1988 OPEL CALIBRA ad blue

12
Wiper blades
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ins. Champion X-4803
Fuses
Rating:
Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A
Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A
Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 A
Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 A
Torque wrench settingsNm lbf ft
Airbag unit to steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Airbag control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Brackets, passenger airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16
Passenger airbag to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6
Steering to column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Chapter 12
Body electrical systems
Aerial - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Aerial mast, electric - removal and refitting . . . . . . . . . . . . . . . . . . . .48
Airbag - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Airbag contact unit - removal and refitting . . . . . . . . . . . . . . . . . . . . .58
Airbag control unit - removal and refitting . . . . . . . . . . . . . . . . . . . . .61
Airbag unit, drivers side - removal and refitting . . . . . . . . . . . . . . . . .56
Airbag unit, passengers side - removal and refitting . . . . . . . . . . . . .59
Anti-theft alarm - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Anti-theft alarm system components - removal and refitting . . . . . . .54
Bracket, passenger airbag unit - removal and refitting . . . . . . . . . . .60
Brake lamp switch - removal and refitting . . . . . . . . . . . . . . . . . . . . .12
Central door locking components - removal and refitting . . . . . . . . .46
Check control system components - removal and refitting . . . . . . . .21
Cigarette lighter - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .15
Clock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Courtesy lamp switch - removal and refitting . . . . . . . . . . . . . . . . . . .10
Direction indicator/lighting switch - removal and refitting . . . . . . . . . .5
Electric door mirror switch - removal and refitting . . . . . . . . . . . . . . . .8
Electric window components - removal and refitting . . . . . . . . . . . . .44
Electric window controls - programming . . . . . . . . . . . . . . . . . . . . . .45
Electrical fault-finding - general information . . . . . . . . . . . . . . . . . . . . .2
Exterior lamp bulbs - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Facia panel switches - removal and refitting . . . . . . . . . . . . . . . . . . . .7
Front indicator lamp unit - removal and refitting . . . . . . . . . . . . . . . .29
Front foglamp - removal, refitting and adjustment . . . . . . . . . . . . . . .31
Fuses and relays - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . . . .1
Handbrake “on” warning lamp switch - removal and refitting . . . . . .13
Headlamp aim adjustment motor - removal and refitting . . . . . . . . . .26
Headlamp dim-dip system - general, removal and refitting . . . . . . . .28
Headlamp unit - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .25
Headlamp washer fluid non-return valve - removal and refitting . . . .43Headlamp wiper motor - removal and refitting . . . . . . . . . . . . . . . . . .40
Headlamps - alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Heated front seats - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Horn(s) - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Ignition switch and lock cylinder - removal and refitting . . . . . . . . . . .4
Instrument panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . .18
Instrument panel components - removal and refitting . . . . . . . . . . . .19
Interior lamp bulbs - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Interior lamps - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .23
Luggage compartment lamp switch - removal and refitting . . . . . . .11
Number plate lamp - removal and refitting . . . . . . . . . . . . . . . . . . . . .33
Oil pressure warning lamp switch - removal and refitting . . . . . . . . .14
Radio/cassette player - removal and refitting . . . . . . . . . . . . . . . . . . .50
Rear lamp unit - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .32
Reversing lamp switch . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 7A
Side repeater lamp - removal and refitting . . . . . . . . . . . . . . . . . . . . .30
Speakers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Speedometer cable - removal and refitting . . . . . . . . . . . . . . . . . . . .52
Steering wheel (with airbag) - removal and refitting . . . . . . . . . . . . . .57
Sunroof motor - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .51
Sunroof operating switch - removal and refitting . . . . . . . . . . . . . . . . .9
Tailgate wiper motor - removal and refitting . . . . . . . . . . . . . . . . . . . .39
Trip computer components - removal and refitting . . . . . . . . . . . . . .20
Wash/wipe switch - removal and refitting . . . . . . . . . . . . . . . . . . . . . .6
Washer fluid reservoir - removal and refitting . . . . . . . . . . . . . . . . . . .41
Washer nozzles - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .37
Washer pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .42
Windscreen wiper motor and linkage - removal and refitting . . . . . . .38
Wiper arms - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Wiper blades - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Wiring diagrams - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
12•1
Specifications Contents
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321

12•22Body electrical systems
Explanations of abbreviations used in wiring diagrams
ABSAnti-lock braking system
ACAir conditioning
AZVTrailer hitch
ATAutomatic transmission
ATCAutomatic temperature control
BRTrip (on-board) computer
CCCheck control system
CRCCruise control
DDiesel
DSTheft protection
DTTurbo Diesel
DWAAnti-theft warning system
DZMTachometer
EFCElectric folding roof (Convertible)
EKSPinch guard (electric windows)
EMPRadio
EUREuronorm (emission control standard)
engine
EZ + ElPlus ignition system (with self-
diagnosis)
EZVEcotronic
FHElectric windows
GBGreat Britain
HSHeated rear window
HWRear window wiper
HZGHeating
HRLLuggage compartment lampINSInstrument panel
IRLCourtesy lamps
KATCatalytic converter
KBSWiring harness
KVContact breaker distributor
L3.1Bosch Jetronic fuel injection system
LCDLiquid crystal display (LCD)
instruments
LHDLeft-hand drive
4WDFour-wheel-drive
LWRHeadlamp aim adjustment
M1.5Bosch Motronic M1.5 engine
management system
M2.5Bosch Motronic M2.5 engine
management system
MOTMotronic (general)
MTManual gearbox
MULMultec fuel injection system
NNorway
NSFront foglamps
NSLRear foglamps
OELOil level/pressure check system
OPTOptional equipment
PBSLPark and brake shift block
(automatic transmission, selector
lever in position ‘P’)P/NPark/neutral (automatic transmission)
POTPotentiometer
RCRear suspension level control
system
RFSReversing lamps
RHDRight-hand drive
SSweden
SDSunroof
SHHeated seats
SRAHeadlamp washers and wipers
TANKFuel level sender unit
TDTurbo Diesel
TEMPTemperature gauge
TFLDaytime driving lamps
TKSCourtesy lamp (door pillar) switches
TSZITransistorised ignition (inductive-
triggered) system
VGSCarburettor
WEGOdometer frequency/roadspeed
sensor
WHRRear suspension level control
system
WSWarning buzzer
ZVCentral locking
ZYLCylinder
Colour codes
BLBlue
HBLLight blue
BRBrown
GEYellow
GRGrey
GNGreenRTRed
WSWhite
SWBlack
LILilac
VIViolet
Wiring identification
Example: GEWS 1.5
GE -Wire basic colour
WS -Wire tracer colour
1.5 -Wire cross-section in mm
2
Note: Not all items shown are fitted to all models. Refer to Section 62 (Chapter 12) for details of diagram usage.

b)Always keep the ignition and fuel systems
well maintained according to the
manufacturers schedule (see “Routine
maintenance” and the relevant Chapter).
In particular, ensure that the air cleaner
filter element, the fuel filter and the spark
plugs are renewed at the correct intervals.
If the inlet air/fuel mixture is allowed to
become too rich due to neglect, the
unburned surplus will enter and burn in
the catalytic converter, overheating the
element and eventually destroying the
converter.
c)If the engine develops a misfire, do not
drive the vehicle at all (or at least as little
as possible) until the fault is cured. The
misfire will allow unburned fuel to enter
the converter, which will result in its
overheating, as noted above.
d)The engine control indicator (the outline
of an engine with a lightning symbol
superimposed), will light when the ignition
is switched on and the engine is started,
then it will go out. While it may light briefly
while the engine is running, it should go
out again immediately and stays unlit. If it
lights and stays on while the engine is
running, seek the advice of a Vauxhall
dealer as soon as possible. A fault has
occurred in the fuel injection/ignition
system that, apart from increasing fuel
consumption and impairing the engine’s
performance, may damage the catalytic
converter.
e)DO NOT push or tow-start the vehicle.
This will soak the catalytic converter in
unburned fuel causing it to overheat when
the engine does start see (b) above.
f)DO NOT switch off the ignition at high
engine speeds. If the ignition is switched
off at anything above idle speed,
unburned fuel will enter the (very hot)
catalytic converter, with the possible risk
of its igniting on the element and
damaging the converter.
g)DO NOT use fuel or engine oil additives.
These may contain substances harmful to
the catalytic converter.
h)DO NOT continue to use the vehicle if the
engine burns oil to the extent of leaving a
visible trail of blue smoke. The unburned
carbon deposits will clog the converter
passages and reduce its efficiency; in
severe cases the element will overheat.
i)Remember that the catalytic converter
operates at very high temperatures hence
the heat shields on the vehicle’s under-
body and the casing will become hot
enough to ignite combustible materials
that brush against it. DO NOT, therefore,
park the vehicle in dry undergrowth, over
long grass or over piles of dead leaves.
j)Remember that the catalytic converter is
FRAGlLE. Do not strike it with tools during
servicing work. Take great care when
working on the exhaust system. Ensure
that the converter is well clear of any
jacks or other lifting gear used to raise thevehicle. Do not drive the vehicle over
rough ground, road humps, etc., in such a
way as to ground the exhaust system.
k)In some cases, particularly when the
vehicle is new and/or is used for
stop/start driving, a sulphurous smell (like
that of rotten eggs) may be noticed from
the exhaust. This is common to many
catalytic converter-equipped vehicles and
seems to be due to the small amount of
sulphur found in some petrol’s reacting
with hydrogen in the exhaust to produce
hydrogen sulphide (CS) gas. While this
gas is toxic, it is not produced in sufficient
amounts to be a problem. Once the
vehicle has covered a few thousand miles
the problem should disappear. In the
meanwhile a change of driving style or of
the brand of petrol may effect a solution.
l)The catalytic converter, used on a
well-maintained and well-driven vehicle,
should last for between 50 000 and 100
000 miles. From this point on, careful
checks should be made at all specified
service intervals of the CO level to ensure
that the converter is still operating
efficiently. If the converter is no longer
effective it must be renewed.
11Carbon canister - removal
and refitting
3
Removal
1Apply the handbrake, then jack up the front
of the vehicle, and support securely on axle
stands placed under the body side members
(see “Jacking and Vehicle Support”).
2Remove the front right hand wheel and
wheel arch liner.
3Note the hose and pipe connections to the
canister, or label them, to ensure that they are
reconnected to their original unions, then
disconnect them (see illustration). Unscrew
the two nuts securing the canister mounting
bracket to the vehicle body.
Refitting
4Refitting is a reversal of removal, however
ensure correct fitment of hose and pipes.
12Oxygen sensor (catalytic
converter models) - removal
and refitting
3
Note: This sensor is also known as a Lambda
sensor.
Removal
1Disconnect the battery negative lead.
2Disconnect the oxygen sensor wiring plug,
which is located behind the coolant expansion
tank.
3Apply the handbrake, then jack up the front
of the vehicle, and support securely on axle
stands placed under the body side members.
4On DOHC models, remove the engine
undershield, as described in Chapter 11.
5On models fitted with Multec injection
system, the sensor is screwed into the
exhaust manifold. Trace the wiring from the
sensor itself to the connector (either clipped
to the radiator cooling fan shroud or behind
the coolant expansion tank). Release it from
any clips or ties; disconnect the wiring before
unscrewing the sensor.
6On other models, unscrew the oxygen
sensor from the front section of the exhaust
system (see illustration). It is advisable to
wear gloves, as the exhaust system will be
extremely hot.
7Withdraw the oxygen sensor and its wiring,
taking care not to burn the wiring on the
exhaust system. If the sensor is to be re-used,
take care that the sealing ring is not lost, and
that the sensor is not dropped.
Refitting
8If a new sensor is being fitted, it will be
supplied with the threads coated in a special
grease to prevent it seizing in the exhaust
system.
9If the original sensor is being refitted,
ensure that the screw thread is clean. Coat
the thread with a lithium based copper grease
(i.e. Vauxhall Part No. 90295397).
10Refitting is a reversal of removal. Check
the exhaust system for leakage when the
engine is re-started.
4C•4Fuel and exhaust systems - exhaust and emissions
12.6 Oxygen sensor location in front
section of exhaust system - DOHC models
11.3 Charcoal canister
A Vent to atmosphere
B Vapour feed hose from filler pipe
C Vapour exhaust hose to inlet tract
D Control valve vacuum pipe from
throttle body

Compression ratio
14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.4 : 1
16 SV, X16 SZ, 18 SV and 20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . .10.0 : 1
C16 NZ, C16 NZ2, C18 NZ, 20 NE and C20 NE . . . . . . . . . . . . . . . . .9.2 : 1
Maximum power:
14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 kW (75 bhp) at 5600 rpm
16 SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 kW (82 bhp) at 5400 rpm
X16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 kW (71 bhp) at 5000 rpm
C16 NZ and C16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 kW (75 bhp) at 5200 rpm
18 SV and C18 NZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 kW (90 bhp) at 5400 rpm
20 NE and C20 NE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 kW (116 bhp) at 5200 rpm
20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 kW (129 bhp) at 5600 rpm
Maximum torque:
14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Nm at 3000 rpm
X16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Nm at 2800 rpm
16 SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Nm at 2600 rpm
C16 NZ and C16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 Nm at 2800 rpm
18 SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148 Nm at 2800 rpm
C18 NZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145 Nm at 3000 rpm
20 NE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175 Nm at 2600 rpm
20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180 Nm at 4600 rpm
C20 NE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170 Nm at 2600 rpm
Firing order:
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3-4-2 (No 1 cylinder at timing belt end)
Cylinder block:
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cast iron
Maximum permissible bore out-of round . . . . . . . . . . . . . . . . . . . . . .0.013 mm
Maximum permissible bore taper . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.013 mm
Maximum permissible rebore oversize . . . . . . . . . . . . . . . . . . . . . . . .0.5 mm
Crankshaft and bearings
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Main bearing journal diameter (mm):
14 NV, 16 SV, C16 NZ and X16 SZ
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54.980 to 54.997
0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54.730 to 54.747
0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54.482 to 54.495
C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57.974 to 57.995
0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57.732 to 57.745
0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57.482 to 57.495
Main bearing shell colour codes:Bearing cap shellsCylinder block shells
14 NV, 16 SV, C16 NZ and X16 SZ
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BrownGreen
0.25 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brown/blueGreen/blue
0.50 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brown/whiteGreen/white
C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brown/green/white
0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brown/blue and Green/blue
0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brown/white and Green/white
Centre (thrust) main bearing journal width (mm):
14 NV, 16 SV, C16 NZ and X 16 SZ
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26.000 to 26.052
0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26.200 to 26.252
0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26.400 to 26.452
C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.950 to 26.002
0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26.150 to 26.202
0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26.350 to 26.402
Big-end bearing journal diameter (mm):
14 NV, 16 SV, C16 NZ and X16 SZ
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.971 to 42.987
0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.721 to 42.737
0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.471 to 42.487
C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48.970 to 48.988
0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48.720 to 48.738
0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48.470 to 48.488
2A•2SOHC engine procedures

Crankshaft and bearings (continued)
Big-end bearing shell colour codes (all models):
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .None
0.25 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue
0.50 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .White
Main and big-end bearing journal out-of-round (all models) . . . . . . . . .0.04 mm maximum
Main bearing permissible movement (mm):
14 NV, 16 SV, C16 NZ and X16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . .0.017 to 0.047
C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . . . .0.015 to 0.040
Big-end bearing permissible movement (mm):
14 NV, 16 SV, C16 NZ and X16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . .0.019 to 0.071
C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . . . .0.006 to 0.031
Crankshaft endfloat (mm):
14 NV, 16 SV, C16 NZ and X16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . .0.1 to 0.2
C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . . . .0.050 to 0.152
Connecting rod endfloat (mm) (all models) . . . . . . . . . . . . . . . . . . . . . . .0.07 to 0.24
Piston and cylinder bores (Ø in mm)Bore diameterPiston diaID mark
14 NV:
Production size 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77.5677.546
77.5777.557
77.5877.568
Production size 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77.5977.5799
77.6077.5800
77.6177.5901
77.6277.6002
0.5 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78.0778.057 + 0.5
16 SV, C16 NZ and X16 SZ:
Production size 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78.9578.935
78.9678.946
78.9778.957
78.9878.968
Production size 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78.9978.9799
79.0078.9800
79.0178.9901
79.0279.0002
Production size 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.0379.0103
79.0479.0204
79.0579.0305
79.0679.0406
Production size 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.0779.0507
79.0879.0608
79.0979.0709
79.1079.081
0.5 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.4879.457 + 0.5
C16 NZ2:
Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.98n/a98
79.90n/a99
80.00n/a00
80.01n/a01
80.02n/a02
18 SV and C18 NZ:
Production size 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.78 mm84.76 mm8
Production size 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.79 mm84.77 mm99
84.80 mm84.78 mm00
84.81 mm84.79 mm01
84.82 mm84.80 mm02
0.5 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85.27 mm85.25 mm7 + 0.5
20 NE, C20 NE and 20 SEH:
Production size 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85.98 mm85.96 mm8
Production size 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85.99 mm85.97 mm99
86.00 mm85.98 mm00
86.01 mm85.99 mm01
86.02 mm86.00 mm02
0.5 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86.47 mm86.45 mm7 + 0.5
Piston clearance in bore (mm) (all models) . . . . . . . . . . . . . . . . . . . . . . .0.02 to 0.04
SOHC engine procedures 2A•3
2A

31Refit the previously removed
components, referring to the relevant
Sections of this Chapter.
35Crankshaft and bearings -
examination
4
Examination
1Examine the crankpin and main journal
surfaces for signs of scoring or scratches, and
check the ovality and taper of the crankpins
and main journals. If the bearing surface
dimensions do not fall within the tolerance
ranges given in the Specifications at the
beginning of this Chapter, the crankpins
and/or main journals will have to be reground.
2Big-end and crankpin wear is accompanied
by distinct metallic knocking, particularly
noticeable when the engine is pulling from low
revs, and some loss of oil pressure.
3Main bearing and main journal wear is
accompanied by severe engine vibration rumble
- getting progressively worse as engine rev’s
increase - and again by loss of oil pressure.
4If the crankshaft requires regrinding, take it
to an engine reconditioning specialist, who
will machine it for you and supply the correct
undersize bearing shells.
5Inspect the big-end and main bearing shells
for signs of general wear, scoring, pitting and
scratches. The bearings should be matt grey
in colour. With leadindium bearings, should a
trace of copper colour be noticed, the
bearings are badly worn, as the lead bearing
material has worn away to expose the indium
underlay. Renew the bearings if they are in
this condition, or if there are any signs of
scoring or pitting. You are strongly advised
to renew the bearings - regardless of their
condition at time of major overhaul.
Refitting used bearings is a false economy.
6The undersizes available are designed to
correspond with crankshaft regrind sizes. Thebearings are in fact, slightly more than the
stated undersize, as running clearances have
been allowed for during their manufacture.
7Main and big-end bearing shells can be
identified as to size by the marking on the
back of the shell. Standard size shell bearings
are marked STD or .00, undersize shells are
marked with the undersize such as 0.020 u/s.
This marking method applies only to
replacement bearing shells, and not to those
used during production.
8An accurate method of determining bearing
wear is by using a Plastigage. The crankshaft
is located in the main bearings (and, if
necessary, the big-end bearings), and the
Plastigage filament is located across the
journal. Vauxhall recommend that the
crankshaft journal and bearing shells are
lightly lubricated, to prevent the Plastigage
from tearing as the bearing cap is removed.
The bearing cap should be fitted, and the
bolts tightened to the specified torque. The
cap is then removed, and the width of the
filament is checked against a scale that shows
the bearing running clearance. The clearance
should be compared with that given in the
Specifications.
9Where applicable, check the teeth of the
crankshaft TDC sensor wheel for damage
(see illustration). If evident, the crankshaft
must be renewed.
10Similarly, check the condition of the pins
in the front crankshaft balance weight, which
serve as detect points for the plug-in
diagnostic sensor used by Vauxhall dealers
(see illustration).
36Cylinder block and bores -
examination and renovation
4
Examination
1Examine the cylinder bores for taper,
ovality, scoring and scratches. Start bycarefully examining the top of the cylinder
bores. If they are at all worn, a very slight
ridge will be found on the thrust side. This
marks the top of the piston ring travel. The
owner will have a good indication of the bore
wear before dismantling the engine, or
removing the cylinder head. Excessive oil
consumption, accompanied by blue smoke
from the exhaust, is a sure sign of worn
cylinder bores and piston rings.
2Measure the bore diameter across the
block, and just below any ridge. This can be
done with an internal micrometer or a dial
gauge. Compare this with the diameter of the
bottom of the bore, which is not subject to
wear. If no measuring instruments are
available, use a piston from which the rings
have been removed, and measure the gap
between it and the cylinder wall with a feeler
blade. Refer to the Specifications. If the
cylinder wear exceeds the permitted
tolerances, then the cylinders will need
reboring, in which case note the following
points:
a)Piston and cylinder bores are closely
matched in production. The actual
diameter of the piston is indicated by
numbers on its crown; the same numbers
stamped on the crankcase indicate the
bore diameter
b)After reboring has taken place, the
cylinder bores should be measured
accurately and oversize pistons selected
from the grades available to give the
specified piston-to-bore clearance
c)For grading purposes, the piston diameter
is measured across the bottom of the skirt
3If the wear is marginal and within the
tolerances given, new special piston rings can
be fitted to offset the wear.
4Thoroughly examine the crankcase and
cylinder block for cracks and damage, and
use a piece of wire to probe all oilways and
waterways to ensure that they are
unobstructed.
SOHC engine procedures 2A•33
35.10 Check the condition of the pins (arrowed) in the front
crankshaft balance weight - 2.0 litre SOHC engine35.9 Check the condition of the TDC sensor wheel teeth at the
front of the crankshaft - 2.0 litre SOHC engine
2A

MOTTest Checks REF•11
MExamine the handbrake mechanism,
checking for frayed or broken cables,
excessive corrosion, or wear or insecurity of
the linkage. Check that the mechanism works
on each relevant wheel, and releases fully,
without binding.
MIt is not possible to test brake efficiency
without special equipment, but a road test can
be carried out later to check that the vehicle
pulls up in a straight line.
Fuel and exhaust systems
MInspect the fuel tank (including the filler
cap), fuel pipes, hoses and unions. All
components must be secure and free from
leaks.
MExamine the exhaust system over its entire
length, checking for any damaged, broken or
missing mountings, security of the retaining
clamps and rust or corrosion.
Wheels and tyres
MExamine the sidewalls and tread area of
each tyre in turn. Check for cuts, tears, lumps,
bulges, separation of the tread, and exposure
of the ply or cord due to wear or damage.
Check that the tyre bead is correctly seated
on the wheel rim, that the valve is sound andproperly seated, and that the wheel is not
distorted or damaged.
MCheck that the tyres are of the correct size
for the vehicle, that they are of the same size
and type on each axle, and that the pressures
are correct.
MCheck the tyre tread depth. The legal
minimum at the time of writing is 1.6 mm over
at least three-quarters of the tread width.
Abnormal tread wear may indicate incorrect
front wheel alignment.
Body corrosion
MCheck the condition of the entire vehicle
structure for signs of corrosion in load-bearing
areas. (These include chassis box sections,
side sills, cross-members, pillars, and all
suspension, steering, braking system and
seat belt mountings and anchorages.) Any
corrosion which has seriously reduced the
thickness of a load-bearing area is likely to
cause the vehicle to fail. In this case
professional repairs are likely to be needed.
MDamage or corrosion which causes sharp
or otherwise dangerous edges to be exposed
will also cause the vehicle to fail.
Petrol models
MHave the engine at normal operating
temperature, and make sure that it is in good
tune (ignition system in good order, air filter
element clean, etc).
MBefore any measurements are carried out,
raise the engine speed to around 2500 rpm,
and hold it at this speed for 20 seconds. Allowthe engine speed to return to idle, and watch
for smoke emissions from the exhaust
tailpipe. If the idle speed is obviously much
too high, or if dense blue or clearly-visible
black smoke comes from the tailpipe for more
than 5 seconds, the vehicle will fail. As a rule
of thumb, blue smoke signifies oil being burnt
(engine wear) while black smoke signifies
unburnt fuel (dirty air cleaner element, or other
carburettor or fuel system fault).
MAn exhaust gas analyser capable of
measuring carbon monoxide (CO) and
hydrocarbons (HC) is now needed. If such an
instrument cannot be hired or borrowed, a
local garage may agree to perform the check
for a small fee.
CO emissions (mixture)
MAt the time of writing, the maximum CO
level at idle is 3.5% for vehicles first used after
August 1986 and 4.5% for older vehicles.
From January 1996 a much tighter limit
(around 0.5%) applies to catalyst-equipped
vehicles first used from August 1992. If the
CO level cannot be reduced far enough to
pass the test (and the fuel and ignition
systems are otherwise in good condition) then
the carburettor is badly worn, or there is some
problem in the fuel injection system or
catalytic converter (as applicable).
HC emissionsMWith the CO emissions within limits, HC
emissions must be no more than 1200 ppm
(parts per million). If the vehicle fails this test
at idle, it can be re-tested at around 2000 rpm;
if the HC level is then 1200 ppm or less, this
counts as a pass.
MExcessive HC emissions can be caused by
oil being burnt, but they are more likely to be
due to unburnt fuel.
Diesel models
MThe only emission test applicable to Diesel
engines is the measuring of exhaust smoke
density. The test involves accelerating the
engine several times to its maximum
unloaded speed.
Note: It is of the utmost importance that the
engine timing belt is in good condition before
the test is carried out.
M
Excessive smoke can be caused by a dirty
air cleaner element. Otherwise, professional
advice may be needed to find the cause.
4Checks carried out on
YOUR VEHICLE’S EXHAUST
EMISSION SYSTEM
REF