1988 OPEL CALIBRA engine oil

18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH:
New belt, cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5
New belt, warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5
Used belt, cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5
Used belt, warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.0
Valves and guidesInletExhaust
Overall length - production (mm):
14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105.0105.0
16 SV, X 16 SZ and C16 NZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.5101.5
C16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104.2104.2
18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . . . . . . . . . . . .104.2104.0
Overall length - service (mm):
14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104.6104.6
16 SV, X 16 SZ and C16 NZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.1101.1
C16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103.8103.8
18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . . . . . . . . . . . .103.8103.6
Head diameter (mm):
14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.029.0
16 SV, X 16 SZ, C16 NZ and C16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . .38.031.0
18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . . . . . . . . . . . .41.836.5
Stem diameter (mm), (all engines):
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.998 to 7.0126.978 to 6.992
0.075 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.073 to 7.0877.053 to 7.067
0.150 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.148 to 7.1627.128 to 7.142
0.250 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.248 to 7.2627.228 to 7.242
Valve guide bore (mm), (all engines):
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.030 to 7.050
0.075 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.105 to 7.125
0.150 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.180 to 7.200
0.250 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.280 to 7.300
Valve clearance in guide (mm), (all engines):
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.018 to 0.052
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.038 to 0.072
Valve seat angle:
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44º
Valve clearances:
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Automatic adjustment by hydraulic lifters
Flywheel
Maximum permissible lateral run-out of starter ring gear (all models) . .0.5 mm
Refinishing limit -maximum depth of material that may be removed
from clutch friction surface (all models) . . . . . . . . . . . . . . . . . . . . . . .0.3 mm
Lubrication system
Lubricant type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Lubricants and fluids in “Weekly checks”
Lubricant capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1 Specifications
Oil pump clearances:
Inner-to-outer gear teeth clearance (backlash) (all models) . . . . . . . .0.0 to 0.2 mm
Gear-to-housing clearance (endfloat):
14 NV, 16 SV, C16 NZ and X 16 SZ . . . . . . . . . . . . . . . . . . . . . . . .0.08 to 0.15 mm
C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . .0.03 to 0.10 mm
Oil pressure at idle (engine warm) (all models) . . . . . . . . . . . . . . . . . . . .1.5 bar (21.8 lbf/in2
)
Torque wrench settingsNmlbf ft
Note:Use new bolts where asterisked (*). The torque settings stated for the cylinder head are only applicable to latest specification bolts, available
from Vauxhall. Earlier type or alternative make, head bolts may require different torques. Consult your supplier.
Air inlet pre-heat to exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . .86
Alternator and inlet manifold to brackets:
1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . . .2015
C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1813
Alternator to bracket (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3022
Alternator to bracket (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4030
Alternator to shackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Big-end bearing cap: *
1.4 and 1.6 litre, (except C16 NZ2)
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 30º
SOHC engine procedures 2A•5
2A

Torque wrench settings (continued)Nmlbf ft
Big-end bearing cap: *
C16 NZ2, 1.8 and 2.0 litre:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3526
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 45º
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 15º
Camshaft housing cover to housing . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Camshaft pulley to camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4533
Camshaft thrust plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Coolant outlet to thermostat housing:
C 16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Coolant pump to cylinder block:
1.4 and 1.6 litre, (except C 16 NZ2) (M6) . . . . . . . . . . . . . . . . . . . . . .86
C16 NZ2, 1.8 and 2.0 litre (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Crankshaft sensor wheel:
C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1310
Cylinder head to cylinder block: *
1.4 and 1.6 litre, (except C16 NZ2):
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 60º
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 60º
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 60º
C16 NZ2, 1.8 and 2.0 litre:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 90º
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 90º
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 90º
Drivebelt (ribbed) pulley/timing belt drive to crankshaft: *
1.4 and 1.6 litre, (except C16 NZ2):
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5541
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 45º
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 15º
Drivebelt pulley to timing belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . .2015
Drivebelt (ribbed) tensioner to cylinder block . . . . . . . . . . . . . . . . . . . . .2015
Drivebelt (ribbed) tensioner to support:
1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . . .2015
C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1813
Engine bracket to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6044
Engine bracket to transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6044
Engine mounting bracket to engine bracket . . . . . . . . . . . . . . . . . . . . . .6044
Engine mounting to engine mounting bracket . . . . . . . . . . . . . . . . . . . .6548
Engine mounting to front axle housing . . . . . . . . . . . . . . . . . . . . . . . . . .4030
Engine mounting to power steering pump support . . . . . . . . . . . . . . . .6044
Engine mounting to side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6548
Exhaust manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2216
Exhaust pipe to manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Flexplate to crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6044
Flywheel to crankshaft: *
1.4 and 1.6 litre, (except C16 NZ2):
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3526
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 30º
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 15º
C16 NZ2, 1.8 and 2.0 litre:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6548
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 30º
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 15º
Front timing belt cover to rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Fuel pump to camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1813
Guide sleeve, release bearing to transmission . . . . . . . . . . . . . . . . . . . .2216
Heat shield sleeves to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . .3022
Inlet manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2216
Knock sensor to cylinder block (X16 SZ) . . . . . . . . . . . . . . . . . . . . . . . .1310
Main bearing cap: *
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5037
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 45º
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 15º
Oil filter to oil pump/cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
2A•6SOHC engine procedures

Oil pick-up pipe bracket to cylinder block . . . . . . . . . . . . . . . . . . . . . . .64
Oil pick-up pipe to oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Oil pipes to radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2216
Oil pressure switch to oil pump:
1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . .3022
C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4030
Oil pressure relief valve to oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .3022
Oil pump cover to oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Oil pump to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Oxygen sensor to exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . .3022
Power steering pump bracket to support:
C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1813
Power steering pump to support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Right engine mounting to subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . .6548
Shackle to alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Starter to cylinder block (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4533
Starter to cylinder block (M12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6044
Sump:
1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . . .86
C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1511
Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5541
Support to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3526
Temperature sender to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . .2015
Thermostat housing:
1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . . .107
C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1511
Timing belt tensioner to oil pump:
1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . . .5541
Timing belt cover to oil pump/camshaft housing:
1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . . .129
C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Timing belt drive gear to crankshaft:
C16 NZ2, 1.8 and 2.0 litre:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13096
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by between 40º to 50º
Transmission to engine (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4533
Transmission to engine (M12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6044
1General description
General
The engine is of four-cylinder, in-line single
or double overhead camshaft type (depending
on model), mounted transversely at the front
of the vehicle.
The crankshaft runs in five shell-type
bearings, and the centre bearing incorporates
a thrust bearing shell to control crankshaft
endfloat.
The connecting rods are attached to the
crankshaft by horizontally split shell-type
big-end bearings. On single overhead
camshaft (SOHC) models, the pistons are
attached to the connecting rods by gudgeon
pins, which are an interference fit in the
connecting rod small-end bore. The
aluminium alloy pistons are fitted with three
piston rings: two compression rings and an oil
control ring.
The camshaft on SOHC engines is driven
from the crankshaft by a toothed composite
rubber belt. Each cylinder has two valves (oneinlet and one exhaust), operated through
rocker arms that are supported at their pivot
ends by hydraulic self-adjusting valve lifters
(tappets).
The inlet and exhaust valves are each
closed by a single valve spring, and operate in
guides pressed into the cylinder head.
A gear-type oil pump is located in a housing
attached to the front of the cylinder block, and
is driven directly from the crankshaft. A
full-flow type oil filter is fitted.
The distributor is driven directly from the
end of the camshaft. On carburettor models,
the mechanical fuel pump is operated from
the front end of the camshaft. The coolant
pump is located at the front of the cylinder
block, and is driven by the timing belt.
Chapter 2A describes the SOHC engine
repair procedures. Many repairs and specifi-
cations to the DOHC engine are similar to the
2.0 litre SOHC. However where they differ,
details can be found in Chapter 2B.
Engine identification codes -
general
Before ordering spare parts, or carrying out
any repair or overhaul operations on the
engine, it is essential to identify the exactengine type being worked on. Later engines,
although outwardly similar in appearance,
often have significant differences in repair
procedures, even though they may be of the
same displacement and model year.
The following sub-Sections in this Chapter
are mainly specific to engine type, as will be
noted from the sub-Section headings. Check
the engine identification code first, which is
located on a horizontal surface on the exhaust
manifold side of the cylinder block, at the
distributor end. On later engines, the code is
on the cylinder block-to-transmission flange,
next to the engine oil dipstick.
2Crankcase ventilation
system - description and
maintenance
2
Description
1A crankcase ventilation system is fitted to
all models, but the systems differ in detail
depending on the model concerned.
2Oil fumes and blow-by gases (combustion
gases that have passed by the piston rings)
are drawn from the crankcase into the area of
SOHC engine procedures 2A•7
2A

the cylinder head above the camshaft(s)
through a hose. From here the gases are
drawn into the inlet manifold/throttle body (as
applicable) and/or the air box on the
carburettor (where applicable), where they are
re-burnt with fresh air/fuel mixture, hence
reducing harmful exhaust emissions.
Maintenance
3Certain models have a mesh filter inside the
camshaft cover, which should be cleaned in
paraffin if clogging is evident (see
illustration).
4On high mileage vehicles, particularly when
regularly used for short journeys, a jelly-like
deposit may be evident inside the crankcase
ventilation system hoses. If excessive
deposits are present, the relevant hose(s)
should be removed and cleaned.
5Periodically inspect the system hoses for
security and damage, and renew as
necessary. Note that damaged or loose hoses
can cause various engine running problems
that can be difficult to trace.
6The crankcase breather/dipstick tube can
be unbolted from the cylinder block after
disconnecting the hose. Use a new gasket
when refitting.
3Compression test -
description
3
Description
1If engine performance is poor, or if misfiring
occurs which cannot be attributed to the
ignition or fuel system, a compression test
can provide diagnostic clues. If the test is
performed regularly, it can give warning of
trouble on a high mileage engine before any
other symptoms become apparent.
2The engine must be at operating
temperature, the battery must be fully
charged, and the spark plugs must be
removed. The help of an assistant will also be
required.
3Disable the ignition system by
disconnecting the coil LT (“+15”) wire. Fit the
compression tester to No 1 cylinder spark
plug hole.4Have the assistant hold the throttle wide
open and crank the engine on the starter.
Record the highest reading obtained on the
compression tester.
5Repeat the test on the remaining cylinders,
recording the pressure developed in each.
6The difference in pressure between any two
cylinders should be no more than 1.0 bar
(14.5 lbf/in2). If the pressure in any cylinder is
low, pour a teaspoonful of clean engine oil
into the spark plug hole, and repeat the test.
7If the addition of oil temporarily improves
the compression pressure, this indicates that
cylinder bore or piston ring wear was
responsible for the pressure loss. No
improvement suggests that leaking or burnt
valves, or a blown head gasket may be to
blame.
8A low reading from two adjacent cylinders
is almost certainly due to the head gasket
leaking between them.
9On completion of the test, refit the spark
plugs and reconnect the coil LT wire.
4Major operations possible
with the engine in the vehicle
1The following operations may be carried out
without removing the engine from the vehicle:
a)Removal and refitting of oil pressure relief
valve (see Section 30)
b)Removal and refitting of timing belt and
sprockets
c)Removal and refitting of camshaft housing
(SOHC engines)
d)Removal and refitting of camshaft(s)
e)Removal and refitting of cylinder head
f)Removal and refitting of sump
g)Removal and refitting of oil pump
h)Removal and refitting of
piston/connecting rod assemblies
i)Removal and refitting of flywheel
j)Renewal of crankshaft front oil seal
k)Removal and refitting of
engine/transmission mountings
Note: It is possible to renew the crankshaft
rear oil seal with the engine in the vehicle, but
this requires the use of special tools, and is a
difficult operation, due to the lack of working
space. For this reason, this operation is
described with the engine removed from the
vehicle.
5Major operations requiring
engine removal
The engine must be removed from the
vehicle to carry out the following operations:
a)Renewal of the crankshaft main bearings
b)Removal and refitting of the crankshaft
c)Renewal of crankshaft rear oil seal
6Method of engine removal
The engine may be removed either on its
own, or together with the transmission. Unless
work is also necessary on the transmission, it
is recommended that the engine is removed
on its own. In either case, the engine or
engine/transmission assembly must be lifted
out through the top of the engine
compartment, using a hoist and lifting tackle.
7Engine - removal and refitting,
(leaving transmission in car)
4
Note: A hoist and lifting tackle will be required
for this operation.If the torque converter is
removed (even partially) from the transmission,
a considerable amount of the fluid inside it will
leak out. To prevent this, when prising the
engine from the transmission and removing it,
be careful to keep the torque converter
pressed firmly into the transmission. If the
transmission is to be removed for some time,
retain the torque converter by bolting a strip of
metal across the bellhousing mating surface.
Removal
1Disconnect the battery negative lead.
2Remove the bonnet (Chapter 11).
3Apply the handbrake, then jack up the front
of the vehicle, and support securely on axle
stands (see “Jacking and Vehicle Support”).
4Drain the cooling system, remove the
radiator and transmission fluid cooler hoses
(automatic models), as described in Chapter 3.
5Drain the engine oil as described in Chapter 1,
remove the oil filter and discard, safely.
6Remove the air cleaner (or air cleaner
cover), the air cleaner trunking, and the air
box from the carburettor or throttle body (as
applicable), referring to Chapter 4A or 4B, if
necessary. On carburettor models,
disconnect the hot air hose from the exhaust
manifold hot air shroud and the air cleaner,
and remove the hose. On automatic models,
disconnect additional wiring, hoses, etc., from
the carburettor, as described in Chapter 4A.
7Remove the alternator, as described in
Chapter 5.
8On models with power steering, remove the
hydraulic pump, as described in Chapter 10.
9Disconnect the brake servo vacuum hose
from the inlet manifold.
10Disconnect the throttle cable from the
throttle lever and the bracket on the
carburettor or inlet manifold, as applicable.
11On carburettor models, disconnect the
coolant hoses from the automatic choke
housing, and disconnect the wiring from the
automatic choke heater and the choke
pull-down solenoid (see illustrations). Also
disconnect the air box vacuum pipe from the
carburettor.
2A•8SOHC engine procedures
2.3 Crankcase ventilation filter removed
from camshaft cover -
1.6 litre engine

12Disconnect the pressure sensor vacuum
pipe from the carburettor (see illustration).
13Remove the coolant hose(s) from the inlet
manifold and/or throttle body, as applicable.
14Disconnect the fuel hoses from the fuel
pump and vapour separator on carburettor
models or from the fuel pipes at the
right-hand side of the engine compartment on
other models. Be prepared for fuel spillage,
and take adequate fire precautions. Plug the
open ends of the pipes and hoses, to prevent
dirt ingress and further fuel leakage (see
illustrations).
15Disconnect all relevant wiring connections
and plugs, and remove the fuel injection
wiring harness. Pull up on the wiring harness
housing, and compress the wiring plug
retaining clips to release the harness housing
from the fuel injectors (see illustration).16Disconnect the heater coolant hoses from
the coolant gallery at the rear of the cylinder
block.
17Disconnect the wiring from the following
components (where applicable):
a)Starter motor
b)Distributor (note HT lead positions)
c)Oil pressure switch
d)Oil temperature switch
e)TDC sensor
f)Oil level sensor
g)Knock sensor
h)Coolant temperature sensor
i)Temperature gauge sender
18Make a final check to ensure that all
relevant hoses, pipes and wires have been
disconnected, and that they are positioned
clear of the engine.
19Remove the front section of the exhaust
system, as described in Chapter 4C.
20Unbolt and remove the bellhousing cover
plate (see illustration).
21Remove the clutch (if applicable), as
described in Chapter 6. On automatic models,
use chalk or a felt-tip pen to mark the
relationship of the torque converter to the
flexplate before unbolting the torque converter.
Refer to note at the beginning of this Section
and to Chapter 7B for further information.
22Remove the crankshaft pulley. Some
pulleys are secured by four bolts, which must
be unscrewed using an Allen key or hexagon
bit. Unscrew each of the three bolts in turn
and remove them. On other engines, the
pulley is secured by a single bolt, which alsosecures the crankshaft sprocket. On manual
transmission models, if the engine is in the
vehicle, the crankshaft can be prevented from
turning by having an assistant engage first
gear and depress the brake pedal.
Alternatively, the flywheel (or flexplate, on
automatics), ring gear teeth can be jammed,
through the bellhousing cover aperture using
a large screwdriver, or similar tool. Access to
the crankshaft pulley is most easily obtained
through the right-hand wheel arch, after
removing the roadwheel.
23Attach a hoist and lifting gear to the
engine lifting brackets on the cylinder head,
and support the weight of the engine.
24Unscrew and remove two of the three
upper engine-to-transmission bolts,
accessible from the engine compartment,
leaving one fastened for safety.
25Unbolt the right-hand engine mounting
from the body and from the cylinder block,
and withdraw the mounting bracket.
26Unscrew and remove the four lower
engine-to-transmission bolts.
27Support the transmission using a trolley
jack and interposed block of wood. Remove
the last upper transmission bolt.
28Manipulate the engine as necessary to
separate it from the transmission. Note that
the transmission locates on dowels in the
cylinder block.
29Carefully raise the hoist, and lift the
engine from the vehicle, taking care not to
damage any of the surrounding components
in the engine compartment.
SOHC engine procedures 2A•9
7.12 Disconnect the pressure sensor
vacuum pipe from the carburettor -
1.6 litre model
7.20 Removing the transmission
bellhousing cover plate7.15 Removing the fuel injection wiring
harness -
2.0 litre SOHC model7.14B Fuel hose-to-pipe connections at
right-hand side of engine compartment -
2.0 litre SOHC model
7.14A Disconnecting a fuel hose from the
fuel pump - 1.6 litre model
7.11B . . .and disconnect the choke
heater/pull-down solenoid wiring plug -
1.6 litre model7.11A Disconnect the coolant hoses from
the automatic choke housing . . .
2A

30With the engine removed, the
transmission can be supported by placing a
length of wood between the bellhousing and
the front suspension subframe. Once the
wooden support is in place, remove the trolley
jack from under the transmission.
Refitting
Note: New left and right-hand
engine/transmission mounting-to-body bolts
must be used on refitting.
31Use an M10 x 1.25 bottoming tap to clean
the threads in the torque converters threaded
bosses and ensure that new bolts are
available for reassembly, where applicable.
32Support the transmission with a trolley
jack and remove the length of wood from
between the bellhousing and the subframe.
33Support the engine with the hoist and
lifting tackle, and gently lower it into position
in the engine compartment.
34Mate the engine and transmission
together, ensuring that the transmission
locates on the dowels in the cylinder block,
then refit the three upper
engine-to-transmission bolts.
35Tighten all nuts and bolts to their specified
torque wrench settings. When tightening the
torque converter-to-flexplate bolts to their
specified torque wrench settings, a
commercially available adapter will be
required (see illustration).
36If the clutch is still bolted to the flywheel,
ensure that the weight of the transmission is
not allowed to hang on the input shaft as it is
engaged with the clutch friction disc.
37Refit the four lower
engine-to-transmission bolts, but again do not
fully tighten them at this stage.
38Fit the right-hand engine mounting
bracket to the cylinder block, and tighten the
securing bolts to the specified torque.39Manipulate the engine and transmission
as necessary to enable the right-hand engine
mounting-to-body bolts to be fitted, then fit
new bolts and tighten them to the specified
torque.
40Tighten all the engine-to-transmission
bolts to the specified torque, then disconnect
the lifting tackle and hoist from the engine,
and remove the trolley jack from beneath the
transmission.
41Refit the transmission bellhousing cover
plate.
42Refit the clutch, as described in Chapter
6.
43Refit the front section of the exhaust
system, as described in Chapter 4C.
44Refit the crankshaft pulley using a reversal
of the removal procedure described earlier in
paragraph 22, and tighten the securing bolt(s)
to the specified torque.
45Lower the vehicle to the ground.
46Refit all relevant wires, pipes and hoses,
etc., using a reversal of the removal
procedure described earlier.
47Where applicable, refit the power steering
pump, tension the pump drivebelt, and bleed
the hydraulic fluid circuit, as described in
Chapter 10.
48Refit the alternator and tension the
drivebelt, as described in Chapter 5.
49Refit the air cleaner components, referring
to Chapter 4A or 4B, if necessary. On
carburettor models reconnect the hot air hose
to the exhaust manifold hot air shroud.
50Fit a new oil filter (if not already replaced),
and fill the engine with oil, as described in
Chapter 1.
51Refit the radiator and refill the cooling
system, as described in Chapter 3.
52Refit the bonnet as described in Chapter
11.
53Reconnect the battery negative lead.
54Refer to Section 37
8Engine and transmission -
removal, separation,
reconnection and refitting
4
Note: A hoist and lifting tackle will be required
for this operation
Removal
1Proceed as described in Section 7,
paragraphs 1 to 18 inclusive.
2Working in the engine compartment,
remove the gear selector linkage, as
described in Chapters 7A and 7B, as
appropriate.
3On manual transmission models, remove
the retaining clip, then slide the clutch cable
from the release lever, pushing the release
lever back towards the bulkhead if necessary
to allow the cable to be disconnected. On
automatic models disconnect the selector
cable from the actuating lever, then either
unbolt the cable bracket or release the cable
from the bracket. In either case, pull the cablesupport from the bracket on the transmission
casing, then move the cable and secure to
one side out of the way, taking note of its
routing.
4Disconnect the wiring from the reversing
lamp switch, which is located at the front of
the manual transmission casing, above the
left-hand mounting bracket. On automatic
models, disconnect the transmission wiring
by unplugging the five connector plugs from
the various switches, solenoids and sensors.
Release also the wiring from any clips or ties
securing to the vehicle.
5Where applicable, withdraw the automatic
transmission breather hose from under the
battery bracket. Disconnect the oxygen
sensor wiring if fitted.
6Unscrew the securing sleeve, and
disconnect the speedometer cable from the
transmission.
7Unscrew the retaining nut, and disconnect
the earth strap from the transmission
endplate.
8Make a final check to ensure that all
relevant hoses, pipes, wires etc. have been
disconnected, and that they are positioned
clear of the engine and transmission.
9Proceed as described in Section 7,
paragraphs 19 and 22.
10Disconnect the inboard ends of the
driveshafts from the differential, referring to
the relevant paragraphs of Chapter 8. Be
prepared for oil spillage as the driveshafts are
withdrawn, and plug the apertures in the
differential, to prevent further loss of oil and
dirt ingress. Support the driveshafts by
suspending them with wire or string - do not
allow them to hang down under their own
weight.
11Attach a hoist and lifting gear to the
engine lifting brackets on the cylinder head,
and support the weight of the engine.
12Remove the left-hand transmission
mounting completely by unscrewing the two
bolts securing the rubber mounting to the
vehicle, body, and the three bolts securing the
mounting bracket to the transmission (see
illustration).
13Unbolt the right-hand engine mounting
from the body and from the cylinder block,
and withdraw the mounting bracket.
2A•10SOHC engine procedures
8.12 Left-hand transmission mounting
viewed from underside of vehicle7.35 Commercially-available torque
wrench adapter being used to tighten
torque converter bolts
If a tap is not available, cut
two slots into the threads of
one of the old flywheel bolts
and use the bolt to remove
the locking compound from the
threads.

14Working under the vehicle, unscrew and
remove the two nuts securing the
engine/transmission rear mounting to the front
subframe, and the three bolts securing the
mounting bracket to the transmission, then
withdraw the mounting bracket (see
illustrations).
15Carefully swing the engine/transmission
assembly across the engine compartment as
necessary, to allow the assembly to be lifted
vertically from the vehicle by raising the hoist.
Take care not to damage any of the
surrounding components in the engine
compartment.
Separation
16With the engine/transmission assembly
removed, support the assembly on blocks of
wood positioned on a workbench, or failing
that, on a clean area of the workshop floor.
17Clean away any external dirt using
paraffin or a water-soluble solvent and a stiff
brush.
18Unbolt and remove the transmission
bellhousing cover plate.
19Ensure that both engine and transmission
are adequately supported, then unscrew and
remove the engine-to-transmission bolts.
20Carefully withdraw the transmission from
the engine, ensuring that the weight of the
transmission is not allowed to hang on the
input shaft while it is engaged with the clutch
friction disc. Note that the transmission
locates on dowels positioned in the cylinder
block.
21On automatic models unbolt the
transmission bellhousing cover plate (three
bolts), then use chalk or a felt-tip pen to mark
the relationship of the torque converter to the
flexplate before unbolting the torque
converter. Note:If the torque converter is
removed (even partially) from the transmission,
a considerable amount of the fluid inside it will
leak out. To prevent this, when prising the
transmission off its locating dowels and
removing it, be careful to keep the torque
converter pressed firmly into the transmission.
If the transmission is to be removed for some
time, retain the torque converter by bolting a
strip of metal across the bellhousing mating
surface. Applying a spanner to the crankshaft
pulley/sprocket bolt, rotate the crankshaft
until the first bolt appears, then use ascrewdriver or similar to jam the flexplate ring
gear teeth to prevent it from rotating as the
bolt is unscrewed. Unscrew each of the three
bolts in turn and remove them.
Reconnection
22Before beginning the refitting operations,
check that the two original bolts that secured
the left-hand transmission rubber mounting to
the vehicle body rotate freely in their threaded
bores in the body. If necessary, re-cut the
threaded bores using an M10 x 1.25 mm tap.
23Where applicable, if the clutch assembly
has been removed from the flywheel, it will
prove easier to refit after the transmission has
been refitted.
24On automatics, if any fluid was spilled from
the torque converter, be careful to refill it as
much as possible. Wipe clean the converter’s
spigot to prevent damage to the transmission’s
input shaft oil seal as the converter is installed,
and ensure that the converter engages
correctly on the fluid pump shaft.
25If the transmission has been renewed, be
careful to flush clean the radiator fluid cooler
passages. Vauxhall recommend the use of
low-pressure compressed air, but this will
require great care to avoid deforming the
radiator.
26Be very careful to ensure that all
components are scrupulously clean, to avoid
the risk of dirt getting into the system.
27Use an M10 x 1.25 bottoming tap to clean
the threads in the torque converters threaded
bosses and ensure that new bolts are
available for reassembly, where applicable.
28Tighten all nuts and bolts to their specified
torque wrench settings.
29Refer also to Section 7, paragraphs 35
and 36.
30Carefully offer the transmission to the
engine until the bellhousing is located on the
dowels in the cylinder block, then refit the
engine-to-transmission bolts, and tighten
them to the specified torque.
31Refit the transmission bellhousing cover
plate.
Refitting
32Working under the vehicle, refit the rear
engine/transmission mounting to the
transmission, using new locking plates under
the bolt heads, and tighten the bolts to the
specified torque.
33Fit the two bolts securing the engine/
transmission rear mounting to the front
subframe, but do not fully tighten at this stage.
34Fit the right-hand engine mounting
bracket to the cylinder block, and tighten the
securing bolts to the specified torque.
35Fit new right-hand engine
mounting-to-body bolts, but do not fully
tighten them at this stage.
36Fit the left-hand transmission mounting
bracket to the transmission, and tighten the
securing bolts to the specified torque.
37Fit new left-hand transmission
mounting-to-body bolts, and tighten them to
the specified torque.
38Tighten the right-hand engine mounting-
to-body bolts and the engine/transmission
rear mounting-to-front subframe bolts to their
specified torques, then remove the lifting
tackle and hoist from the engine.
39Where applicable, the clutch can now be
fitted, and the transmission input shaft can be
pressed into engagement with the splined hub
of the clutch friction disc, (see Chapter 5).
40Reconnect the inboard ends of the
driveshafts to the differential, with reference
to the relevant paragraphs of Chapter 8, and
using new snap rings.
41Refit the front section of the exhaust
system, as described in Chapter 4C.
42Refit the crankshaft pulley, using a
reversal of the removal procedure described
in Section 7, paragraph 22, and tighten the
securing bolt(s) to the specified torque.
43On automatic models, connect the wires
to the various switches, solenoids and
sensors. Replace the transmission breather
hose and oxygen sensor (if fitted).
44Reconnect the transmission earth strap,
and tighten the securing nut.
45Lower the vehicle to the ground.
46Reconnect the speedometer cable to the
transmission, and tighten the securing sleeve.
47Reconnect the reversing lamp wiring.
48On manual transmission models, refit the
clutch cable to the bracket on the
transmission casing, then reconnect the cable
to the release lever, and adjust the cable as
described in Chapter 6. Ensure that the cable
is routed as noted during removal.
49Refit the gear selector linkage, as
described in Chapter 7A, if applicable.
50Proceed as described in Section 7,
paragraphs 41 to 52 inclusive.
51Top-up the transmission oil level, as
described in Chapters 7A and 7B.
52Adjust the selector cable on completion,
and refill the transmission with fluid (see
above).
53Reconnect the battery negative lead.
54Refer to Section 37
SOHC engine procedures 2A•11
8.14B Rear engine/transmission mounting-
to-transmission bolts (arrowed)8.14A Rear engine/transmission
mounting-to-front subframe nuts
2A
If a tap is not available, cut
two slots into the threads of
one of the old flywheel bolts
and use the bolt to remove
the locking compound from the threads.

9Engine and transmission
mountings - renewal
3
Note: New left and right-hand
engine/transmission mounting-to-body bolts
must be used on refitting
1The engine/transmission assembly is
suspended in the engine compartment on
three mountings, two of which are attached to
the transmission, and one to the engine.
Right-hand mounting
2If not already done, apply the handbrake,
then raise the front of the vehicle, and support
securely on axle stands (see “Jacking and
Vehicle Support”)..
3Attach lifting tackle and a hoist to the
engine lifting brackets on the cylinder head,
and support the weight of the engine.
4Working under the vehicle, unbolt the
engine mounting bracket from the cylinder
block, and unbolt the mounting block from the
body, then withdraw the bracket/mounting
assembly (see illustration).
5Unbolt the mounting block from the
bracket.
6Fit the new mounting block to the bracket,
and tighten the securing bolts to the specified
torque.
7Refit the mounting bracket to the cylinder
block, and tighten the securing bolts to the
specified torque.
8Fit new mounting block-to-body bolts, and
tighten them to the specified torque.
9Disconnect the lifting tackle and hoist from
the engine.
10Lower the vehicle to the ground.
Left-hand mounting
11Proceed as described in paragraphs 2
and 3.
12Working under the vehicle, unbolt the
mounting block from the mounting bracket
and the body (see illustration).13Before fitting the new mounting block,
check that the original engine bolts which
secured the mounting block to the body
rotate freely in their threaded bores in the
body. If necessary, re-cut the threaded bores
using an M10 x 1.25 mm tap.
14Fit the new mounting block to the bracket,
and tighten the securing bolts to the specified
torque.
15Fit new mounting block-to-body bolts,
and tighten them to the specified torque.
16Proceed as described in paragraphs 9
and 10.
Rear mounting
17Proceed as described in paragraphs 2
and 3.
18Working under the vehicle, unbolt the
mounting block from the front subframe and
the mounting bracket.
19Fit the new mounting block to the
subframe and mounting bracket, and tighten
the securing bolts to the specified torque.
20Proceed as described in paragraphs 9
and 10.
10Engine dismantling and
reassembly - general
4
General
1Ideally, the engine should be mounted on a
dismantling stand, but if this is not available,
stand the engine on a strong bench, at a
comfortable working height. Failing this, the
engine will have to be stripped down on the
floor.
2Cleanliness is most important, and if theengine is dirty, it should be cleaned with
paraffin in an upright position.
3Avoid working with the engine directly on a
concrete floor, as grit presents a real source
of trouble.
4If the engine oil appears extremely dirty or
contaminated, avoid inverting the engine until
the sump has been removed. This will prevent
any contaminated “sludge” from entering the
oilways.
5As parts are removed, clean them in a
paraffin bath. Do not immerse parts with
internal oilways in paraffin, as it is difficult to
remove, usually requiring a high pressure
hose. Clean oilways with nylon pipe cleaners.
6It is advisable to have containers available
to hold small items, to prevent loss and
confusion when refitting.
7Always obtain complete sets of gaskets
when the engine is being dismantled. Keep
the old gaskets as they can be used as
patterns to make replacements should new
gaskets not be available.
8Where possible, refit nuts, bolts and
washers to their locations after removal of the
relevant components, as this helps protect
the threads, and will also prove helpful during
reassembly.
9Retain unserviceable components, to
compare them with the new components
supplied.
10Many of the engine components are
secured using socket-headed “Torx” or
“Allen” bolts, and tools will be required to
remove and refit such bolts.
11Read through each relevant Section of
this Chapter carefullybeforebeginning work,
to ensure that any special tools that may be
required are available. Many components
(gaskets, oil seals, and certain bolts) must be
renewed on reassembly; where applicable,
obtain the required new components before
starting work.
12Before beginning a complete strip of the
engine, the following ancillary components
can be removed once the engine has been
removed from the vehicle:
2A•12SOHC engine procedures
9.4 Right-hand engine mounting
1 Mounting block-to-body bolts
2 Mounting bracket-to-cylinder block bolts9.12 Left-hand engine/transmission mounting
1 Mounting block-to-body bolts
2 Mounting block-to-mounting bracket bolts
If a tap is not available, cut
two slots into the threads of
one of the old flywheel bolts
and use the bolt to remove
the locking compound from the threads.