1988 OPEL CALIBRA steering wheel adjustment

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

5Direction indicator/lighting
switch - removal and refitting
2
Removal
1Disconnect the battery negative lead.
2Turn the steering wheel as necessary to
expose the two front steering column shroud
securing screws, which are covered by plastic
caps. Prise out the caps and remove the
screws.
3Remove the three securing screws from the
underside of the lower column shroud, then
remove both the upper and lower shrouds.
4Disconnect the wiring plug from the switch.
5Depress the switch retaining clip, and
withdraw the switch from the housing.
Refitting
6Refitting is a reversal of removal.
6Wash/wipe switch - removal
and refitting
2
Proceed as described in Section 5.
7Facia panel switches -
removal and refitting
2
1Disconnect the battery negative lead.
Lighting switch
Removal
2Turn the switch to the “dipped beam on”
position, then insert a small screwdriver or rod
through the hole in the bottom of the switch
knob to depress the knob retaining clip. Pull
the knob from the switch (see illustration).
3Press the two now-exposed switch
securing clips towards the switch spindle,
then pull the switch from the facia and
disconnect the wiring plug (see illustrations).
4Note that the switch assembly cannot be
dismantled, and if any part of the switch is
faulty, the complete assembly must be
renewed.
Refitting
5Refitting is a reversal of removal.
Push-button switches
Removal
6First check beneath the switch, if there is a
small hole in the facia, insert a slim
screwdriver or metal rod into it. Release the
switch retaining spring clip by pressing it
upwards against the switch, then remove the
switch and disconnect its wiring. If there is no
hole, remove the switch by prising it out of the
facia using a small screwdriver. Lever gently
under the switch’s lower edge (use adhesive
tape or a piece of card to protect the facia’s
finish). Disconnect the switch wiring plug and
withdraw the switch (see illustration).
Refitting
7Refitting is a reversal of removal.
Headlamp aim adjustment
switch
8The procedure is as described for push-
button switches.
Hazard warning switch
Removal
9Using a screwdriver, carefully prise the cap
from the switch (see illustration).
10Using a screwdriver with a piece of card
under the blade to avoid damage to the facia
trim, prise the ventilation nozzle from the
facia.
11Prise the switch from the facia and
disconnect the wiring (see illustration).
Refitting
12Refitting is a reversal of removal.
Heater blower motor switch
Removal
13Remove the heater control panel, as
described in Chapter 11.
14Disconnect the wiring plug from the
switch, if not already done.
15Prise the switch out from the rear of the
heater control panel.
Refitting
16Refitting is a reversal of removal, but refer
to Chapter 11, when refitting the heater
control panel.
12•4Body electrical systems
7.2 Using a thin rod to depress the
lightning switch knob retaining clip
7.3B . . . then pull the switch from the facia
7.11 Withdrawing the hazard warning
flasher switch from the facia7.9 Prising the cap from the hazard
warning flasher switch7.6 Prising a push-button switch from the
facia
7.3A Press the switch securing clips
towards the switch spindle . . .

8Disconnect the battery negative lead.
9Unclip the lid and open the relay box, then
pull out the relay (see illustration).
Refitting
10Refitting is a reversal of removal, with
reference to paragraph 6.
24Rear brake pressure-
proportioning valves -
removal and refitting
4
Note: Refer to the note at the beginning of
Section 3 before proceeding. Note also that
the valve must only be renewed in pairs, and
both valves must be of the same calibration.
Ensure that correct type of valves are fitted.
The bodies have been stamped for easier
identification.
Master cylinder-mounted valves
Removal
1Remove the brake fluid reservoir cap, and
secure a piece of polythene over the filler
neck with a rubber band, or by refitting the
cap. This will reduce the loss of fluid during
the following procedure.
2Locate a container beneath the master
cylinder, to catch the brake fluid that will be
released.
3Identify the two lower brake pipes for
position, then unscrew the union nuts and
disconnect the pipes from the proportioning
valves in the base of the master cylinder. Plug
the open ends of the pipes to prevent dirt
ingress.
4Unscrew the proportioning valves from the
master cylinder, and plug the open ends of
the cylinder to prevent dirt ingress.
Refitting
5Refitting is a reversal of removal, but on
completion, remove the polythene from the
brake fluid reservoir filler neck, and bleed the
complete hydraulic system, as described in
Section 3.
Rear underbody-mounted valves
Removal
6Proceed as described in paragraph 1.
7Chock the front wheels, then jack up the
rear of the vehicle, and support securely on
axle stands (see “Jacking and Vehicle
Support”) positioned under the body side
members.
8Working under the rear of the vehicle,
unscrew the union nut and disconnect the
brake pipe from one of the valves. Be
prepared for fluid spillage, and plug the open
end of the pipe to prevent dirt ingress and
further fluid spillage.
9Similarly, disconnect the flexible hose from
the valve.
10Pull the valve retaining clip from the
bracket on the underbody, noting that on
certain models, the retaining clip also secures
the ABS sensor wiring, and withdraw the valve
(see illustration).
11Repeat the procedure for the other valve.
Refitting
12Proceed as described in paragraph 5.
25Brake fluid pipes and hoses
- general, removal and refitting
4
Note: Refer to the note at the beginning of
Section 3, before proceeding.
General
1When checking the condition of the
system’s pipes and/or hoses, carefully check
that they do not foul other components such
as the power steering gear pipes (where
applicable), so that there is no risk of the
pipes chafing. If necessary use clips or ties to
secure braking system pipes and hoses well
clear of other components.
Rigid pipes
Removal
2Some of the commonly used brake pipes
can be obtained from Vauxhall parts dealers,
ready-formed and complete with unions, but
other brake pipes must be prepared using
4.75 mm (0.19 in) diameter brake pipe. Kits for
making the brake pipes can be obtained from
certain motor accessory shops.
3Before removing a brake pipe, remove the
brake fluid reservoir cap, and secure a piece
of polythene over the filler neck with a rubber
band, or by refitting the cap. This will reduce
the loss of fluid when the pipe is
disconnected.4Jack up the vehicle, and support securely
on axle stands (see “Jacking and Vehicle
Support”) positioned under the body side
members.
5To remove a brake pipe, unscrew the
unions at each end, and release the pipe from
the retaining clips.
Refitting
6Refitting is a reversal of removal, taking
care not to overtighten the unions.
7On completion, remove the polythene from
the brake fluid reservoir filler neck, and bleed
the relevant hydraulic circuit(s), as described
in Section 3.
Flexible hoses
Removal
8Proceed as described previously for the
rigid pipes, but note that a flexible pipe must
never be installed twisted, although a slight
“set” is permissible to give it clearance from
adjacent components.
Refitting
9When reconnecting a flexible hose to a
front brake caliper, note that the sealing rings
on the union bolt must be renewed.
26Handbrake - adjustment
2
Models with rear drum brakes
1The handbrake will normally be kept in
correct adjustment by the self-adjusting
action of the rear brake shoes. However, due
to cable stretch over a period of time, the
travel of the handbrake lever may become
excessive, in which case the following
operations should be carried out.
2Chock the front wheels, jack up the rear of
the vehicle, and support securely on axle
stands (see “Jacking and Vehicle Support”)
positioned under the body side members.
3Fully release the handbrake.
4Turn the knurled nut on the cable adjuster
(mounted on the torsion beam), until the brake
shoes can just be heard to rub when the rear
wheels are turned by hand in the normal
direction of rotation (see illustration).
9•18Braking system
23.9 ABS surge arrester relay (arrowed)
26.4 Handbrake cable adjuster. Knurled
nut arrowed - all SOHC models24.10 Brake pressure-proportioning valve
on rear underbody - DOHC model
1 Valve 2 Retaining clip

1Introduction
This Chapter is designed to help the home
mechanic maintain his/her vehicle for safety,
economy, long life and peak performance.
The Chapter contains a master maintenance
schedule, followed by Sections dealing specifically
with each task in the schedule. Visual checks,
adjustments, component renewal and other helpful
items are included. Refer to the accompanying
illustrations of the engine compartment and the
underside of the vehicle for the locations of the
various components.
Servicing your vehicle according to the
mileage/time maintenance schedule and the
following Sections will provide a planned
maintenance programme, which should result in a
long and reliable service life. This is a comprehensiveplan, so maintaining some items but not others at
the specified service intervals, will not produce the
same results.
As you service your vehicle, you will
discover that many of the procedures can -
and should - be grouped together, because of
the particular procedure being performed, or
because of the proximity of two otherwise-
unrelated components to one another. For
example, if the vehicle is raised for any
reason, the exhaust can be inspected at the
same time as the suspension and steering
components.
The first step in this maintenance
programme is to prepare yourself before the
actual work begins. Read through all the
Sections relevant to the work to be carried
out, then make a list and gather all the parts
and tools required. If a problem is found, seek
advice from a parts specialist, or a dealer
service department.
2Intensive maintenance
If, from the time the vehicle is new, routine
maintenance schedule is followed closely,
frequent checks made of fluid levels and high-
wear items, as recommended, the engine will
be kept in relatively good running condition.
The need for additional work will be minimised
It is possible that there will be times when
the engine is running poorly due to the lack of
regular maintenance. This is even more likely
if a used vehicle, which has not received
regular and frequent maintenance checks, is
purchased. In such cases, additional work
may need to be carried out, outside of the
regular maintenance intervals.
If engine wear is suspected, a compression
1•8Maintenance - component location
Rear underbody view of a 1990 GSi 2000 model (fully independent rear suspension)
1 Fuel tank securing strap
2 Shock absorber
3 ABS wheel sensor
4 Semi-trailing arm
5 Suspension crossmember
mounting bracing bracket
6 Handbrake cable
7 Suspension crossmember
8 Exhaust expansion box
9 Fuel pump
Maintenance procedures

14Brake fluid renewal
3
Renew the brake and bleed the system.
Refer to Chapter 9 for full details.
15Brake pad check
2
With the front or rear (as applicable) of the
vehicle raised, remove the wheels and check
brake pads for wear. Renew the pads if the
lining is below that specified. See Chapter 9,
for specifications and full details.
16Handbrake linkage check
2
With the vehicle raised, check the operation
of the handbrake and lubricate the linkages.
Refer to Chapter 9, for further details.
17Power steering fluid check
2
1With the engine off, remove the cap from
the power steering reservoir. It is fitted with a
dipstick.
2The fluid should be visible up to the ‘MAX’
mark (1), (see illustration). If not, top it up
using specified fluid.
3Start the engine and immediately top-up
the fluid to the ‘MIN’ mark (2).
4Do not allow the reservoir to run dry.
5For details on how to bleed the system,
refer to Chapter 10.
18Power steering pump
drivebelt check
2
Note:Vauxhall specify the use of a special
gauge. Checking values for use with this
gauge are given in the Specifications in
Chapter 10, for reference.
Checking
1The correct belt tension can be
approximated by adjusting the length of the
threaded rod. This should give a belt
deflection of approximately 10.0 mm (0.4 in)
under moderate thumb pressure at the
midpoint of the belt run between the pulleys. If
in doubt, err on the slack side, as an
excessively tight belt may cause pump
damage.
2Check the condition of the belt and renew it
if there are any signs of damage or excessive
wear
Adjustment
3Slacken the adjuster and mounting bolts.
4Slacken the adjuster nuts, and adjust the
length of the threaded rod to remove or
tension the belt as desired (see illustration).
5Tighten the adjuster nuts, and tighten the
adjuster and mounting bolts to the specified
torque (see Chapter 10), on completion.
6If a new drivebelt has been fitted, recheck
the tension after a few hundred miles.
19Rear suspension level
control system check
2
Refer to Chapter 10, for details.
20Bodywork check
1
1Clean the outside of the vehicle. If possible,
clean underneath as well. If using a pressure
cleaner take care not to damage any electrical
components, especially in the engine
compartment.
2Check all around for signs of damage or
corrosion and treat accordingly. Repair stone
chips when you can to prevent rusting.
3Read Chapter 11, for more details.
21Lock and hinge check
2
1Lubricate locks and hinges on all doors,
tailgates (or boot lid) and bonnet.
2Check for wear or damage and ensure
correct operation of safety catches.
3Check security of the bonnet stay and it’s
securing clip.
4Read Chapter 11, for further details.
22Alternator V-belt check
2
Note:The new ribbed V-belt, fitted to later
models, can not be adjusted.
1Although special tools are available for
measuring the belt tension, a good
approximation can be achieved. Tension the
belt so that there is approximately 13.0 mm
(0.5 in) of free movement under firm thumb
pressure at the mid-point of the longest run
between pulleys.
2With the mounting bolts just holding the
unit, lever the alternator away from the engine
using a wooden lever at the mounting bracket
end until the correct tension is achieved. Then
1•12Every 9000 miles or 12 months
17.2 Topping-up the power steering fluid
level
18.4 Adjusting the length of the power
steering pump threaded rod
Warning: Brake hydraulic fluid
can harm your eyes and
damage painted surfaces, so
use extreme caution when
handling and pouring it. Do not use fluid
that has been standing open for some
time, as it absorbs moisture from the air.
Excess moisture can cause a dangerous
loss of braking effectiveness.
Old hydraulic fluid is usually
darker in colour than new
fluid.
For a quick check, the thickness of the
friction material on each brake pad can
be measured through the aperture in
the caliper body.

Torque wrench settings (continued)Nmlbf ft
Starter to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4533
Starter support to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Temperature regulator plug (M20) * . . . . . . . . . . . . . . . . . . . . . . . . . . . .3022
Timing belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Timing belt drive gear to crankshaft: *
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250184
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by between 40°and 50°
Timing belt guide roller bracket to block . . . . . . . . . . . . . . . . . . . . . . . .2518
Timing belt guide roller to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Timing belt guide roller to cylinder block:
Engines up to 1993
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 45°
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Angle tighten by 15°
1993-on engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Transfer box bracket to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . .6044
Transmission to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6044
1General
This part of Chapter 2 describes
procedures that are specific to the DOHC
engine. It should be read in conjunction with
Part A.
The lower engine is basically the same as
the 2.0 litre SOHC. However the pistons are
attached to the connecting rods by gudgeon
pins, which are fully floating, and are secured
by circlips.
Both camshafts on these engines are driven
from the crankshaft by one toothed
composite rubber belt. Each cylinder has four
valves (two inlet and two exhaust), operated
directly from the camshafts by hydraulic
self-adjusting valve lifters. One camshaft
operates the inlet valves, and the other
operates the exhaust valves.
DOHC models are fitted with a remotely
mounted oil cooler.
The distributor is driven directly from the
exhaust camshaft.
2Engine - removal and refitting
4
Removal
1Carry out procedure in Chapter 2A, noting
the following differences.
2With the car safely raised, remove the
engine undershield.
3The fuel hoses need to be disconnected
from the fuel rail.
4Disconnect coolant hoses from the cylinder
block and cylinder head. Also disconnect the
oil cooler pipe unions from the oil pump.
5Unbolt the right-hand driveshaft centre
bearing support bracket from the rear of the
cylinder block.
Refitting
6Refitting the engine is similar to theprocedure in Chapter 2A. The exceptions
being, replacement of the right-hand
driveshaft centre bearing support bracket at
the rear of the cylinder block and retightening
the securing bolts.
7Replace the undershield.
3Engine/transmission
mountings- renewal
3
The procedure for replacing the engine/
transmission is similar to SOHC models, see
Chapter 2A. However this engine is fitted with
an undershield that needs to be removed
before replacing the mounts. Do not forget to
replace the undershield before lowering the
car.
4Timing belt, sprockets and belt
tensioner and idler pulleys-
removal, refitting and adjustment
3
Note: The timing belt should be renewed on
refitting. A two-legged puller may be required
to remove the crankshaft sprocket
Removal
1Disconnect the battery negative lead.2Disconnect the air cleaner trunking from the
airflow meter, then remove the cover and the
air cleaner element from the air cleaner. If
desired, for improved access, the complete
air cleaner assembly can be removed, as
described in Chapter 4B.
3Remove the power steering pump drivebelt,
as described in Chapter 10.
4Remove the alternator drivebelt, as
described in Chapter 5.
5Remove the three securing screws, and
withdraw the outer timing belt cover. Recover
the rubber grommets from the screw holes in
the cover if they are loose.
6Turn the crankshaft using a Torx socket on
the crankshaft sprocket bolt, until the timing
marks on the camshaft sprockets are aligned
with the notches in the camshaft cover. The
notch in the crankshaft pulley should also be
aligned with the pointer on the rear timing belt
cover (see illustrations).
7Extract the six securing bolts using a
splined bit, and withdraw the crankshaft
pulley (see illustration). If necessary,
counterhold the crankshaft using a socket on
the crankshaft sprocket bolt. 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 ring gear teeth can
be jammed using a large screwdriver or
similar tool. Before removing the pulley, check
that the timing marks are still aligned.
DOHC engine procedures 2B•3
4.6B . . .and notch in crankshaft pulley
aligned with pointer on rear timing belt
cover (circled)4.6A Camshaft sprocket TDC mark
aligned with notch in camshaft cover
2B

a)Inlet and exhaust manifolds (where
applicable)
b)Starter motor
c)Rear coolant gallery and hoses
d)Oil pressure switch
e)Oil temperature switch (where applicable)
f)Oil level sensor (where applicable)
g)Knock sensor (where applicable)
h)TDC sensor (where applicable)
i)Distributor components
j)Fuel pump (where applicable)
k)Thermostat/housing (N 16 NZ2, 1.8 and
2.0 litre models)
l)Power steering pump and mounting
bracket (where applicable)
m)Alternator mounting bracket
n)Engine lifting brackets
o)Dipstick/crankcase breather tube
p)Inlet manifold mounting bracket (where
applicable)
13To ensure maximum life, with minimum
trouble, from a rebuilt engine, not only must
everything be correctly assembled, but it must
also be spotlessly clean. All oilways and
coolant passages must be clear, and all
washers must be fitted in their original
positions. Oil all bearings and other moving
surfaces thoroughly with clean engine oil
during assembly.
14Before assembly begins, renew any bolts
or studs with damaged threads.
15Obtain a torque wrench, an angle-torque
gauge, sockets and bits, an oil can, clean
lint-free rag, and a set of engine gaskets and
oil seals, together with a new oil filter.16If they have been removed, new cylinder
head bolts, flywheel bolts, big-end bearing
cap bolts and main bearing cap bolts will also
be required.
17On completion of reassembly, refit the
applicable ancillary components listed in
paragraph 12.
18Follow procedure shown in Section 37.
11Timing belt and sprockets
(without automatic tensioner) -
removal, refitting and adjustment
3
Note: A two-legged puller may be required to
remove the crankshaft sprocket on N 16 NZ2,
1.8 and 2.0 litre models.Some of the later 1.4
and 1.6 litre engines, identifiable by the
squared-off top surfaces of the timing belt
covers, are fitted with spring-loaded auto-matic timing belt tensioners to ensure correct
belt tensioning on assembly.
Removal
1Disconnect the battery negative lead.
2On models with power steering, remove the
pump drivebelt, see Chapters 1 and 10.
3Remove the alternator drivebelt, as
described in Chapter 5.
4On C 16 NZ2, 1.8 and 2.0 litre models,
disconnect the wiring from the temperature
gauge sender.
5Release the securing clips (or hexagon-
headed screws, if fitted), and remove the main
outer timing belt cover, then unclip the smaller
outer timing belt cover from the coolant pump.
Where applicable, three screws retain the lower
(small) outer cover to the rear cover, the fourth
secures the tensioner (see illustrations).
6On 1.6 litre models with power steering,
remove the power steering pump, as
described in Chapter 10.
7Turn the crankshaft using a socket or
spanner on the crankshaft sprocket bolt, until
the timing mark on the camshaft sprocket is
aligned with the notch in the rear timing belt
cover, and the notch in the crankshaft pulley
is aligned with the pointer on the rear timing
belt cover (see illustrations). Note that on 1.4
litre engine there are two notches in the
crankshaft pulley, representing 5°and 10°
BTDC, and the 10°BTDC notch should be
aligned with the pointer (see illustration).
8Loosen the three coolant pump securing
bolts (see illustration), and turn the pump to
relieve the tension in the timing belt, then slide
the belt from the camshaft sprocket.
SOHC engine procedures 2A•13
11.5C Timing belt lower (small) outer
cover screws (A), tensioner screw (B),
ignition timing fixed reference mark (C)
11.8 Loosening a coolant pump securing
bolt - 2.0 litre engine11.7C Crankshaft pulley 10°BTDC notch
aligned with pointer on rear timing belt
cover - 1.4 litre engine11.7B . . .and notch in crankshaft pulley
aligned with pointer on rear timing belt
cover - 2.0 litre engine
11.7A Camshaft sprocket TDC mark
aligned with notch in rear timing belt
cover . . .
11.5B . . .and the smaller cover from the
coolant pump - 2.0 litre engine11.5A Remove the main outer timing belt
cover . . .
2A

REF•8MOTTest Checks
This is a guide to getting your vehicle through the MOT test.
Obviously it will not be possible to examine the vehicle to the same
standard as the professional MOT tester. However, working through
the following checks will enable you to identify any problem areas
before submitting the vehicle for the test.
Where a testable component is in borderline condition, the tester
has discretion in deciding whether to pass or fail it. The basis of such
discretion is whether the tester would be happy for a close relative or
friend to use the vehicle with the component in that condition. If the
vehicle presented is clean and evidently well cared for, the tester may
be more inclined to pass a borderline component than if the vehicle is
scruffy and apparently neglected.
It has only been possible to summarise the test requirements here,
based on the regulations in force at the time of printing. Test standards
are becoming increasingly stringent, although there are some
exemptions for older vehicles. For full details obtain a copy of the Haynes
publication Pass the MOT! (available from stockists of Haynes manuals).
An assistant will be needed to help carry out some of these checks.
The checks have been sub-divided into four categories, as follows:
HandbrakeMTest the operation of the handbrake.
Excessive travel (too many clicks) indicates
incorrect brake or cable adjustment.
MCheck that the handbrake cannot be
released by tapping the lever sideways. Check
the security of the lever mountings.
Footbrake
MDepress the brake pedal and check that it
does not creep down to the floor, indicating a
master cylinder fault. Release the pedal, wait
a few seconds, then depress it again. If the
pedal travels nearly to the floor before firm
resistance is felt, brake adjustment or repair is
necessary. If the pedal feels spongy, there is
air in the hydraulic system which must be
removed by bleeding.MCheck that the brake pedal is secure and in
good condition. Check also for signs of fluid
leaks on the pedal, floor or carpets, which
would indicate failed seals in the brake master
cylinder.
MCheck the servo unit (when applicable) by
operating the brake pedal several times, then
keeping the pedal depressed and starting the
engine. As the engine starts, the pedal will
move down slightly. If not, the vacuum hose or
the servo itself may be faulty.
Steering wheel and column
MExamine the steering wheel for fractures or
looseness of the hub, spokes or rim.
MMove the steering wheel from side to side
and then up and down. Check that the
steering wheel is not loose on the column,
indicating wear or a loose retaining nut.
Continue moving the steering wheel as before,
but also turn it slightly from left to right.
MCheck that the steering wheel is not loose
on the column, and that there is no abnormalmovement of the steering wheel, indicating
wear in the column support bearings or
couplings.
Windscreen and mirrors
MThe windscreen must be free of cracks or
other significant damage within the driver’s
field of view. (Small stone chips are
acceptable.) Rear view mirrors must be
secure, intact, and capable of being adjusted.
1Checks carried out
FROM THE DRIVER’S SEAT
1Checks carried out
FROM THE DRIVER’S
SEAT2Checks carried out
WITH THE VEHICLE
ON THE GROUND3Checks carried out
WITH THE VEHICLE
RAISED AND THE
WHEELS FREE TO
TURN4Checks carried out on
YOUR VEHICLE’S
EXHAUST EMISSION
SYSTEM