1988 OPEL CALIBRA warning

3Air cleaner - removal and
refitting
2
Removal
1Remove the air cleaner element, as
described in Chapter 1.
2Release the crankcase ventilation hose
from the plastic clip on the left-hand side of
the air cleaner body.
3Disconnect the inlet duct from the hot air
hose on the exhaust manifold (see
illustration), and lift the air cleaner body from
the carburettor.
4With the body tilted to the rear, disconnect
the crankcase ventilation hose from the stub
on the underside of the body (see
illustration).Where applicable, disconnect
the vacuum hose from the air temperature
control flap thermostat.
5Remove the seal from under the air cleaner
body.
Refitting
6Check the hot air hose for condition, and
renew it if necessary.
7Fit a new air cleaner body-to-carburettor
seal.
8Connect the crankcase ventilation hose to
the stub on the underside of the body, and
connect the vacuum hose for the air
temperature control flap.
9Locate the body on the carburettor, and at
the same time locate the inlet duct on the hot
air hose on the exhaust manifold.
10Engage the crankshaft ventilation hose in
the plastic clip.
11Refit the air cleaner element, referring to
Chapter 1 if necessary.
4Air cleaner inlet air
temperature control -
description and testing
3
Description
1The air cleaner is thermostatically-
controlled, to provide air at the most suitable
temperature for combustion with minimum
exhaust emission levels.
2The optimum air temperature is achieved
by drawing in cold air from an inlet at the front
of the vehicle, and blending it with hot airdrawn from a shroud on the exhaust manifold.
The proportion of hot and cold air is varied by
the position of a flap valve in the air cleaner
inlet spout, which is controlled by either a
vacuum diaphragm or wax-type unit. The
vacuum diaphragm type is regulated by a heat
sensor located within the air cleaner body
(see illustration).
Testing
3To check the operation of the air
temperature control, the engine must be cold.
First check the position of the flap valve. On
the vacuum type, remove the air cleaner cover
and check that the flap is open to admit only
cold air from outside the car. Then start the
engine and check that the flap now moves to
admit only hot air from the exhaust manifold.
On the wax type, the flap should already be
positioned to admit only hot air from the
exhaust manifold.
4Temporarily refit the cover on the vacuum
type.
5Run the engine until it reaches its normal
operating temperature.
6On the vacuum type, remove the air cleaner
cover and check that the flap is now
positioned to admit only cold air from outside
the car. In cold weather it should be a mixture
of hot and cold air. Refit the cover after
making the check. On the wax type, use a
mirror to check that the flap is positioned in
the same way as given for the vacuum type.
7If the flap does not function correctly, the
air cleaner casing must be renewed. Note that
the vacuum type thermostat can be renewed
separately if necessary.
5Fuel pump - testing
2
Note: Refer to Section 2 before proceeding
1Disconnect the ignition coil LT lead.
2Place a clean piece of rag under the pump
outlet, then disconnect the pump outlet hose.
Be prepared for fuel spillage, and take
adequate fire precautions.
3Have an assistant crank the engine on the
starter. Well-defined spurts of fuel must be
ejected from the pump outlet - if not, the
pump is probably faulty (or the tank is empty).
Dispose of the fuel-soaked rag safely.
4No spare parts are available for the pump,
and if faulty, the unit must be renewed.
6Fuel pump - removal and
refitting
3
Note: Refer to Section 2 before proceeding
Removal
1The fuel pump is located at the rear right-
hand end of the camshaft housing.
2Disconnect the battery negative lead.
3Disconnect the fuel hoses from the pump
(see illustration). If necessary, label the
hoses so that they can be reconnected to
their correct locations. Be prepared for fuel
spillage, and take adequate fire precautions.
Plug the open ends of the hoses to prevent
dirt ingress and further fuel spillage.
Fuel and exhaust systems - carburettor models 4A•3
3.4 Disconnecting the crankcase
ventilation hose (arrowed)
6.3 Disconnecting a fuel hose from the
fuel pump - 1.6 litre model4.2 Air cleaner flap valve operating
mechanism
1 Flap valve 2 Operating rod
3.3 The air cleaner body locates over the
hot air hose
4A
Warning: Many of the
procedures given in this
Chapter involve the
disconnection of fuel pipes and
system components, which may result in
some fuel spillage. Before carrying out
any operation on the fuel system, refer to
the precautions given in the “Safety first!”
Section at the beginning of this manual
and follow them implicitly. Petrol is a
highly dangerous and volatile substance,
and the precautions necessary when
handling it cannot be overstressed.

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.

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 . . .

8Electric door mirror switch -
removal and refitting
2
Removal
1Disconnect the battery negative lead.
2Prise the plastic surround from the door
interior handle.
3Free the trim panel from the top edge of the
door by releasing the securing clips. This can
be done using a screwdriver, but it is
preferable to use a forked tool, to minimise
the possibility of damage to the trim panel and
the clips.
4Note the position of the mirror switch wiring
connector in the bracket at the top of the
door, then separate the two halves of the
connector.
5Prise the switch from the door trim panel,
and feed the wiring through the panel.
Refitting
6Refitting is a reversal of removal, but ensure
that the wiring is correctly routed, so as not to
foul the door interior handle mechanism.
9Sunroof operating switch -
removal and refitting
2
Removal
1Disconnect the battery negative lead.
2Prise the courtesy lamp from the roof trim
panel, and disconnect the wiring.
3Remove the two trim panel securing
screws, and withdraw the trim panel from the
roof, disconnecting the wiring from the
sunroof operating switch.
4Release the securing clips, then pull the
switch from the rear face of the trim panel.
Refitting
5Refitting is a reversal of removal.
10Courtesy lamp switch -
removal and refitting
2
Removal
1Disconnect the battery negative lead.
2Open the door and remove the switch
securing screw.
3Withdraw the switch from the door pillar,
and pull the wiring out sufficiently to prevent it
from springing back into the pillar.4Disconnect the wiring and remove the
switch.
Refitting
5Refitting is a reversal of removal.
11Luggage compartment lamp
switch - removal and refitting
2
Removal
1Disconnect the battery negative lead.
2Open the boot lid or tailgate, as applicable,
and remove the switch securing screw.
3Withdraw the switch from the body panel,
and pull the wiring out sufficiently to prevent it
from springing back into the body.
4Disconnect the wiring and remove the
switch.
Refitting
5Refitting is a reversal of removal.
12Brake lamp switch - removal
and refitting
2
Removal
1Disconnect the battery negative lead.
2Remove the lower trim panel from the
driver’s footwell.
3Disconnect the wiring plug from the brake
lamp switch, then twist the switch
anti-clockwise and remove it from its bracket.
Refitting
4Refitting is a reversal of removal.
13Handbrake “on” warning
lamp switch - removal and
refitting
3
For access to the switch, the handbrake
lever must be removed. Removal and refitting
of the switch is described as part of the
handbrake lever removal and refitting
procedure, in Chapter 9.
14Oil pressure warning lamp
switch - removal and refitting
3
Removal
1Disconnect the battery negative lead.
2The switch is screwed into the oil pump, on
the inlet manifold side of the engine. On 1.4
and 1.6 litre (except C16 NZ2), models the
switch projects at right-angles to the
crankshaft axis, while on C16 NZ2, 1.8 and
2.0 litre models it is parallel to the crankshaft
(see illustration).
3In most cases the switch can be reached
quite easily from above. However, on some
models access will be easier if the front of the
vehicle is jacked up and supported on axle
stands (see “Jacking and Vehicle Support”)
(ensure that the handbrake is securely
applied) and the front right-hand roadwheel is
removed.
4Disconnect the switch wire and use a
spanner to unscrew the switch (see
illustration). As you withdraw the switch,
swiftly plug the hole in the oil pump to
minimise the loss of oil and to prevent the
entry of dirt.
Refitting
5Refitting is the reverse of the removal
procedure; tighten the switch securely but do
not overtighten it, reconnect its wire, then
check and if necessary top-up the oil level, as
described in Chapter 1. Wash off any spilt oil
and check for leaks when the engine is
restarted.
15Cigarette lighter - removal
and refitting
2
Removal
1Disconnect the battery negative lead.
2Slide the ashtray/cigarette lighter assembly
from the facia, then disconnect the wiring and
slide the illumination bulb from the cigarette
lighter.
Body electrical systems 12•5
14.4 Unscrewing the oil pressure warning
lamp switch -
SOHC model (engine removed)14.2 Oil pressure warning lamp switch
(arrowed) viewed from underneath vehicle
- SOHC model
12
Tape the wiring to the door
pillar, to prevent if falling
back into the door pillar.
Alternatively, tie a piece of
string to the wiring to retrieve it.

3To remove the cigarette lighter assembly,
simply pull it from the illumination ring
assembly. If desired, the illumination ring
assembly can be removed, by pulling it from
the housing after depressing the retaining
clips.
Refitting
4Refitting is a reversal of removal.
16Clock - removal and refitting
2
Removal
1Disconnect the battery negative lead.
2Using a thin-bladed screwdriver, carefully
prise the clock from the facia panel.
3Disconnect the wiring plugs and withdraw
the clock (see illustration).
Refitting
4Refitting is a reversal of removal.
17Heated front seats - general
2
Heating pads are fitted to the front seats of
some models. Before attempting to remove a
seat so equipped, disconnect the battery and
the leads from the heating pad.
18Instrument panel -removal
and refitting
3
Removal
1Disconnect the battery negative lead.
2Remove the steering wheel, (Chapter 10).
3Remove the steering column shrouds, and
the instrument panel upper and lower trim
panels, (Chapter 11).
4Remove the single upper, and two lower,
instrument panel securing screws (see
illustration).
5Carefully withdraw the instrument panel,
and disconnect the speedometer cable and
the two wiring plugs. Note that the
speedometer cable is retained by a clip, which
must be pressed towards the speedometer to
release the cable (see illustration).6If desired, the instrument panel can be
dismantled, with reference to Section 19.
Refitting
7Refitting is a reversal of removal, but ensure
that the speedometer cable is not kinked or
twisted between the instrument panel and the
bulkhead as the panel is refitted.
19Instrument panel
components - removal and
refitting
3
1With the instrument panel removed, as
described in Section 18, continue as follows.
Panel illumination and warning
lamp bulbs
Removal
2Twist the relevant bulbholder clockwise,
and withdraw it from the printed circuit board
on the rear of the instrument panel (see
illustration).
3The bulbs are integral with the bulbholders,
and must be renewed as a unit.
Refitting
4Refitting is a reversal of removal.
Voltage stabiliser
Removal
5Remove the single securing screw from the
rear of the instrument panel, then pull the
voltage stabiliser from the contacts on the
printed circuit board (see illustration).
Refitting
6Refitting is a reversal of removal.
Fuel and temperature gauges -
“low series” models
Removal
7Pull the trip meter reset pin from the front of
the panel.
8Release the two retaining clips at the top of
the panel, and remove the panel shroud (see
illustration).
9Unscrew the two securing nuts, and
withdraw the relevant gauge through the front
of the instrument panel.
12•6Body electrical systems
16.3 Disconnecting the wiring plugs from
the clock
18.5 Disconnecting an instrument panel
wiring plug. Note speedometer cable
retaining clip (arrowed)
19.8 Removing the instrument panel
shroud19.5 Instrument panel voltage stabiliser
(arrowed)19.2 Withdrawing an instrument panel
illumination lamp bulb
18.4 Unscrewing a lower instrument panel
securing screw

Refitting
10Refitting is a reversal of removal.
Fuel and temperature gauge
assembly -“high series” models
11The procedure is as described in
paragraphs 7 to 10 inclusive, except that the
gauge assembly is secured by four nuts.
Tachometer
12The procedure is as described in
paragraphs 7 to 10 inclusive except that the
tachometer is secured by three nuts (see
illustration).
Speedometer
Removal
13Proceed as described in paragraphs 7
and 8.
14Extract the four securing screws from the
rear of the panel (see illustration).
Refitting
15Refitting is a reversal of removal.
Printed circuit board
Removal
16Remove all bulbs and instruments, and
the voltage stabiliser, as described previously
in this Section.
17Carefully peel the printed circuit board
from the instrument panel.
Refitting
18Refitting is a reversal of removal, but
ensure that the printed circuit board is seated
correctly on the rear of the instrument panel.
20Trip computer components -
removal and refitting
2
1Disconnect the battery lead.
Display module
Removal
2Using a thin-bladed screwdriver, carefully
prise the module from the facia panel.
3Disconnect the wiring plug and withdraw
the module.
Refitting
4Refitting is a reversal of removal.
Display module illumination bulb
Removal
5Remove the display module, as described
previously in this Section.
6Using a length of rubber sleeving of similar
diameter, or an alternator tool, extract the
bulb by inserting the tool through the hole in
the side of the display module (see
illustration).
Refitting
7Refitting is a reversal of removal.
Operating switch
Removal
8Remove the rear section of the centre
console, as described in Chapter 11.
9Release the wiring plug from the switch
using a screwdriver.
10Lift the switch, then pull it down and out
from the centre console.
Refitting
11Refitting is a reversal of removal.
Outside air temperature sensor
Removal
12The sensor is located at the left-hand end
of the front bumper (see illustration).
13Prise the cover cap from the bumper, then
unclip the sensor, and disconnect the wiring
plug.
Refitting
14Refitting is a reversal of removal.
21Check control system
components - removal and
refitting
3
1Disconnect the battery negative lead.
Warning lamp bulbs
2The warning lamp bulbs are located in the
instrument panel, and removal and refitting
are described in Section 19.
Control module
Removal
3The control module is located behind the
passenger side of the facia, above the
glovebox.
4Remove the glovebox assembly, as
described in Chapter 11.
5Disconnect the control module wiring plug,
then release the control module from its
mounting and withdraw the unit.
Refitting
6Refitting is a reversal of removal.
Coolant level sensor
Removal
7The coolant level sensor is integral with the
coolant expansion tank cap.
8Disconnect the wiring from the top of the
cap, then unscrew the cap and withdraw it
from the expansion tank.
9If faulty, the complete cap assembly must
be renewed.
Refitting
10Refitting is a reversal of removal.
Washer fluid level sensor
Removal
11The sensor is mounted in the side of the
fluid reservoir.
12Disconnect the wiring from the sensor,
then unscrew the sensor from the fluid
reservoir. If the fluid level is above the level of
the sensor, be prepared for fluid spillage.
Refitting
13Refitting is a reversal of removal.
Body electrical systems 12•7
20.6 Removing the trip computer display
module illumination bulb20.12 Trip computer outside air
temperature sensor location (arrowed)
19.14 Speedometer securing screws
(arrowed)19.12 Tachometer securing nuts (arrowed)
12

27Headlamps -alignment
2
1Correct alignment of the headlamp beams
is most important, not only to ensure good
vision for the driver, but also to protect other
drivers from being dazzled.
2Accurate alignment should be carried out
using optical beam setting equipment.
3In an emergency, adjustments may be
made by turning the adjustment screws
shown (see illustrations). If an adjustment is
made, the alignment should be checked using
beam setting equipment at the earliest
opportunity.
4All 1992-on models are fitted with the
headlamp aim adjustment system, operated
through the facia-mounted switch (see
illustration).
a)Position ‘0’, is for correct alignment if just
the driving seat is occupied.
b)Position ‘1’, if all seats are occupied.
c)Position ‘2’, if all seats occupied and
luggage.
d)Position ‘3’, for just driver and luggage.
28Headlamp dim-dip system -
general, removal and refitting
3
General
1The system (where fitted) is governed by the
dim-dip control unit mounted either behind
and above the glovebox (early models), or
behind the main fuse panel (later models).
2The control unit uses the oil pressure
warning lamp circuit to ensure that, when theengine is running and the sidelamps are
switched on, reduced current is fed to the
headlamp dipped-beam circuits. This lights
the headlamps with approximately one-sixth
of their normal power so that the vehicle
cannot be driven using sidelamps alone.
3To locate the dim-dip control unit, open the
main fuse panel covering flap and unclip it
from its bottom and top mountings (Section 3).
Then use a torch to see whether the unit is
fastened to the plastic bracket behind the facia
and fuse panel. The unit is usually rectangular,
of black plastic, and can be identified by the
colours of the five wires leading to it (see
applicable wiring diagram).
Removal
4If the unit can be seen, remove the driver’s
side lower facia and footwell trim panels
(Chapter 11), then unscrew the four retaining
screws and lower the plastic bracket until the
control unit can be detached.
5If the unit cannot be seen, remove the
glovebox assembly (Chapter 11). The unit will
be fastened to the underside of the facia top
surface.
Refitting
6Refitting is the reverse of the removal
procedure.
26Headlamp aim adjustment
motor - removal and refitting
3
Removal
1Remove the headlamp, (Section 25).
2Twist the motor clockwise to release it from
the headlamp, then carefully disconnect the
motor from the balljoint (see illustrations).
Refitting
3Refitting is a reversal of removal, but ensure
that the motor is correctly engaged with the
balljoint.
12•10Body electrical systems
26.2A Headlamp aim adjustment motor
(headlamp removed)
27.4 The headlamp aim adjustment switch
- 1992-on models
27.3B Headlamp alignment adjustment screws - models with
electric aim adjustment
A Vertical adjustment screw B Horizontal adjustment screw27.3A Headlamp alignment adjustment screws - models without
electric aim adjustment
A Vertical adjustment screw B Horizontal adjustment screw
26.2B Headlamp aim adjuster balljoint
(arrowed)