF•13
fuel and exhaust systems - REF•12, REF•15
manual transmission - REF•12, REF•16
steering - REF•12, REF•17
suspension - REF•12, REF•17
Flexplate (automatic transmission)- 2A•26
Flushing (cooling system)- 3•2
Flywheel- 2A•26
Foglamp- 12•11
Fuel and exhaust (carburettor) systems-
4A•1 et seq
Fuel and exhaust (fuel injection) systems-
4B•1 et seq
Fuel and exhaust systems - emissions-
4C•1 et seq
Fuel and exhaust systems:
accelerator cable - 4A•5
accelerator pedal - 4A•5
air box - 4B•5
air cleaner - 1•3, 1•13, 4A•3, 4B•4
air pump/cut off valve - 4C•2
air temperature control - 4B•5
airflow meters - 4B•12
automatic choke - 4A•9
carbon canister - 4C•4
carburettor - 4A•5, 4A•11
catalytic converter - 4C•3
control unit - 4B•16
depressurising fuel system - 4B•5
EGR components - 4C•2
exhaust manifold - 4C•5
exhaust system check - 1•11, 4C•5
fault diagnosis - REF•12, REF•15
filler cap - 11•13
fuel filters - 1•3, 1•14, 4B•6
fuel flow damper - 4B•8
fuel injector(s) - 4B•13
fuel level sender unit - 4A•4, 4B•8
fuel pressure regulator - 4B•10
fuel pump - 4A•3, 4B•6fuel tank - 4A•4, 4B•7
fuel vapour separator - 4A•4
idle speed/mixture adjustment - 4A•7,
4A•12, 4B•9, 4B•11
inlet manifold - 4A•12, 4B•17
knock sensor - 4B•17
lambda sensor - 4C•4
manifolds - 4A•12, 4B•17, 4C•5
mixture (CO) - 4A•7, 4A•12, 4B•9
oxygen sensor - 4C•4
Pierburg 2E3 - 4A•5
potentiometer - 4B•12, 4B•16
throttle cable - 4A•5
throttle pedal - 4A•5
Fuses- 12•1, 12•3
GGear selector linkage- 7A•2
Gearbox - see Manual or Automatic
transmission
Gearbox oil- 0•17, 1•2, 1•15
Gearchange lever- 7A•3
Glass- 11•9
Glossary of technical terms- REF•20
Glove compartment- 11•18
HHandbrake adjustment- 9•18
Handbrake cables- 9•19
Handbrake lever- 9•20
Handles (door)- 11•7
Hazard warning switch- 12•4
Headlamp alignment- 12•10
Headlamp unit- 12•9
Headlining- 11•19
Heater blower motor switch- 12•4
Heater control panel- 3•6
Heater matrix- 3•7
Heating systems- 3•1 et seq
Horn- 12•8
Hose and fluid leak check- 0•9, 1•9
Hoses brake- 9•18
IIdle speed/mixture/adjustment- 4A•7,
4A•12, 4B•9, 4B•11
Ignition coil- 5•9
Ignition switch- 12•3
Ignition system- 5•2
Igniton timing- 5•2, 5•13
Indicator lamps- 12•11
Indicator switch- 12•4
Injector(s)- 4B•13
Inlet manifold- 4A•12, 4B•17
Input shaft (clutch) oil seal- 7A•4
Instrument panel- 12•6
Interior lamps- 12•8
Interior trim panels- 11•14
Introduction to the Vauxhall Cavalier- 0•4
JJacking and vehicle support- REF•5
Jump starting- 0•7
KKickdown switch - 7B•3
Knock sensor- 4B•17
LLambda sensor- 4C•4
Lamps- 12•8, 12•9
Leaks- 0•9, 1•9
Light switch- 12•4
Locks bonnet- 11•4
Locks door- 11•8
Locks tailgate- 11•6
Lubricants and fluids- 0•17
MMain and big-end bearings- 2A•31
Maintenance - see Routine maintenance
Maintenance schedule- 1•4
Manifolds- 4A•12, 4B•17, 4C•5
Manual transmission- 7A•1 et seq
differential bearing oil seals - 7A•3
fault diagnosis - REF•12, REF•16
gear selector linkage - 7A•2
gearbox oil - 0•17, 1•2, 1•15
gearchange lever - 7A•3
input shaft (clutch) oil seal - 7A•4
overhaul -7A•5
removal and refitting - 7A•4
reversing lamp switch - 7A•6
speedometer drive - 7A•6
Master cylinder (brake)- 9•13
Mirrors- 11•11
Mixture (CO)- 4A•7, 4B•9
MOT test checks- REF•8
Mountings (engine/transmission)- 2A•12,
2B•3
NNumber plate lamp- 12•11
OOil change- 0•17, 1•2, 1•9
Oil cooler- 2B•10
Oil filter- 1•2, 1•9
Oil pressure warning lamp switch- 12•5
Oil pump- 2A•28, 2B•9
Oil seals:
differential bearing - 7A•3
general - REF •4
camshaft - 2A•18, 2B•6
crankshaft - 2A•26, 2B•6, 2B•9
Oils- 0•17, 1•2
Open-circuit, finding - 12•2
Oxygen sensor- 4C•4
PPads (brake)- 9•4
Paintwork damage- 11•2
Parts- REF•3
Pedals
brake - 9•21
clutch - 6•3
throttle - 4A•5
REF•26Index

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