1988 OPEL CALIBRA radio

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

1General information and
precautions
The electrical system is of 12-volt negative
earth type. Power for the lights and all
electrical accessories is supplied by a
lead/acid type battery, which is charged by
the alternator.
This Chapter covers repair and service
procedures for the various electrical
components not associated with engine.
Information on the battery, alternator and
starter motor can be found in Chapter 5.
It should be noted that, before working on
any component in the electrical system, the
battery negative terminal should first be
disconnected, to prevent the possibility of
electrical short-circuits and/or fires.
Whenever the occasion arises, carefully
check the routing of the wiring harness,
ensuring that it is correctly secured by the
clips or ties provided so that it cannot chafe
against other components. Carefully check
points such as the clutch cable bracket,
clutch housing and harness support bracket,
the inlet manifold, the horn mounting bracket,
the starter motor terminals, and the rear
bumper and number plate lamp.
If evidence is found of the harness having
chafed against other components, repair the
damage and ensure that the harness is
secured or protected so that the problem
cannot occur again.
2Electrical fault-finding -
general information
Note:Refer to the precautions given in “Safety
first!” (at the beginning of this manual) and to
Section 1 of this Chapter before starting work.
The following tests relate to testing of the main
electrical circuits, and should not be used to
test delicate electronic circuits (such as anti-
lock braking systems), particularly where an
electronic control module is used.
A typical electrical circuit consists of an
electrical component, any switches, relays,
motors, fuses, fusible links or circuit breakers
related to that component, and the wiring and
connectors that link the component to boththe battery and the chassis. To help to
pinpoint a problem in an electrical circuit,
wiring diagrams are included at the end of this
Chapter.
Before attempting to diagnose an electrical
fault, first study the appropriate wiring
diagram, to obtain a complete understanding
of the components included in the particular
circuit concerned. The possible sources of a
fault can be narrowed down by noting
whether other components related to the
circuit are operating properly. If several
components or circuits fail at one time, the
problem is likely to be related to a shared fuse
or earth connection.
Electrical problems usually stem from
simple causes, such as loose or corroded
connections, a faulty earth connection, a
blown fuse, a melted fusible link, or a faulty
relay (refer to Section 3 for details of testing
relays). Visually inspect the condition of all
fuses, wires and connections in a problem
circuit before testing the components. Use
the wiring diagrams to determine which
terminal connections will need to be checked,
to pinpoint the trouble-spot.
The basic tools required for electrical fault-
finding include the following:
a)a circuit tester or voltmeter (a 12-volt bulb
with a set of test leads can also be used
for certain tests).
b)a self-powered test light (sometimes
known as a continuity tester).
c)an ohmmeter (to measure resistance).
d)a battery.
e)a set of test leads.
f)a jumper wire, preferably with a circuit
breaker or fuse incorporated, which can
be used to bypass suspect wires or
electrical components.
Before attempting to locate a problem with
test instruments, use the wiring diagram to
determine where to make the connections.
To find the source of an intermittent wiring
fault (usually due to a poor or dirty
connection, or damaged wiring insulation), a
“wiggle” test can be performed on the wiring.
This involves wiggling the wiring by hand, to
see if the fault occurs as the wiring is moved.
It should be possible to narrow down the
source of the fault to a particular section of
wiring. This method of testing can be used in
conjunction with any of the tests described in
the following sub-Sections.
Apart from problems due to poor
connections, two basic types of fault can
occur in an electrical circuit - open-circuit, or
short-circuit.
Open-circuit faults are caused by a break
somewhere in the circuit, which prevents
current from flowing. An open-circuit fault will
prevent a component from working, but will
not cause the relevant circuit fuse to blow.
Short-circuit faults are caused by a “short”
somewhere in the circuit, which allows the
current flowing in the circuit to “escape” along
an alternative route, usually to earth. Short-
circuit faults are normally caused by abreakdown in wiring insulation, which allows a
feed wire to touch either another wire, or an
earthed component such as the bodyshell. A
short-circuit fault will normally cause the
relevant circuit fuse to blow.
Finding an open-circuit
To check for an open-circuit, connect one
lead of a circuit tester or voltmeter to either
the negative battery terminal or a known good
earth.
Connect the other lead to a connector in
the circuit being tested, preferably nearest to
the battery or fuse.
Switch on the circuit, remembering that
some circuits are live only when the ignition
switch is moved to a particular position.
If voltage is present (indicated either by the
tester bulb lighting or a voltmeter reading, as
applicable), this means that the section of the
circuit between the relevant connector and
the battery is problem-free.
Continue to check the remainder of the
circuit in the same fashion.
When a point is reached at which no
voltage is present, the problem must lie
between that point and the previous test point
with voltage. Most problems can be traced to
a broken, corroded or loose connection.
Finding a short-circuit
To check for a short-circuit, first disconnect
the load(s) from the circuit (loads are the
components that draw current from a circuit,
such as bulbs, motors, heating elements, etc.).
Remove the relevant fuse from the circuit,
and connect a circuit tester or voltmeter to the
fuse connections.
Switch on the circuit, remembering that
some circuits are live only when the ignition
switch is moved to a particular position.
If voltage is present (indicated either by the
tester bulb lighting or a voltmeter reading, as
applicable), this means that there is a short-
circuit.
If no voltage is present, but the fuse still
blows with the load(s) connected, this indicates
an internal fault in the load(s).
Finding an earth fault
The battery negative terminal is connected
to “earth” (the metal of the
engine/transmission and the car body), and
most systems are wired so that they only
receive a positive feed. The current returning
through the metal of the car body. This means
that the component mounting and the body
form part of that circuit. Loose or corroded
mountings can therefore cause a range of
electrical faults, ranging from total failure of a
circuit, to a puzzling partial fault. In particular,
lights may shine dimly (especially when
another circuit sharing the same earth point is
in operation). Motors (e.g. wiper motors or the
radiator cooling fan motor) may run slowly,
and the operation of one circuit may have an
affect on another. Note that on many vehicles,
earth straps are used between certain
components, such as the engine/transmission
and the body, usually where there is no metal-
12•2Body electrical systems
Warning: Before carrying out
any work on the electrical
system, read through the
precautions given in “Safety
first!” at the beginning of this manual, and
in Chapter 5.
Caution:If the radio/cassette player fitted
to the vehicle is one with an anti-theft
security code, as the standard unit is, refer
to “Radio/cassette player anti-theft system
- precaution”in the Reference Section of
this manual before disconnecting the
battery.

22Unscrew the two screws securing the
motor to the mounting bracket, then
manipulate the motor to disconnect the lock
operating rod. Withdraw the motor.
Refitting
23Refitting is a reversal of removal.
47Aerial - removal and refitting
3
Removal
1On models with an electric aerial,
disconnect the battery negative lead.
2Remove the left-hand rear quarter trim
panel, as described in Chapter 11.
3Remove the screw securing the earth
lead(s) to the body panel (see illustration).
4Remove the screw securing the aerial
bracket to the body panel, then ensure that
the aerial is fully retracted, and pull it through
the grommet in the bodywork into the luggage
compartment. Disconnect the wiring plug on
models with an electric aerial, and disconnect
the aerial lead (see illustrations).
Refitting
5Refitting is a reversal of removal, but ensure
that the rubber grommet is correctly seated in
the bodywork.
48Aerial mast, electric -
removal and refitting
3
Removal
1The mast on “factory fitted”, fully automatic
electric aerials, can be replaced separately.
2Extend the aerial as far as possible, by
switching on the radio.
3Unscrew the mounting nut.
4Pull the sprung sleeve upwards and clear of
its base.
5The assembly can now be removed from
the clutch mechanism, by pulling the
assembly upwards.
Refitting
6Insert the ball end of the mast assembly
into the base.7Carefully push the mast assembly down as
far as possible, until it engages into the clutch
mechanism (see illustration).
8Switch the radio off to retract the aerial.
9If the aerial does not fully retract into its
base, guide the remaining mast into the base
by hand.
10Insert the sprung sleeve into the base and
tighten the mounting nut.
11Check the aerial works properly by turning
the radio on and off a few times.
49Speakers - removal and
refitting
2
1Disconnect the battery negative lead.
Facia-mounted speaker
Removal
2Using a thin-bladed screwdriver, carefully
prise the speaker from the top of the facia
panel. Take care not to damage the facia trim
(see illustration)
3Disconnect the wiring and withdraw the
speaker. If desired, the plastic trim panel can
be unclipped from the top of the speaker.
Refitting
4Refitting is a reversal of removal.
Front door-mounted speaker
Removal
5Remove the door inner trim panel, as
described in Chapter 11.
Body electrical systems 12•17
47.4A Unscrewing the radio aerial bracket
securing screws - electric aerial
49.2 Removing a facia-mounted speaker
(viewed through windscreen)48.7 Push the mast assembly down, until it
engages in the clutch mechanism47.4B Disconnecting the aerial lead -
electric aerial
47.3 Radio aerial earth lead securing
screw (arrowed) - electric aerial46.21 Disconnecting the wiring plug from
the fuel filler flap operating motor -
Hatchback model
12
Always clean the aerial mast
in an upwards direction. This
should minimise dirt being
forced down, into the mast
sections.
Always clean the aerial mast
in an upwards direction. This
should minimise dirt being
forced down, into the mast
sections.

6Remove the three securing screws, and
withdraw the speaker from the door.
Disconnect the wiring plug (see illustration).
Refitting
7Refitting is a reversal of removal, but note
that the speaker can only be fitted one way
up, so that the lug on the bottom of the
speaker rim engages with the corresponding
hole in the door skin.
Rear speaker -Hatchback
models
Removal
8Remove the upper rear quarter trim panel,
as described in Chapter 11.
9Remove the four securing screws, and
withdraw the speaker.
Refitting
10Refitting is a reversal of removal.
Rear speaker Saloon models
Removal
11Carefully prise the trim cover from the
parcel shelf, to expose the speaker.
12Remove the four securing screws,
withdraw the speaker and disconnect the
wiring.
Refitting
13Refitting is a reversal of removal.
50Radio/cassette player -
removal and refitting
2
Removal
1All the radio/cassette players fitted to the
Cavalier range have DIN standard fixings. Two
special tools, obtainable from in-car
entertainment specialists, are required for
removal.
2Disconnect the battery negative lead.
3Unscrew the four grub screws from the
corners of the radio cassette player, using an
Allen key or hexagon bit (see illustration).
4Insert the tools into the holes exposed by
removal of the grub screws, and push them
until they snap into place. Pull the tools
outwards to release the unit (see illustration).
5Pull the unit forwards, and withdraw it from
the facia.
Refitting
6To refit the radio/cassette player, simply
push the unit into the facia until the retaining
lugs snap into place, then refit the grub
screws.
51Sunroof motor - removal and
refitting
3
Removal
1Ensure that the sunroof is fully closed.
2Disconnect the battery negative lead.
3Prise the courtesy lamp from the roof trim
panel, and disconnect the wiring.
4Remove the two trim panel securing
screws, and withdraw the trim panel from the
roof, disconnecting the wiring from the
sunroof operating switch.
5Disconnect the wiring plugs from the motor.
6Unscrew the securing nut, and withdraw
the motor assembly.
Refitting
7Refitting is a reversal of removal.
52Speedometer cable - removal
and refitting
3
Removal
1Remove the instrument panel, as described
in Section 18.
2Pull the cable through the bulkhead into the
engine compartment, noting its routing.
3Working in the engine compartment,
unscrew the securing sleeve and disconnect
the speedometer cable from the top of the
transmission (see illustration).
4The cable can now be withdrawn from the
vehicle, noting its routing so that it can be
refitted in the same position.
Refitting
5Refitting is a reversal of removal, ensuring
that the cable is correctly routed. Make sure
that the cable is not kinked or twisted
between the instrument panel and the
bulkhead as the instrument panel is refitted.
Note that the cable should be routed to the
right of the steering column support bracket.
12•18Body electrical systems
49.6 Withdrawing a front door-mounted
speaker - wiring plug arrowed
50.4 . . . and withdraw the radio/cassette player using the special
tools52.3 Speedometer cable securing sleeve (arrowed) at
transmission - SOHC model
50.3 Unscrew the grub screws . . .

53Anti-theft alarm - general
1Certain models are fitted with an anti-theft
alarm as standard equipment.
2The alarm system is triggered by door,
bonnet and boot lid/tailgate mounted
switches, and by ultrasonic sensors mounted
inside the passenger compartment (see
illustration).
3The alarm features a self-diagnostic
function, and any faults should be referred to
a Vauxhall dealer, who will have access to the
necessary specialist diagnostic equipment.
54Anti-theft alarm system
components -removal and
refitting
4
Control unit
Removal
1Disconnect the battery negative lead.
2Remove the driver’s side lower facia panel
as described in Chapter 11.
3If necessary, remove the footwell side trim
panel as described in Chapter 11.4Undo the control unit retaining bolt,
disconnect the wiring plug and remove the
unit from its location.
Refitting
5Refitting is a reversal of removal.
Ultrasonic sensor
6Disconnect the battery negative lead.
7Remove the centre body pillar trim panel as
described in Chapter 11.
8Carefully release the ultrasonic sensor trim
panel and withdraw it downwards.
9Release the ultrasonic sensor from its
location, disconnect the wiring plug and
remove the unit from the car.
Refitting
10Refitting is a reversal of removal.
Bonnet contact unit
Removal
11Disconnect the battery negative lead.
12Using a screwdriver, depress the catch at
the base of the contact unit and withdraw the
contact from its location.
13Disconnect the contact wiring and remove
the unit.
Refitting
14Refitting is a reversal of removal.
55Airbag - general
All 1993 Cavalier models are available with
an airbag that is designed to prevent serious
chest and head injuries to the driver during an
accident. A similar bag for the front seat
passenger is also available on certain models.
Sensors in the centre of the car measure the
vehicle deceleration rate and pass these
signals to a microprocessor. This unit
analyses the sensor data and compares the
information with pre-programmed values
stored in its memory, triggering the airbag if
the deceleration is severe. The airbag is
inflated in 50 milliseconds by a gas generator
that forces the bag out of the module cover in
the centre of the steering wheel.
No repairs are possible on the airbag unit or
its associated parts. The contents of the
following Sections are confined to removal
and refitting of the airbag, purely for access to
other non-related components.
Should a fault be suspected on the airbag
unit, indicated by the warning light on the
instrument panel, or if the car has been
involved in an accident, however minor,
consult a Vauxhall dealer immediately. Do not
attempt to dismantle any of the airbag
components or carry out any work
whatsoever, other than the procedures
described in the following Sections.
On vehicles fitted with a passenger side
airbag, do notfit accessories in the airbag
zone. Items like telephones, cassette storage
boxes, additional mirrors, etc., can be ripped off
and cause serious injury, if the airbag inflates.
Body electrical systems 12•19
12
53.2 Anti-theft alarm system component
locations
(Calibra model shown - component locations
identical on Cavalier)
1 Control unit
2 Ultrasonic sensor
with LED
3 Ultrasonic sensor
with probe4 Radio contact
5 Bonnet contact unit
6 Horn
7 Relay
Warning: Before starting any
work on airbag or related
components, disconnect the
battery. Cover the battery’s
terminals and wait a minimum of 1
minutes as a precaution against
accidental firing of the airbag unit. This
period ensures that any stored energy in
the back-up capacitor is dissipated.
Handle the airbag unit with extreme care
as a precaution against personal injury,
and always hold it with the cover facing
away from the body. If in doubt
concerning any proposed work involving
the airbag unit or its control circuitry,
consult a Vauxhall dealer or other
qualified specialist.

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.

Wiring diagrams 12•23
12
Key to wiring diagrams for 1989 models
E1Sidelamp - left406
E2Tail lamp -left302, 380, 407
E3Number plate lamp413
E4Side lamp right409
E5Tail lamp right382, 410
E6Engine compartment lamp416
E7Headlamp main beam - left437
E8Headlampmain beam - right438
E9Headlampdipped beam - left384, 439
E10Headlamp dipped beam - right386, 440
E11Instrument illumination lamps328 to 329
E12Gear selector lever illumination lamp (automatics)799
E13Luggage compartment lamp485
E14Courtesy lamp487
E15Glovebox lamp599
E16Cigarette lighter illumination lamp598
E17Reversing lamp - left497
E18Reversing lamp - right498
E19Heated rearwindow572
E20Front foglamp -left448
E21Front foglamp - right447
E24Rear foglamp - left454
E25Seat heater -front left575
E30Seat heater - front right579
E32Clock illumination lamp552
E38Trip computer illumination lamp539
E39Rear foglamp - right455
E41Courtesy lamp (with delay)488 to 490
E50Kerb lamp - driver’s door635
E51Kerb lamp - passenger door653
F1 toFuse (in fusebox)Various
F30
F32Fuse - mixture preheating (not UK)232
F33Fuse - electronic carburettor (not UK)201
F34Fuse (in relay box, engine compartment)834
F35Voltage stabiliser302
F36Fuse - fuel filter heating (Diesel models)866
G1Battery101
G2Alternator110
G3Battery - Diesel models846
G6Alternator - Diesel models850 to 852
H2Horn591
H3Direction indicator warning lamp318, 320
H4Oil pressure warning lamp310
H5Brake fluid level warning lamp313
H6Hazard warning flasher warning lamp470
H7Alternator charge warning lamp310
H8Headlamp main beam warning lamp322
H9Brake lamp - left388
H10Brake lamp - right390H11Direction indicator lamp - front left472
H12Direction indicatorlamp - rear left473
H13Direction indicator lamp - front right481
H14Direction indicator lamp - rear right482
H16Glow plug warning lamp (Diesel models)323
H17Trailer direction indicator warning lamp321
H18Horns (twin)592, 593
H19Headlamps-on warning buzzer494, 495
H21Handbrake-on warning lamp315
H23Radio/cassette player585, 586
H25Door mirror heater warning lamp678
H26ABS warning lamp319
H30Engine fault warning lamp324
H33Direction indicator side repeater lamp - left476
H34Direction indicator side repeater lamp - right478
H42Automatic transmission warning lamp325
H45Four-wheel-drive warning lamp327
H46Catalytic converter temperature warning lamp (not UK)329
K1Relay-heated rear window571 to 572
K5Relay - front foglamps448 to 450
K6Relay - air conditioning (not UK)801 to 802
K7Relay - air conditioning blower (not UK)808 to 809
K8Relay - intermittent windscreen wipe503 to 506
K9Relay - headlamp wash522 to 523
K10Relay - direction indicator/hazard warning flashers467 to 469
K20HEI ignition control unit122 to 124
K25Relay - glow plugs (Diesel models)856 to 859
K30Relay - intermittent rear window wipe515 to 517
K35Relay - door mirror heater683 to 685
K37Central locking control unit606 to 612
K45Relay - mixture preheating (not UK)231 to 232
K47Relay - surge arrester (ABS)702 to 703
K50ABS control unit707 to 721
K51Relay - cooling fan830 to 831
K54Electronic carburettor control unit (not UK)203 to 226
K55Relay - electronic carburettor (not UK)203 to 206
K57Fuel injection control unit (not UK)139 to 161
K58Relay -fuel pump (not UK)162 to 163
K59Relay - daytime running lamps (not UK)420 to 426
K61Motronic M4.1 control unit170 to 194
K62Dim-dip control unit428 to 432
K63Relay - horn593 to 594
K64Relay - air conditioning blower (not UK)802 to 803
K67Relay -cooling fan827 to 828
K68Relay -fuel injection system294 to 299, 196 to 199
K69Motronic M2.5 control unit267 to 297
K71Ride control unit (not UK)739 to 754
K80Relay -fuel filter heater (Diesel models)865 to 866
K82Relay - engine revolution862 to 863
K83Four-wheel-drive control unit725 to 731 NoDescriptionTrackNoDescriptionTrack

12•38Wiring diagrams
Key to wiring diagrams for 1991 models
NoDescriptionTrackNoDescriptionTrack Wiring diagrams for 1991 models
Location of applicable circuitsTrackLocation of applicable circuitsTrack
Air conditioning system800 to 850
Alternator111
Anti-lock braking system (ABS)701 to 722
Anti-theft alarm system633 to 647
Automatic transmission control system773 to 799
Battery100
Brake lamps461 to 462
Carburettor118 to 121
Central locking system600 to 627
Check control system347 to 371
Cigarette lighter597 to 598
Clock661 to 663
Courtesy lamps - front487 to 494
Courtesy lamps - rear569 to 573
Direction indicator and hazard warning lamps467 to 482
Door mirrors536 to 548
Electric windows665 to 699
Engine compartment lamp415
Foglamps - front444 to 452
Foglamps - rear444 to 457
Fuel injection and ignition (Multec) - C16NZ engine129 to 164
Fuel injection and ignition (Multec) - C18NZ engine972 to 997
Fuel injection/ignition (Motronic M1.5) - 2.0litre sohc 168 to 199
Fuel injection/ignition (Motronic M2.5) - 2.0litre dohc 261 to 299
Glovebox lamp599Headlamp aim adjustment system758 to 766
Headlamp dim-dip427 to 431
Headlamp washers519 to 532
Headlamps437 to 442
Headlamps “ON” warning buzzer493 to 495
Heated front seats560 to 566
Heated rear window549 to 556
Heater blower motor853 to 862
Horn(s)592 to 596
Ignition (HEI) - 14NV engine121 to 128
Ignition (MSTS/EZ+) - 16SV, 18 SV engines236 to 256
Instruments301 to 344
Luggage compartment lamp485
Radiator cooling fan113, 115
Radio/cassette player586 to 591
Rear number plate lamp413
Reversing lamps496 to 498
Side and tail lamps401 to 410
Starter motor102 to 110
Sunroof863 to 870
Tailgate wiper510 to 516
Trip computer650 to 662
Windscreen and tailgate washers511 to 529
Windscreen wipers501 to 506
E1Side lamp - left406
E2Tail lamp - left356, 374, 407
E3Number plate lamp413
E4Side lamp - right409
E5Tail lamp - right358, 376, 410
E6Engine compartment lamp415
E7Headlamp main beam - left437
E8Headlamp main beam - right438
E9Headlamp dipped beam - left360, 378, 439
E10Headlamp dipped beam - right362, 380, 440
E11Instrument illumination lamps328 to 329
E12Selector lever illumination lamp (automatic transmission)799
E13Luggage compartment lamp485
E14Courtesy lamp487
E15Glovebox lamp599
E16Cigarette lighter illumination lamp596
E17Reversing lamp - left497
E18Reversing lamp - right498
E19Heated rear window552
E20Front foglamp - left448
E21Front foglamp - right447
E24Rear foglamp - left454
E25Driver’s seat heater580
E27Courtesy lamp - rear left569 to 570
E28Courtesy lamp - rear right572 to 573
E30Passenger front seat heater564
E32Clock illumination lamp663
E38Trip computer illumination lamp654
E39Rear foglamp - right455
E41Courtesy lamp (with delay)488 to 490
E50Kerb lamp - driver’s door666
E51Kerb lamp - passenger door684
F1 onFusesVarious
G1Battery101
G2Alternator111
G3Battery - (Diesel models)882, 901
G6Alternator - (Diesel models)884 to 886, 909 to 911H1Radio/cassette player589 to 590, 634
H2Horn592
H3Direction indicator warning lamp315 to 320
H4Oil pressure warning lamp310
H5Brake fluid level warning lamp313
H6Hazard warning flasher lamp470
H7Alternator charge warning lamp310
H8Headlamp main beam warning lamp322
H9Brake lamp - left364, 382, 461
H10Brake lamp - right366, 384, 462
H11Direction indicator lamp - front left472
H12Direction indicator lamp - rear left473
H13Direction indicator lamp - front right461
H14Direction indicator lamp - rear right482
H15Fuel level warning lamp305
H16Glow plug warning lamp (Diesel models)323
H17Trailer direction indicator warning lamp321
H18Horn593
H19Headlamps-on warning buzzer494 to 495
H21Handbrake-on warning lamp315
H25Door mirror warning lamp542, 952
H26ABS warning lamp319
H30Engine fault warning lamp324
H33Direction indicator side repeater lamp - left476
H34Direction indicator side repeater lamp - right478
H42Automatic transmission warning lamp325
H45Four-wheel-drive warning lamp327
H46Catalytic converter temperature warning lamp329
H47Anti-theft alarm horn638
H48Horn594
K3Relay - starter motor (anti-theft alarm)109 to 110
K5Relay - front foglamps448 to 450
K6Relay - air conditioning801 to 802
K7Relay - air conditioning blower804 to 805
K8Relay - intermittent windscreen wipe503 to 506
K9Relay - headlamp wash519 to 520
K10Relay - direction indicator/hazard warning flashers467 to 469