Opel Kadett Owner's Manual
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Opel Kadett Owner's Manual

Opel kadett
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Table of Contents

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Chapter 1

Routine maintenance and servicing

Contents
Air Cleaner Filter Element Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Automatic Transmission Fluid Level Check . . . . . . . . . . . . . . . . . . . . . .13
Automatic Transmission Fluid Renewal . . . . . . . . . . . . . . . . . . . . . . . . .33
Auxiliary Drivebelt Check And Renewal . . . . . . . . . . . . . . . . . . . . . . . . .9
Battery Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Brake Fluid Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Brake pad, caliper and disc check . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Carburettor Fuel Inlet Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Clutch Adjustment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Coolant Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Driveshaft CV joint and gaiter check . . . . . . . . . . . . . . . . . . . . . . . . .20
Electrical System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Exhaust System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Fluid Level Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Fuel Filter Renewal - Fuel Injection Models . . . . . . . . . . . . . . . . . . . . . .25
Fuel Pump Filter Cleaning - carburettor models . . . . . . . . . . . . . . . . .12

Degrees of difficulty

Easy, suitable for
Fairly easy, suitable
novice with little
for beginner with
experience
some experience

1 Vauxhall Astra/Belmont maintenance schedule

The maintenance intervals in this manual are provided with the
assumption that you, not the dealer, will be carrying out the work.
These are the minimum maintenance intervals recommended by the
manufacturer for vehicles driven daily. If you wish to keep your vehicle
in peak condition at all times, you may wish to perform some of these
procedures more often. We encourage frequent maintenance, because
it enhances the efficiency, performance and resale value of your
Handbrake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Headlamp Aim Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Hinge And Lock Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Hose And Fluid Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Idle Speed And Mixture Adjustments . . . . . . . . . . . . . . . . . . . . . . . . .11
Ignition System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Manual Transmission Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . .27
Rear brake shoe, wheel cylinder and drum check . . . . . . . . . . . . . . .29
Rear Wheel Bearing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Roadwheel bolt tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Tyre Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Vauxhall Astra/Belmont maintenance schedule . . . . . . . . . . . . . . . . . .1
Wiper Blade Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Fairly difficult, suitable
Difficult, suitable for
for competent DIY
experienced DIY
mechanic
mechanic
vehicle. If the vehicle is driven in dusty areas, used to tow a trailer, or
driven frequently at slow speeds (idling in traffic) or on short journeys,
more frequent maintenance intervals are recommended.
When the vehicle is new, it should be serviced by a factory-
authorised dealer service department, in order to preserve the factory
warranty.
1•1
1
Very difficult,
suitable for expert DIY
or professional

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Do you have a question about the Kadett and is the answer not in the manual?

Questions and answers

Shaun
January 18, 2025

How to remove back seat on opel kaddet 1982 model

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Willem
January 28, 2025

Wiring connection to starter

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1 comments:
Mr. Anderson
February 10, 2025

For wiring the starter on an Opel Kadett:

- Red (4mm): Connect to the battery for a 12V feed to the car’s electrical system.
- Red/Black (1.5mm): Connect to the starter solenoid to activate the starter motor.
- Yellow/Black: This wire should originate from the coil, with the yellow ending at the coil and the black running down to the starter.

Ensure all connections are secure and properly insulated before attempting to start the vehicle.

This answer is automatically generated

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Summary of Contents for Opel Kadett

  • Page 1 1•1 Chapter 1 Routine maintenance and servicing Contents Air cleaner filter element renewal ......24 Handbrake adjustment .

  • Page 2: Maintenance Schedule

    Maintenance schedule 1•2 Every 250 miles (400 km) or weekly Every 18 000 miles (30 000 km) or 12 months, whichever comes first See Weekly checks In addition to all the items listed previously, carry out the following: Renew the air cleaner filter element (Section 24) Renew the fuel filter (fuel injection models) (Section 25) Every 9000 miles (15 000 km) or Clean the carburettor fuel inlet filter (Section 26)
  • Page 3 Maintenance - component location 1•3 Underbonnet view of an early 1.6 litre model (air cleaner removed for clarity) 1 Wiper motor 11 Radiator cooling fan 21 Fuel pump 12 Distributor cover 22 Alternator 2 Heater blower motor 3 Heater blower motor resistor 13 Engine oil filler 23 Accelerator cable 4 Windscreen washer tube...
  • Page 4 Maintenance - component location 1•4 Underbonnet view of an early 1.8 litre model 11 Radiator fan 21 Breather hose 1 Screen washer reservoir 22 Throttle valve housing 2 Headlamp washer filler cap 12 Distributor 3 Headlamp washer relay and fuse 13 Engine oil filler 23 Fuel rail 4 Suspension turrets...
  • Page 5 Maintenance - component location 1•5 Underbonnet view of a 2.0 litre 16-valve model 1 Radiator top hose 10 Engine oil filler cap 18 Fuel injection control relay 11 Pre-volume chamber 19 Ignition coil 2 Air cleaner 3 Suspension turrets 12 Brake servo non-return valve 20 Battery 4 Coolant filler cap 13 Power steering hoses...
  • Page 6 Maintenance - component location 1•6 Front underbody view of a 1.8 litre model - other models similar 1 Control arm rear bush 8 Radiator 15 Steering balljoint attachment 2 Control arm 9 Exhaust downpipes 16 Engine/transmission rear mounting 3 Anti-roll bar link 10 Sump drain plug 17 Gearchange tube 4 Driveshaft damper weight...
  • Page 7 Maintenance - introduction 1•7 Rear underbody view of a 1.8 litre model - other models similar 1 Centre silencer 2 Handbrake adjuster 3 Handbrake cables 4 Fuel tank 5 Brake pipe 6 Brake and fuel pipes 7 Brake hoses 8 Axle beam 9 Axle mountings 10 Spring 11 Shock absorber mounting...

  • Page 8: Tyre Checks

    Maintenance procedures 1•8 The following series of operations are those d) Renew the spark plugs (Section 7). Secondary operations most often required improve e) Inspect the ignition system components All items listed under “Primary operations”, performance of a generally poor-running (Section 10).

  • Page 9: Spark Plug Renewal

    Every 9000 miles 1•9 the engine is first started, as the oil circulates through the new oil filter and the engine oil galleries before the pressure builds up. 15 Stop the engine, and wait a few minutes for the oil to settle in the sump once more. With the new oil circulated and the filter now completely full, recheck the level on the dipstick, and add more oil as necessary.
  • Page 10 Every 9000 miles 1•10 7 Carefully check all rubber hoses and metal start with and the tension should be fuel lines leading away from the petrol tank. rechecked, and if necessary adjusted, after 8 Hose and fluid leak check Check for loose connections, deteriorated about 5 minutes running.

  • Page 11: Ignition System Check

    Every 9000 miles 1•11 15 Refit the belt, and tension it as described previously. Note that when a new belt has been fitted it will probably stretch slightly to start with and the tension should be rechecked, and if necessary adjusted, after about 5 minutes running.
  • Page 12 16 On models without a catalytic converter, 1 Distributor vacuum take-off entrusted to a Vauxhall/Opel dealer. the mixture (CO level) can be adjusted as 2 Idle speed adjustment screw described above in paragraphs 9 and 11 to...

  • Page 13: Wiper Blade Check

    Every 9000 miles 1•13 3 Remove the filter from the cover and wash it fresh fuel to remove any debris from it. 15 Wiper blade check Inspect the filter for signs of clogging or splitting and renew it if necessary. 4 Locate the filter in the cover and fit the Check the condition of the wiper blades.
  • Page 14 Every 9000 miles 1•14 12 Repeat the operation on the other brake. 18 Rear wheel bearing 13 Tighten the cable adjuster nut until the shoes start to drag again. This should happen adjustment on both sides. 14 Release and fully reapply the handbrake a Refer to Chapter 10, Section 9.

  • Page 15: Air Cleaner Filter Element Renewal

    If any problems are found, they 5 Check that the steering feels positive, with engine to run for at least two minutes, and should be referred to a Vauxhall/Opel dealer. no excessive “sloppiness”, or roughness, and then switch it off. If the brake pedal is...
  • Page 16 Every 18 000 miles 1•16 24.7 On 1.8 and 2.0 litre 8-valve models, 24.8a . . . then release the retaining 24.8b . . . and remove the air cleaner disconnect the airflow sensor wiring clips . . . housing cover, complete with the filter connector .

  • Page 17: Brake Fluid Renewal

    (see illustration). If a rod of carried out by a Vauxhall/Opel dealer or the same diameter as the specified minimum service station with the necessary facilities.

  • Page 18: Maintenance Procedures

    Maintenance procedures 1•18 Every 2 Years 32 Coolant renewal Cooling system draining Warning: Wait until the engine is cold before starting this procedure. Do not allow antifreeze to come in contact with your skin or painted surfaces of the vehicle. Rinse off spills immediately with plenty of water.

  • Page 19: Automatic Transmission Fluid Renewal

    Maintenance procedures 1•19 Every 36 000 miles fluid in a suitable container. mating surfaces are clean and dry and bolt on 33 Automatic transmission fluid 4 Remove the remaining screw and the pan. the fluid pan using a new gasket. Where no renewal Peel off the gasket (where fitted) or remove all gasket is fitted, apply a bead of sealant about...

  • Page 20: Specifications

    2A•1 Chapter 2 Part A: OHV engine Contents Ancillary components - removal and refitting ....6 Engine lubrication system - general description ....22 Camshaft and tappets - removal and refitting .

  • Page 21: Piston Rings

    2A•2 OHV engine Camshaft Radial run-out ..........0.03 mm max Endfloat .
  • Page 22 OHV engine 2A•3 Main bearing shell identification - 0.25 undersize: Colour code Embossed code Front, top ..........Brown-blue 1 OA or 006-A Front, bottom .
  • Page 23 2A•4 OHV engine tappets and short pushrods. The inlet and as to whether a particular pressure reading is 2 Drain the oil into a suitable container and exhaust valves are each closed by a single acceptable. then thoroughly clean the exterior of the valve spring and operates in guides, integral 9 If the pressure in any cylinder is low, carry engine using a degreasing solvent or paraffin.
  • Page 24 OHV engine 2A•5 7 Valve clearances - adjustment 1 This adjustment should be carried out with engine normal operating temperature. If it is being done after overhaul when the engine is cold, repeat the adjustment after the car has been driven a few kilometres when the engine will then be hot.
  • Page 25 2A•6 OHV engine 8.24 Fitting a cylinder head gasket 8.26 Cylinder head bolt tightening 8.29 Inlet manifold gasket in position sequence 19 Lift the cylinder head from the block. If it is gasket, and secure with the four bolts and 6 As they are released and removed, keep stuck, tap it free with a soft-faced mallet.
  • Page 26 OHV engine 2A•7 9.15 Fitting a valve to its guide 9.17 Fitting an exhaust valve rotator 9.18a Fit the valve spring . . . specification, replace them all. Springs suffer Lubricate the sleeve and push on the seal, from fatigue and it is a good idea to renew ring downwards.
  • Page 27 2A•8 OHV engine 11.7 Insert the cork strips in the main 11.9 Refitting the sump 12.2a Undo the two socket-headed bolts bearing cap grooves (arrowed) . . . matter with the side of a steel rule or a similar 9 Refit the sump (see illustration) and secure article.
  • Page 28 OHV engine 2A•9 13.4 Oil pump and pressure relief valve 13.8 Check the pump gear teeth backlash 14.2 Clutch access plate components 4 Undo the large nut on the side of the relief valve assembly and assemble the pump towards the engine and slip the drivebelt off housing and remove the sealing washer and gears.
  • Page 29 2A•10 OHV engine 14.13 Using a drift to remove the timing 14.14a Fit the new seal to the holder 14.14b . . . and refit the holder and seal to cover oil seal the timing cover paraffin and dry them with a lint-free cloth. camshaft and will have its timing mark in 15 Pistons and connecting rods Remove all traces of old gasket from the faces...
  • Page 30 OHV engine 2A•11 Refitting 5 Refitting is the reverse sequence to removal. Tighten the flywheel retaining bolts to the specified torque. 17 Engine/transmission mountings - removal and refitting Removal 1 The engine/transmission assembly is 15.11 Offering the piston to the bore 15.12 Piston ring compressor fitted supported in a triangular arrangement of three mountings: one on the right-hand side...
  • Page 31 2A•12 OHV engine 18.4a Camshaft retaining plate bolts 18.4b Removing the engine front plate 18.5 Removing the camshaft (arrowed) 9 Lubricate the camshaft bearing journals into position. Make sure that the seal is fully 18 Camshaft and tappets - and carefully insert the camshaft. entered into its location so that its outer face 10 Place a new gasket in position and then is flush with the edge of the bearing cap and...
  • Page 32 OHV engine 2A•13 20.9 Bearing shell tab engages with 20.12 Lubricate the bearing shells 20.13 Fitting the crankshaft groove (arrowed) holes, while only the centre main bearing cap fitting the retaining bolts smear them with half-shells has an oil duct hole. jointing compound and then tighten to the 12 When the shells are fully located in the specified torque wrench setting.
  • Page 33 2A•14 OHV engine suitable for re-use. Check for cracks, damage or damage. If this is badly worn it will mean You are strongly advised to to the piston ring grooves and lands, and renewing the camshaft. renew the bearings - scores or signs of picking-up the piston walls.
  • Page 34 OHV engine 2A•15 flows into galleries drilled in the engine block worn but, if they are a very loose fit in their bolts, which are accessible from below. bores and can readily be rocked, they should to feed the main bearings on the crankshaft 13 Secure the lifting tackle to the engine and be exchanged for new ones.

  • Page 35: Specifications

    2B•1 Chapter 2 Part B: OHC engines Contents Ancillary components - removal and refitting ....5 Engine components - examination and renovation ....21 Camshaft - removal and refitting .

  • Page 36: Cylinder Head

    2B•2 OHC engines Cylinder head Material ..........Light alloy Maximum permissible distortion of sealing face .
  • Page 37 OHC engines 2B•3 Camshaft bearing (direct in housing) diameters: 1.3, 1.4 and 1.6 (C16NZ) litre engines: No 1 ..........39.500 to 39.525 mm No 2 .

  • Page 38: Lubrication System

    2B•4 OHC engines Flywheel Refinishing limit - depth of material which may be removed from clutch friction surface ........0.3 mm max Lubrication system Oil pump tolerances:...
  • Page 39 OHC engines 2B•5 Torque wrench settings (continued) lbf ft Camshaft sprocket bolt ........Crankshaft pulley bolt: 1.3, 1.4 and 1.6 (16SV and C16NZ) litre engine: Bolt with 23 mm thread length .
  • Page 40 2B•6 OHC engines 7.4 Jamming the flywheel ring gear 7.8 Slackening a water pump bolt 7.9 Swivelling the water pump using a spanner on the flats necessary, unscrew the union nuts and accessible through holes in the belt backplate clockwise). Tighten the water pump bolts disconnect the oil cooler pipes from the filter (see illustration).
  • Page 41 OHC engines 2B•7 13 Disconnect the HT leads, identifying them if necessary. Remove the distributor cap and the distributor itself, (Chapter 5). 14 Disconnect the temperature gauge wire from the sender on the thermostat housing or inlet manifold. 15 Unbolt the exhaust downpipe(s) from the exhaust manifold.
  • Page 42 2B•8 OHC engines Inlet Flywheel 8.26b Using a marked card to measure angular rotation when tightening cylinder head bolts Exhaust 8.26a Cylinder head bolt tightening sequence 9 Camshaft - removal and refitting their original positions. If new hydraulic valve each side of the spacer. Reconnect the fuel lifters are being used, or if they were supply and return lines.
  • Page 43 OHC engines 2B•9 9.5a Removing the Allen screws which 9.5b Removing the camshaft thrust plate 9.6 Removing the camshaft from the secure the camshaft thrust plate housing plate. Push the camshaft rearwards and 10 Refit the thrust plate and tighten its 15 Change the engine oil (but not the filter, extract the plate (see illustrations).
  • Page 44 2B•10 OHC engines 10.2 Exhaust valve spring rotator seat (A) 10.6 Hydraulic valve lifter components 10.12 Locate the ball (1) on its seat (2) in and inlet valve spring seat (B) the base of the plunger 1 Collar 5 Plunger cap distortion, or corrosion, may be corrected by (external surfaces).
  • Page 45 OHC engines 2B•11 10.16 Cylinder head oil pressure 12.6 Oil pick-up support bracket 12.7a Removing the oil baffle plate. This regulating valve (arrowed) model has two cork gaskets . . . be driven into position. Care must be taken to sump from side to side with a hide or plastic 13 Oil pump - removal and keep foreign matter and swarf out of the...
  • Page 46 2B•12 OHC engines 13.4 Oil pick-up pipe retaining bolts 13.6 Tape the crankshaft nose 14.1 Using an impact screwdriver to undo (arrowed) the oil pump rear cover screws b) Steps must be taken to protect the seal 3 Check the endfloat between the gear outer 16 Flywheel - removal and lips from damage or turning back on the faces and the housing (see illustration).
  • Page 47 OHC engines 2B•13 described in Section 7. On 1.6 (16SH), 1.8 and 2.0 litre models, note that it will also be necessary to undo the crankshaft sprocket centre bolt (see Section 7, paragraph 4) and remove the sprocket and spacers, noting their correct fitted locations.
  • Page 48 2B•14 OHC engines 20.15 Fitting the crankshaft 20.16a Fitting a main bearing cap 20.16b Tightening a main bearing cap bolt Valve lifters, rockers and thrust pads 9 Any signs of wear in a hydraulic lifter can only be rectified by renewal, the unit cannot be dismantled.
  • Page 49 OHC engines 2B•15 22.7a Crankcase ventilation hose attached 22.7b Camshaft housing filter 22.8 Crankcase ventilation system oil to camshaft cover (1 .8 litre engine shown) separator - 1.3 litre engine block. Although it is not a specified maintenance task, the separator can be removed for cleaning (see illustration).
  • Page 50 2B•16 OHC engines 23 Engine - removal and refitting Removal 1 The OHC engines may be removed either with or without the manual gearbox. To remove the engine alone, proceed as described in Chapter 2A, Section 23, making allowances for differences in the attachment of components such as the carburettor or fuel injection items.
  • Page 51 2C•1 Chapter 2 Part C: DOHC (16-valve) engine Contents Ancillary components - removal and refitting ....5 Engine - removal and refitting ......25 Camshaft sprocket oil seals - renewal .
  • Page 52 2C•2 DOHC (16-valve) engine Crankshaft Number of main bearings ........Main bearing journal diameter .
  • Page 53 DOHC (16-valve) engine 2C•3 Valves (continued) Valve guide internal diameter: Standard ..........7.000 to 7.015 mm Oversizes .
  • Page 54 2C•4 DOHC (16-valve) engine 7.6a Removing a belt cover bolt . . . 7.6b . . . and the rubber bush 7.6c The belt cover seal cleaner-to-air mass meter trunking. Slacken E20, will be needed. If this is not available, 6 Oil pressure regulating valve - the clips and remove the trunking.
  • Page 55 DOHC (16-valve) engine 2C•5 serious. The only way to be certain that tension is correct is to use the maker’s tool, or to have a Vauxhall garage carry out the work. 20 Whichever tensioning method was used, now turn the crankshaft through two full turns clockwise and check that the pulley and sprocket timing marks come back into correct alignment.
  • Page 56 2C•6 DOHC (16-valve) engine 10.6 Matching numbers on bearing cap 10.7 Distributor housing bearing cap has 10.11 Fitting a camshaft bearing cap and cylinder head two extra nuts 6 Check that the camshaft bearing caps carry identification numbers, and note which way round they are fitted.
  • Page 57 DOHC (16-valve) engine 2C•7 11.11 Disconnecting the heater hose from 11.15 Disconnecting the large breather 11.16 Removing a camshaft cover screw the cylinder head hose 9 Remove the exhaust manifold (Chapter 4B). secure the top of the belt backplate to the careful not to get any debris into the cylinder 10 Remove the radiator top hose.
  • Page 58 2C•8 DOHC (16-valve) engine 11.24a Cylinder head bolt tightening 11.24b Angle tightening a cylinder head 11.25 Fitting a new gasket to the camshaft sequence bolt cover 25 The remainder of refitting is a reversal of b) Use a new camshaft toothed belt and 4 Using a sucker or a magnet, remove the the removal procedure, noting the following tension it as described in Section 7.
  • Page 59 DOHC (16-valve) engine 2C•9 12.12a Fit a valve stem oil seal into a 12.12b . . . and press it home 12.13 Fitting a valve collet socket or tube . . . 7 Repeat the operations on the other 15 compressor.
  • Page 60 2C•10 DOHC (16-valve) engine Refitting 21 Crankshaft rear oil seal - 9 Commence refitting by smearing a new renewal gasket with grease and placing it on the pump. Grease the lips of the oil seal and refit Remove the flywheel as described in the pump, being careful not to damage the oil Section 20.
  • Page 61 DOHC (16-valve) engine 2C•11 2 Disconnect both leads from the battery. 21 Unbolt earth strap from 3 Depressurise the fuel system (Chapter 4B). transmission. 4 Remove the bonnet. 22 Disconnect the speedometer cable, or 5 Remove the air cleaner (Chapter 4B). disconnect speedometer sender...
  • Page 62 3•1 Chapter 3 Cooling, heating and ventilation systems Contents Heater components - removal and refitting .....9 Antifreeze mixture ......See Chapter 1 Coolant level check .
  • Page 63 3•2 Cooling, heating and ventilation systems avoid damaging the radiator If preferred, the Warning: Do not allow 1 General information and cooling fan may be removed first, as antifreeze to come into contact described in Section 6, to provide greater precautions with skin or painted surfaces of access.
  • Page 64 Cooling, heating and ventilation systems 3•3 4.3a Remove the thermostat retaining 4.3b . . . and withdraw the thermostat - 1.2 4.6 Removing the thermostat housing . . . snap-ring . . . litre model 1.2 litre models 7 Remove the thermostat from its recess, 11 If a thermometer is available, the precise opening temperature of the thermostat may noting how the projections on the thermostat...
  • Page 65 3•4 Cooling, heating and ventilation systems disturbed components as described in Chapter 2 Part C. On completion refill the system as described in Chapter 1. 6 Radiator electric cooling fan - testing, removal and refitting Testing 1 The cooling fan is supplied with current via the ignition switch, relay and a fuse (see Chapter 12).
  • Page 66 Cooling, heating and ventilation systems 3•5 13 If the gauge needle remains at the `hot’ 8 To separate the fan motor from the cowl Refitting unscrew the three nuts. The fan blades may end of the scale, disconnect the sender wire. 7 Refitting is a reversal of removal using a be withdrawn from the motor spindle after If the needle then returns to the `cold’...
  • Page 67 3•6 Cooling, heating and ventilation systems 9.3 Exploded view of heater components 1 Facia panel 9 Side vent housing 17 Air mix (temperature) cable 2 Bulkhead 10 Side vent housing 18 Upper distribution cable 3 Blower motor 11 Side ducts 19 Lower distribution cable 4 Centre duct 12 Windscreen ducts...
  • Page 68 Cooling, heating and ventilation systems 3•7 9.4a Removing a screw from the top of the 9.4b Heater control panel side screw 9.5 Removing the heater control panel radio aperture 3 Detach the three control cables from the air 8 Remove the water deflector by freeing it control panel is recommended, as described distribution housing, noting their locations for from under the rubber seal and extracting its...
  • Page 69 3•8 Cooling, heating and ventilation systems 10 Vents and grilles - removal and refitting 1 The flat grilles at each end of the facia simply unclip. According to equipment level they may also cover a loudspeaker (see illustration). 2 The swivelling vents can be unclipped after swivelling them downwards as far as possible.
  • Page 70 4A•1 Chapter 4 Part A: Fuel and exhaust systems - carburettor models Contents Accelerator cable - removal, refitting and adjustment ... . .8 Idle cut-off solenoid - description and testing ....17 Accelerator pedal - removal and refitting .
  • Page 71 4A•2 Fuel and exhaust systems - Carburettor models 32TL Carburettor data - 12SC engine (Continued) Accelerator pump return jet ........Accelerator pump delivery .
  • Page 72 Fuel and exhaust systems - Carburettor models 4A•3 2E3 Carburettor data - 14 NV engine Primary Secondary Venturi diameter ......... . . 20 mm 24 mm Main jet .
  • Page 73 4A•4 Fuel and exhaust systems - Carburettor models Recommended fuel grade (Continued): 1.4 litre models ......... . 98 RON leaded (4-star) or 95 RON unleaded (unleaded premium) 1.6 litre models: 16SH engines .
  • Page 74 Fuel and exhaust systems - Carburettor models 4A•5 3.2a Hot air pick-up tube (arrowed) 3.2b Air cleaner vacuum hose connection 3.2c Air cleaner hose connection engages with air cleaner disengaging the hot air pick-up from the cold air ports according to temperature and 2 The pump can also be tested by removing it.
  • Page 75 4A•6 Fuel and exhaust systems - Carburettor models 6.2 Fuel gauge sender unit (screw-fit 6.3 Fuel gauge sender unit secured by 7.11 Fuel tank filler pipe-to-neck junction sender unit) bolts 2 Disconnect the electrical leads from the thread protruding through the handbrake Estate and Van sender unit (see illustration).
  • Page 76 Fuel and exhaust systems - Carburettor models 4A•7 enrichment valve, ensure efficient operation under all speed and load conditions. 4 The GM Varajet ll carburettor fitted to 1.6 models is also a twin barrel type, but the main fuel jet is controlled by a tapered needle valve. The design is well proven and has been used on several earlier models.
  • Page 77 4A•8 Fuel and exhaust systems - Carburettor models 12.4 Fast idle adjusting screw (arrowed) 12.11a Using a drill bit to check the choke 12.11b Choke valve gap adjusting screw valve gap (arrowed) 5 If the carburettor is in the car, first allow the 16 With the carburettor assembled and the Accelerator pump delivery engine to reach normal operating temperature...
  • Page 78 Fuel and exhaust systems - Carburettor models 4A•9 14.4 Removing the tamperproof cap from 14.5 Notches on choke cover and 14.6 Position choke cover with opening the fast idle adjustment screw carburettor housing (arrowed) aligned lever to the left of drive lever screw on the cam plate if necessary and Vacuum pull-down unit correct the alignment, then retighten the...
  • Page 79 4A•10 Fuel and exhaust systems - Carburettor models 15.7 Choke drive lever (A) engages with 15.9a Checking the choke pull-down gap. 15.9b Choke pull-down adjusting screw loop (B) Apply vacuum to hose arrowed Choke pull-down 11 Press in the screw further until the arm 16 Check that the fast idle adjustment screw moves to its stop.
  • Page 80 Fuel and exhaust systems - Carburettor models 4A•11 16.4 Fast idle screw (arrowed) positioned 16.10 Choke pull-down measurement on cam second highest step A See Specifications (Choke valve gap A) B Adjustment screw valve plate. A twist drill or similar should be 18 If adjustment has been necessary, used as a gauge (see illustration).
  • Page 81 4A•12 Fuel and exhaust systems - Carburettor models Manual choke carburettor Idle speed and mixture 38 Refer to Chapter 1. Fast idle speed 39 The idle speed must be correct and the engine must be at operating temperature. Remove the air cleaner and plug its vacuum hose.
  • Page 82 Fuel and exhaust systems - Carburettor models 4A•13 19.3 Removing the throttle return spring 19.4 Disconnecting the vacuum hose 19.5a Four screws (arrowed) secure the carburettor cover to the float chamber housing 19.5b Separating the cover from the float 19.6 Undo the screw (arrowed) to 19.7 Throttle valve housing components chamber housing separate the throttle valve and float...
  • Page 83 4A•14 Fuel and exhaust systems - Carburettor models 19.12 Extracting the float pivot pin 19.13 Lift off the gasket 19.14 Removing the float needle valve. Main jet is arrowed posts and withdraw the pin using long-nosed and choke valve rod. Remove the cam and 27 Check the float level as shown after pliers (see illustration).
  • Page 84 Fuel and exhaust systems - Carburettor models 4A•15 20.2 Exploded view of 35 PDSI carburettor 1 Cover 2 Gasket 3 Fuel inlet needle valve 4 Float pivot pin clip 5 Float pivot pin 6 Float 7 Body 8 Fuel cut-off solenoid valve 9 Accelerator pump diaphragm spring 10 Diaphragm 11 Diaphragm housing cover...
  • Page 85 4A•16 Fuel and exhaust systems - Carburettor models 21.3 Lifting off the carburettor top cover 21.4 Adjustment screws and idle cut-off 21.5 Throttle valve shaft lever and nut valve plug (arrowed) (arrowed) 4 Remove the idle speed and mixture adjustment screws, and the idle cut-off valve 21 1B1 carburettor - overhaul or plug (see illustration).
  • Page 86 Fuel and exhaust systems - Carburettor models 4A•17 Clean and inspect the various components as described in Section 19, paragraphs 19 to 25. 14 Reassembly reversal dismantling procedure. Note that float level is not adjustable on this carburettor. 15 After refitting, adjust the idle speed and mixture setting as described in Chapter 1 then carry out the other adjustments described in Section 14 of this Chapter.
  • Page 87 4A•18 Fuel and exhaust systems - Carburettor models 23.3 Exploded view of Varajet ll carburettor 1 Cover 2 Gasket 3 Packing piece 4 Float pin 5 Accelerator pump piston 6 Spring 7 Float 8 Fuel inlet needle valve 9 Check ball (accelerator pump) 10 Fuel inlet union 11 Fuel filter 12 Idle speed adjustment screw...
  • Page 88 Fuel and exhaust systems - Carburettor models 4A•19 23.13 Float and needle valve 23.22 Measuring the float level 23.23 Float adjustment points (arrowed) 11 Pull or twist out the vacuum piston spring automatic choke engages positively with the 10 Disconnect the brake servo vacuum hose. choke valve plate spindle arm.
  • Page 89 4A•20 Fuel and exhaust systems - Carburettor models 27.4a Exhaust system flexible joint 27.4b Exhaust system rubber mounting 27.5 Graphite sealing ring fitted at the ring flexible joint 6 Remove the securing nuts or bolts from the Removal Removal manifold-to-downpipe joint. 2 Disconnect the battery earth (negative) 2 To remove the exhaust system, jack up the 7 Remove the manifold securing nuts and...
  • Page 90 4B•1 Chapter 4 Part B: Fuel and exhaust systems - fuel-injected models Contents Accelerator cable - removal, refitting and adjustment ... . .3 Fuel system - depressurisation ......6 Air cleaner filter element renewal .
  • Page 91 4B•2 Fuel and exhaust systems - fuel-injected models Torque wrench setting lbf ft Multec CFI components: Throttle body/injector unit retaining nuts ..... . Throttle body/injector housing upper section retaining screws .
  • Page 92 Fuel and exhaust systems - fuel-injected models 4B•3 control unit, and from these signals, the this is necessary to avoid detenation (knocking and pinking) which could lead to appropriate control impulses for the fuel possible engine damage injectors are generated Additional circuitry within the control unit operates 5 On early (18E engine) models, to allow the an overrun fuel cut-off to reduce fuel...
  • Page 93 4B•4 Fuel and exhaust systems - fuel-injected models pipe, and controls the operating pressure Later (1987 onwards) 1.8 litre models dealers or other specialists with the necessary test equipment. in the fuel system. The unit consists of a 9 A Bosch L3 Jetronic fuel injection system is 19 If a fault is detected by the control unit, a metal housing, divided into two chambers fitted to all later 1.8 litre models fitted with the...
  • Page 94 Fuel and exhaust systems - fuel-injected models 4B•5 11 Single-point fuel injection 9 Fuel tank - removal and refitting system components (1.4 and 1.6 litre models) - removal and refitting Refer to Chapter 4 Part A, Section 7. 1 Disconnect the battery negative lead and 10 Fuel injection system - testing proceed as described under the relevant sub- and adjustment...
  • Page 95 4B•6 Fuel and exhaust systems - fuel-injected models 11.1 Single-point fuel injection system components and location on 1.4 litre model 1 Throttle valve injection housing 2 Fuel pump sensor 3 Filter 4 Fuel pressure regulator 5 Injection valve 6 Throttle valve (potentiometer) 7 Idle air stepper motor 8 Inlet manifold pressure...
  • Page 96 Fuel and exhaust systems - fuel-injected models 4B•7 11.3a Detach the wiring connector from 11.3b Throttle valve potentiometer removal 11.6a Disconnect the wiring connector . . . the throttle valve potentiometer 11.6b . . . undo the retaining screw . . . 11.6c .
  • Page 97 4B•8 Fuel and exhaust systems - fuel-injected models Ensure that the new diaphragm and its seatings are clean. Note that no adjustment to the regulator unit is necessary (or possible). Inlet manifold pressure sensor 19 This unit is located on the engine side of bulkhead.
  • Page 98 Fuel and exhaust systems - fuel-injected models 4B•9 12.14 Airflow meter securing bolts 12.36a Removing the control relay and 12.36b Unplugging the control relay (arrowed) bracket 18 Remove the footwell trim panel. temperature gauge sensor, it is known as 37 Refit in the reverse order to removal. 19 Make sure that the ignition is switched off, temperature sensor ll.
  • Page 99 4B•10 Fuel and exhaust systems - fuel-injected models 12.46b . . . and peel back the door 12.47 Prise out the clips to release the trim 12.48 Motronic control unit location surround strip panel 47 Open the access panel in the side trim. injectors to the fuel rail by prising them out.
  • Page 100 Fuel and exhaust systems - fuel-injected models 4B•11 12.73 Disconnecting the fuel return line 12.74 Disconnecting the vacuum hose 12.77 Removing a pre-volume chamber from the fuel pressure regulator screw 70 Refitting is the reverse of the removal 75 Remove the four Torx screws which 83 Refitting is the reverse of the removal secure the pressure regulator to the fuel rail.
  • Page 101 4B•12 Fuel and exhaust systems - fuel-injected models 12.91 Knock sensor multi-plug (arrowed) 12.94 Disconnecting the oxygen sensor 12.95 Removing the oxygen sensor seen from below multi-plug 12.98a Canister clamp nut (arrowed) 12.98b Disconnecting a hose from the 12.100 Disconnecting the vent valve canister multi-plug 92 Refitting is the reverse of the removal...
  • Page 102 Fuel and exhaust systems - fuel-injected models 4B•13 13.3b Disconnecting a fuel injector plug 13.3c Unplugging the throttle valve switch 13.3d Unplugging the auxiliary air valve lead connector wire clip, and the outer is retained in its adjuster strap nut and bolt (see Chapter 1). 24 Bearing in mind the information given in bracket by an E-clip (see illustration).
  • Page 103 4B•14 Fuel and exhaust systems - fuel-injected models 13.27a Disconnect the brake servo 13.27b . . . and the large coolant hose 13.32 Removing the inlet manifold - 2. litre hose . . . 16-valve model adjuster and the knock sensor. Disconnect b) Tighten the manifold nuts to the specified support bracket (see illustration).

  • Page 104: Battery Check

    5A•1 Chapter 5 Part A: Starting and charging systems Contents Alternator - removal and fitting .......7 General information and precautions .
  • Page 105 5A•2 Starting and charging systems Always remove rings, watches, etc before or deterioration of the internal plates. Standard and low maintenance working on the electrical system. Even with 3 If the specific gravity variation is 0.040 or battery - charging battery disconnected, capacitive...
  • Page 106 Starting and charging systems 5A•3 brushes at a reasonable cost. However, check on the cost of repairs before proceeding as it 4 Battery - removal and refitting may prove more economical to obtain a new or exchange alternator. Removal 9 Starting system - testing 1 The battery is located on the left-hand side of the engine bay.
  • Page 107 5A•4 Starting and charging systems 5 The solenoid contacts can be checked by 2.0 litre 16-valve models 2 Disconnect the battery negative lead and connecting a voltmeter or test lamp between disconnect the wiring from the switch/sender 8 Remove the starter motor-to-transmission the battery positive feed connection on the (see illustration).
  • Page 108 5B•1 Chapter 5 Part B: Contact breaker ignition system Contents Condenser - testing, removal and refitting ..... .5 General information ........1 Contact breaker points - gap and dwell angle adjustment .
  • Page 109 5B•2 Contact breaker ignition system distributor cap is cracked, the rotor arm is 17 If there is still no spark, examine the faulty or the carbon brush in the top of the distributor cap carefully for tracking. This can 2 Ignition system - testing distributor cap is not making good contact be recognised by a very thin black line running with the spring on the rotor arm.
  • Page 110 Contact breaker ignition system 5B•3 of one type of meter is outlined as follows. Refitting 12 To set the dwell angle, remove the 5 Locate the new contact set on the distributor cap and rotor arm and connect one baseplate and refit the retaining screw. lead of the dwell meter to the ‘+’...
  • Page 111 5B•4 Contact breaker ignition system 6.3 Ignition timing marks (arrowed) in 6.8 Correct position of oil pump driveshaft 6.7 Distributor rotor position prior to refitting alignment prior to fitting distributor A LT lead grommet B No1 reference mark 6 Move the contact breaker arm spring blade 12 Refer to Section 8 and adjust the ignition away from the plastic insulator and withdraw the distributor shaft is in the correct position...
  • Page 112 Contact breaker ignition system 5B•5 7.6a Remove the vacuum unit retaining 7.6b . . . and disengage the operating arm 7.7 Undo the baseplate retaining screws screws (arrowed) . . . (arrowed) while withdrawing the unit (arrowed) weights for cleaning or inspection, this can and springs in position, hold the skew gear at number of degrees BTDC when the marks are now be done.
  • Page 113 5B•6 Contact breaker ignition system be felt by removing No 1 spark plug and are two sets of each windings. Compare the 9 Ignition HT coil - removal, results obtained to those given in the feeling for compression with your fingers as Specifications at the start of this Chapter.
  • Page 114 5C•1 Chapter 5 Part C: Electronic (breakerless) ignition systems Contents Distributor - overhaul ........4 Ignition module (control unit) - removal and refitting .
  • Page 115 5C•2 Electronic (breakerless) ignition systems 1.6 litre (16SH engine) models and signals are derived from an inductive pulse Carburettor models and 1.8 litre 1.8 litre (18E engine) models sensor mounted on the front face of the (18E engine) models cylinder block and a segmented disc attached On these models a Bosch (Hall effect) Note: Refer to the warning given in Section 1 to the crankshaft No 1 counterweight.
  • Page 116 Electronic (breakerless) ignition systems 5C•3 3.3 Crankshaft pulley timing notch 3.4 Disconnecting the distributor wiring 3.5 Removing the distributor from the (arrowed) aligned with pointer (1.3 litre connector at the ignition coil camshaft housing model shown, others similar) resistance as described later in this Section; in the distributor cap.
  • Page 117 5C•4 Electronic (breakerless) ignition systems 3.6c Removing the flash shield to expose 3.6d Removing the distributor upper 3.6e Removing the distributor - note peg- the No 1 cylinder reference mark (arrowed) securing nut (1.6 litre carburettor and-hole drive (1.6 litre carburettor (1.6 litre carburettor model shown) model shown) model shown)
  • Page 118 Electronic (breakerless) ignition systems 5C•5 3.14 On 2.0 litre 16-valve models, 3.16 . . . then undo the retaining bolts . . . 3.17 . . . and remove the distributor disconnect the Hall sensor wiring . . . 3.19a Distributor rotor contact, and arrow 3.19b .
  • Page 119 5C•6 Electronic (breakerless) ignition systems 4.2 Exploded view of AC Delco breakerless type distributor - 1.3 litre models 1 Distributor cap 2 Rotor 3 Shaft 4 Pin 5 Drive dog 6 Spring 7 Washer 8 Spring 9 O-ring 10 Body 11 Seal 12 Ignition module 13 Induction sensor...
  • Page 120 Electronic (breakerless) ignition systems 5C•7 distributor is correctly refitted (Section 3), the 4.14 Exploded view of the Bosch breakerless type distributor - timing should be accurate enough to start the 1.6 litre (16SH engine) and 1.8 litre (18E engine) models engine and permit it to run.
  • Page 121 5C•8 Electronic (breakerless) ignition systems 6.2 Disconnecting a coil LT lead (1.8 litre 6.3 Ignition module wiring plug 6.4a Removing a coil securing bolt model shown) Specifications at the start of this Chapter. the coil, as described in Section 6. Note the resistance of the coil windings will 3 With the coil removed from its bracket, the vary slightly according to the coil temperature,...

  • Page 122: Fluid Level Checks

    9•1 Chapter 9 Braking system Contents Anti-lock braking system (ABS) - general information ... .21 Hydraulic fluid renewal ......See Chapter 1 Anti-lock braking system (ABS) components - removal and refitting .22 Hydraulic pipes and hoses - renewal .
  • Page 123 In the The handbrake provides an independent event of rupture of the hydraulic system in one genuine Vauxhall/Opel replacement parts, or mechanical means of rear brake application. circuit, the remaining circuit will still function at least those of known good quality. Note the On 2.0 litre GTE models the handbrake...
  • Page 124 Braking system 9•3 basic (two-man) method must be used which 19 When no more air bubbles appear, tighten is described in detail below. the bleed screw securely, remove the tube 2 Hydraulic system - bleeding 9 If a kit is to be used, prepare the vehicle as and spanner and refit the dust cap.
  • Page 125 Use brake side is against the disc. When fitting disc pads Vauxhall/Opel dealers. All that is then supplied by the vehicle manufacturer, it may cleaner or methylated spirit only. necessary is to bend it to shape, following the be found that two pads out of the four have line of the original, before fitting it to the car.
  • Page 126 Braking system 9•5 4.10b Pad retaining pins and anti rattle 4.16 On later ATE type calipers, unclip the 4.17 . . . then lever out the spring clip springs correctly fitted pad wear sensor . . . 12 Refit the roadwheels and lower the 20 Lift the caliper body and inboard pad off tightening them to the specified torque.
  • Page 127 9•6 Braking system 5.3 Driving out a rear disc pad retaining pin 5.9a Fitting a rear pad 5.9b Hooking the spring under one retaining pin middle of the vehicle (see illustration). anti-seize compound to the backs of the new Recover the spring. pads, and to the sides of the backplate.

  • Page 128: Handbrake Adjustment

    Braking system 9•7 6.6 Handbrake cable attachment to 6.13 Self-adjusting strut components 6.16 Handbrake lever secured by pin operating lever (arrowed) right-hand side 6 Disconnect the handbrake cable from the and the other ‘handed’ components are colour- pass over the new linings. Make sure that the coded: black for the left-hand side, and silver handbrake lever is correctly positioned (pin on operating lever (see illustration).
  • Page 129 9•8 Braking system made on removal, then lower the vehicle to the ground and tighten the roadwheel bolts to the specified torque. On completion, repeatedly depress the brake pedal until normal (non-assisted) pedal pressure returns. 8 Rear brake disc - inspection, removal and refitting Note: Before starting work, refer to the note at the beginning of Section 5 concerning the...
  • Page 130 Braking system 9•9 surface being recessed by excessive wear, an assistant listen to the rear drums to check Overhaul then the drum must be renewed. that the adjuster strut is functioning correctly; Early ATE type caliper 7 If the drum is thought to be excessively if this is so a clicking sound will be emitted by worn, or oval, its internal diameter must be the strut as the pedal is depressed.
  • Page 131 9•10 Braking system 38 Fit the new sealing rings to the sliding 11 Rear brake caliper - removal, sleeve recesses and apply the grease supplied in the repair kit to the sleeves. Install overhaul and refitting the sleeves making sure they are fitted the correct way around.
  • Page 132 Braking system 9•11 9 Push the piston into its bore and repeat the 8 Inspect the surfaces of the piston and the operation on the opposite piston. cylinder bore for rust, scoring or metal-to- metal rubbed areas. If these are evident, Refitting renew the wheel cylinder complete.
  • Page 133 9•12 Braking system 17 Insert the assembly tube into the cylinder bore as far as the collar on the short sleeve. Use a blunt rod to push the secondary piston into the bore until it contacts the end of the cylinder.
  • Page 134 Braking system 9•13 4 Wipe clean the area around the valves and 13.26 Exploded view of GMF master cylinder place absorbent rags beneath the pipe unions to catch any surplus fluid. Make a note of the 1 Body correct fitted positions of the unions then 2 Seals unscrew the union nuts and carefully 3 Circlips...
  • Page 135 9•14 Braking system 2 Unscrew the hose union nut at the inlet manifold (see illustration). 3 Pull or prise the elbow connector out of the servo (see illustration). 4 Cut the hose off the non-return valve, the elbow and the manifold connectors. 5 Cut the new hose to length - it is sold by the yard - and secure it to the valve and fittings using hose clips.
  • Page 136 Braking system 9•15 16.12 Servo clevis adjustment - Left-hand 16.13a Servo mounting bracket lower half 16.13b Fit the servo with the vacuum drive models remains on bulkhead connector (arrowed) positioned as shown A = 278.5 mm (10.97 in) a) Use sealing compound on the bracket removing the clevis pin retainer (split pin or plastic sleeve from each brake backplate.
  • Page 137 9•16 Braking system Refitting 7 Commence refitting bolting handbrake lever in place. Tighten the bolts to the specified torque. 8 Secure the carpet with glue and/or sticky tape. (The cut area will be covered by the console.) 9 Refit and secure the console, and its switches when applicable.
  • Page 138 Braking system 9•17 21.2 Main components of the ABS 1 Front wheel speed sensors 2 Rear wheel speed sensors 3 Master cylinder 4 Servo 5 Hydraulic unit 6 Electronic control unit 7 Brake proportioning valves 8 Diagnostic Plug components is required. The hydraulic pipes anti-seize compound to the body of the 22 Anti-lock braking system and unions must be inspected for condition...
  • Page 139 9•18 Braking system 22.3a Rear sensor connectors next to 22.3b Separating a front sensor connector 22.10 ABS surge arrester relay (arrowed) petrol tank (earlier models) 22.15 Two screws (arrowed) which secure 22.16a Removing the relays from the 22.16b Squeeze the multi-plug catch the hydraulic unit cover hydraulic unit (arrowed) to realise it...
  • Page 140 10•1 Chapter 10 Suspension and steering Contents Control arm balljoint - renewal .......7 Rear axle mounting bushes - renewal .
  • Page 141 10•2 Suspension and steering Roadwheels Type ........... . Pressed-steel or aluminium alloy (depending on model) Size .
  • Page 142 Suspension and steering 10•3 shock absorbers used, mounted A collapsible steering column is fitted; on independently of each other. Again, an some models the top part of the column is 1 General information anti-roll bar is fitted to most models (see adjustable to provide different steering wheel illustration).
  • Page 143 10•4 Suspension and steering 1.2 Exploded view of rear suspension components 1 Shock absorber (Estate) 5 Hub nut 9 Inner bearing 13 Axle arm bush 10 Oil seal 14 Anti-roll bar 2 Spring* 6 Thrustwasher 3 Shock absorber (Hatchback) 7 Outer bearing 11 Stub axle 15 Rubber damper 4 Spring*...
  • Page 144 Suspension and steering 10•5 3.5b Removing a hub bearing circlip 4.6a One method of unscrewing the strut ring nut 10 Refit the brake disc shield. 6 To remove the shock absorber cartridge, 11 Support the bearing inner race with a tube unscrew the ring nut from the top of the strut and press the hub into position.
  • Page 145 10•6 Suspension and steering 5.3 Control arm balljoint nut (arrowed) 5.4 Control arm clamp bolts (arrowed) 11 Reconnect the anti-roll bar (if applicable). and drill accurately into a centre punch mark Refer to Section 8 for tightening procedure. on each rivet head. Have this work done 4.10 Sectional view of strut top mounting 12 Refit the roadwheel, lower the vehicle and professionally if need be: sloppy drilling will...
  • Page 146 Suspension and steering 10•7 5 Renew the rubber mountings as necessary. 9.10 Rear wheel hub assembly - later Use a silicone-based lubricant on the (1992 onwards) models bulkhead bracket bushes. 1 Hub Refitting 2 Bearing housing 6 When refitting, fasten the two brackets first; 3 Stud tightening their bolts to the specified torque.
  • Page 147 10•8 Suspension and steering 2 Prise the oil seal out of the inboard side of the hub. 3 Extract the inner bearing race, then press or drive the bearing outer tracks from the hub. 4 Clean out the old grease from the hub cavity.
  • Page 148 Suspension and steering 10•9 13 Fit the new spring and dampers. Where conical type springs are fitted, ensure that the upper ends are correctly located in the spring seat (see illustration 14.8). 14 Raise the jack and reconnect the shock absorber lower mounting on that side, then transfer the jack to the other side and secure the other shock absorber.
  • Page 149 10•10 Suspension and steering Refitting 11 With the aid of an assistant, offer the new axle to the vehicle, remembering to pass the handbrake cable over the exhaust system. Insert the axle arm mounting bolts, but do not tighten them yet. 12 Fit the springs and secure the shock absorbers, as described in Section 14.
  • Page 150 Suspension and steering 10•11 2 Unload the shock absorber mounting by jack and a block of wood or a cradle. 4 Maintenance consists of checking the jacking up under the axle arm. 24 Remove the shock absorber lower pressure lines and unions for security and 3 Slacken and remove the upper and lower mounting bolts on both sides.
  • Page 151 10 If a new column assembly is to be fitted, a cylinder and carefully withdraw the cylinder Vauxhall/Opel dealer for further information. large plastic washer will be found at the base from its housing (see illustration). It is of the column tube. This is to centre the shaft...
  • Page 152 Suspension and steering 10•13 7 Refit the roadwheel, lower the vehicle and 2 Remove the securing nut at the moving end tighten the wheel bolts. of the damper (see illustration). Recover the 8 Check the front wheel alignment and adjust washer.
  • Page 153 10•14 Suspension and steering 27.11 Steering gear centralising diagram A = 325 mm 11 Before connecting the flexible coupling 2 On models equipped with power-assisted until the fluid level stabilises. It is important steering inspect all the steering gear fluid that the pump is not allowed to run dry.
  • Page 154 Suspension and steering 10•15 Refitting rear of the vehicle at its upper end. described, with the car stationary. The second Steering axis inclination is the angle, type, known as a scuff plate, measures the 3 Refit in the reverse order to removal. Bleed when viewed from the front or rear of the actual position of the contact surface of the the system on completion, as described in...
  • Page 155 11•1 Chapter 11 Bodywork and fittings Contents Bonnet - removal and refitting .......6 Maintenance - bodywork and underframe .
  • Page 156 11•2 Bodywork and fittings 3 Periodically, except on vehicles with a wax- 8 The use of automatic car washes is not and to clear the surrounding bodywork of wax based underbody protective coating, it is a recommended for convertible models, as polish.
  • Page 157 Bodywork and fittings 11•3 13 Aluminium tape should be used for small 5 Should the dent be in a section of the bodystopper, and once more smooth the bodywork which has a double skin or some or very narrow holes. Pull a piece off the roll surface with abrasive paper.
  • Page 158 Vauxhall/Opel dealer using special jigs. If the body is left misaligned, it is primarily dangerous as the car will not handle properly,...
  • Page 159 Bodywork and fittings 11•5 Refitting 8.4 Front trim panel mounting points 5 Clean all sealant away from the body flange; commence refitting by applying a thick bead of new sealant. 6 Offer the wing to the vehicle and bolt it loosely into position.
  • Page 160 11•6 Bodywork and fittings 12.2 Window winder handle spring clip 12.3 Removing the surround from the 12.4 Unscrewing the lock button (arrowed) remote control handle 5 The two halves of the wind deflector can be are two Torx screws at the fore end (see separated if wished by pulling them apart.
  • Page 161 Bodywork and fittings 11•7 3 Disconnect the control rods and remove the Refitting lock. (In the case of the front door, do not 4 Reassemble in the reverse order, noting the disconnect the interior lock button rod, but position of the spring legs and their withdraw the lock and rod complete.) relationship to the arm.
  • Page 162 11•8 Bodywork and fittings 18.2 Convertible electric window lifter arm 18.5a Two window lifting mechanism 18.5b Window lifting channel bolts secured (1) prior to removal of the securing rivets (arrowed) (arrowed) regulator unit 5 Carefully lift the window out through its 21 Tailgate hinge - removal and opening in the door.
  • Page 163 Bodywork and fittings 11•9 22.2 Releasing a tailgate strut spring clip 23.2 Tailgate lock retaining screws 23.3 Lock operating rod connection to arm (arrowed) - Hatchback (arrowed) not remove the spring clips completely, nor 3 Unhook the operating rod from the lock 25 Boot lid and torsion rods - prise them out further than 6 mm (0.24 in).
  • Page 164 11•10 Bodywork and fittings Refitting 5 Refit in the reverse order to removal. 29 Rear quarterlight (opening type) - weatherstrip renewal 1 Remove the quarterlight, as described in the previous Section. 2 Cut the old weatherstrip and rubber mount from the body flange. Clean up the flange, but do not remove the old adhesive completely.
  • Page 165 Bodywork and fittings 11•11 30.4 Mirror retaining screws (arrowed) 31.1 Seat rail trim removal 31.2a Seat rail front retaining bolt (one of two) trim. Undo the three retaining screws and Refitting remove the mirror (see illustration). 4 Refit in the reverse order to removal, but 5 Refitting is the reverse of removal.
  • Page 166 11•12 Bodywork and fittings 33.3a Unscrewing the side hinge plate 33.3b Seat pivot lifts out of hinge 33.3c Unscrewing the centre hinge cover 33.3d Centre hinge top half bearing 33.3e Rear seat backrest catch retaining 33.5a Seat backrest catch striker - nut - Saloon Hatchback 34 Luggage area trim panel...
  • Page 167 Bodywork and fittings 11•13 35.2b Removing the centre console rear 35.4a Centre console screw (arrowed) to 35.4b Centre console screw (arrowed) in half screw rear of gear lever front of gear lever 5 Release the two retaining clips and remove 1 Inertia reel front seat belts are fitted to all the oddments box from below the heater models.
  • Page 168 11•14 Bodywork and fittings 37.6b Belt feeds through guide in pillar trim 37.7a Rear seat belt inertia reel 37.7b Rear seat belt upper mounting on 5-door models the door seal will have to be the handle clockwise when the roof is closed disturbed to remove the panels.
  • Page 169 12•1 Chapter 12 Body electrical system Contents Battery - removal and refitting ....See Chapter 5A Heated seats - general information ......17 Battery check and maintenance .
  • Page 170 12•2 Body electrical system Fuses - early models Fuse Rating (amps) Circuit(s) protected 10 ..........LH side and tail lamps, instrument and engine compartment illumination, “lights-on”...

  • Page 171: Fuses And Relays

    Body electrical system 12•3 faulty, dismantle the connection and clean fault can be narrowed down by noting if other 11 Switch on the circuit, bearing in mind that components related to the circuit are some circuits are live only when the ignition back to bare metal both the bodyshell and the operating properly.

  • Page 172: Switches - Removal And Refitting

    12•4 Body electrical system 3.8a Relay identification 3.7a Headlamp washer relay and fuse 3.7b Removing the headlamp washer fuse Flasher unit Heated rear window relay 7 Models with a full range of optional Hazard warning switch Windscreen wiper relay/delay unit equipment may carry one or two fuses on the 4 This is removed and refitted in the same Front foglamp relay...
  • Page 173 Body electrical system 12•5 Refitting 3 Refit in the reverse order to removal. 7 Cigarette lighter - removal and refitting Removal 1 Disconnect the battery earth lead. 2 Extract the heater element from the lighter socket. 3 Carefully prise the lighter socket out of the 4.14a Drawing the steering column 4.14b Unclipping a steering column switch illuminating ring.
  • Page 174 12•6 Body electrical system 8.4 Removing an instrument panel 8.5 Withdrawing the instrument panel 8.7a Removing the instrument panel surround screw surround securing screw making notes if there is any possibility of confusion later. When an econometer is fitted, disconnect the vacuum hose. Refitting 8 Refit in the reverse order of removal.
  • Page 175 Body electrical system 12•7 11.2a Disconnecting the headlamp wiring 11.2b Rubber cover removed to expose the 11.3 Removing a headlamp bulb plug spring clip e) Always ensure that the new bulb is of the Sidelamp (front parking lamp) 12 Unclip and remove the bulb, separating its correct rating and that it is completely electrical connector at the first junction, not at 6 Open the bonnet and disconnect the wiring...
  • Page 176 12•8 Body electrical system 11.19 Removing a rear foglamp lens 11.22 Prising out the number plate lamp 11.23 Number plate lamp bulb holder and lens separated 11.25a Under-bonnet lamp unclipped note 11.25b Luggage area lamp unclipped 11.25c Removing the cover from the main earth screw (arrowed) interior lamp Rear foglamp...
  • Page 177 12 Disconnect the battery earth lead. equipment and this work should therefore be 13 Disconnect the fuel flow meter multi-plug. carried out by a Vauxhall/Opel dealer or 14 Identify the fuel hoses, then disconnect suitably equipped workshop. and plug them. Be prepared for fuel spillage.
  • Page 178 12•10 Body electrical system 16.1 Central locking system components (LHD shown, RHD similar) 1 Central wiring connector 2 Electronic control unit 3 Servo motor 4 Servo motor 5 Earth point 6 Driver’s door switch Computer display lighting Component renewal 4 Remove securing screws, disconnect the switch plug and unhook the...
  • Page 179 Body electrical system 12•11 16.8 . . . to gain access to the boot latch 18.3 Removing the tailgate contact pins 19.1 Removing a wiper blade from its arm nuts (1), servo unit mounting screw (2) and 1 +ve permanent feed (wiper parking) - the manual release control rod (3) retainer and slide the blade off the arm (see black/violet...
  • Page 180 12•12 Body electrical system 20.7 Wiper motor securing screw (arrowed) 20.8a Wiper motor spindle nut (arrowed) 20.8b Undoing the wiper motor securing the motor from its bracket, also remove the 9 Undo the retaining nut, withdraw the motor three securing screws (see illustrations). from its location a little way and support it (see illustration).
  • Page 181 Body electrical system 12•13 22 Windscreen/rear window washer system - general information 1 All models fitted with electrically-operated windscreen washer. The reservoir is mounted on the left-hand side of the engine bay; the pump is a push fit into a grommet in the base of the reservoir.
  • Page 182 12•14 Body electrical system 25.7 On later models it will be necessary to 26.2a On Saloon models, unclip the plastic 26.2b . . . the speakers are retained by four remove the blanking screws to be able to covers to gain access to the underside of screws insert the removal tools the rear speakers .
  • Page 183 Wiring diagrams 12•15 Key to Diagram 1 - all models to 1986 (Not all items are fitted to all models) Description Track Description Track RH sidelamp Fuel injection control module 173 to 1 83 RH tail lamp 237, 440 Ignition module (electronic ignition) 118, 119 Number plate lamp 238, 451 Preheater relay (Diesel)
  • Page 184 12•16 Wiring diagrams Key to Diagram 1 - all models to 1986 (Not all items are fitted to all models) (continued) Description Track Description Track Automatic choke heater U5.1 Bulb failure warning lamp Ignition/starter switch 106, 107 U5.2 Stop-lamp failure warning lamp S2.1 Main lighting switch 239, 240, 439, 440...
  • Page 185 Diagram 1 - all models to 1986...
  • Page 186 Diagram 1 - all models to 1986 (continued)
  • Page 187 Diagram 1 - all models to 1986 (continued)
  • Page 188 Diagram 1 - all models to 1986 (continued)
  • Page 189 Wiring diagrams 12•21 Key to diagram 2 - all 1987 models Not all items are fitted to all models; not all engines or systems are found in UK models Description Track Description Track Parking lamp left Engine systems warning lamp 151, 209 Tail lamp left 329, 528...
  • Page 190 12•22 Wiring diagrams Key to diagram 2 - all 1987 models (continued) Description Track Description Track Manifold vacuum sensor 125, 127, 158, 160, 177, 179 U3.1 Clock switch Oil temperature sensor 128, 129, 182, 183, 276, 277 U3.2 Function select switch Bulb failure sensor 537, 550 U3.3...
  • Page 191 Diagram 2 - 1987 models...
  • Page 192 Diagram 2 - 1987 models (continued)
  • Page 193 Diagram 2 - 1987 models (continued)
  • Page 194 Diagram 2 - 1987 models (continued)
  • Page 195 Diagram 2 - 1987 models (continued)
  • Page 196 Diagram 2 - 1987 models (continued)
  • Page 197 Diagram 2 - 1987 models (continued)
  • Page 198 Diagram 2 - 1987 models (continued)
  • Page 199 Diagram 2 - 1987 models (continued)
  • Page 200 Diagram 2 - 1987 models (continued)
  • Page 201 Wiring diagrams 12•33 Key to diagram 3 - all models from 1990 on Not all items are fitted to all models; not all engines or systems are found in UK models Description Track Description Track Parking lamp left Relay headlamp washer 411, 413 Tail lamp left 329, 550...
  • Page 202 12•34 Wiring diagrams Key to diagram 3 - all models from 1990 on (continued) Description Track Description Track Throttle position sensor 160 to 162, 212/3, 256 to 258 U5.1 Brake pad wear warning Inductive sensor (crankshaft) 221 to 223, 273 to 275, 619 U5.2 Brake fluid level warning Air mass meter...
  • Page 203 Diagram 3 - all models from 1990 on...
  • Page 204 Diagram 3 - all models from 1990 on (continued)
  • Page 205 Diagram 3 - all models from 1990 on (continued)
  • Page 206 Diagram 3 - all models from 1990 on (continued)
  • Page 207 Diagram 3 - all models from 1990 on (continued)
  • Page 208 Diagram 3 - all models from 1990 on (continued)
  • Page 209 Diagram 3 - all models from 1990 on (continued)
  • Page 210 Diagram 3 - all models from 1990 on (continued)
  • Page 211 Diagram 3 - all models from 1990 on (continued)
  • Page 212 Diagram 3 - all models from 1990 on (continued)
  • Page 213 Diagram 3 - all models from 1990 on (continued)
  • Page 214 Diagram 3 - all models from 1990 on (continued)
  • Page 215 Diagram 3 - all models from 1990 on (continued)
  • Page 216 Diagram 3 - all models from 1990 on (continued)
  • Page 217 Key to wiring diagram for the MULTEC Central Fuel injection system fitted to later C 14 NZ engines Description Track Fuse(in fuse box) Engine telltale (in instrument Ignition coil ignition module 235 to 237 Fuel pump relay 260, 261 K100 IEFI control unit 240, 259 Ignition coil...
  • Page 218 Reference REF•1 General dimensions and Weights ... . REF•1 Tools and Working Facilities ....REF•5 Conversion Factors .
  • Page 219 Conversion factors REF•2 Length (distance) Inches (in) x 25.4 = Millimetres (mm) x 0.0394 = Inches (in) Feet (ft) x 0.305 = Metres (m) x 3.281 = Feet (ft) Miles x 1.609 = Kilometres (km) x 0.621 = Miles Volume (capacity) Cubic inches (cu in;...

  • Page 220: Vehicle Identification Numbers

    Buying spare parts REF•3 Spare parts are available from many vehicle identification number, and if possible, accessories, usually have convenient opening sources; for example, Vauxhall garages, other take the old parts along for positive hours, charge lower prices, and can often be identification.
  • Page 221 General Repair Procedures REF•4 Whenever servicing, repair or overhaul work Screw threads and fastenings such cases should be renewed as a matter of is carried out on the car or its components, it course. Seized nuts, bolts and screws are quite a is necessary to observe the following Split pins must always be replaced with common occurrence where corrosion has set...

  • Page 222: Tools And Working Facilities

    Tools and working facilities REF•5 Introduction Maintenance and minor repair motor vehicle, and are additional to those given in the Maintenance and minor repair list. tool kit A selection of good tools is a fundamental Included in this list is a comprehensive set of The tools given in this list should be requirement for anyone contemplating the sockets.
  • Page 223 Tools and working facilities REF•6 Special tools Buying tools attention with emery cloth or a file will soon restore items like this to a good serviceable The tools in this list are those which are not For practically all tools, a tool factor is the finish.
  • Page 224 MOT test checks REF•7 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.
  • Page 225 MOT test checks REF•8 Electrical equipment Inspect both front brake flexible hoses for cracks or deterioration of the rubber. Turn the Switch on the ignition and check the steering from lock to lock, and ensure that the operation of the horn. hoses do not contact the wheel, tyre, or any Check the windscreen washers and wipers, part of the steering or suspension mechanism.
  • Page 226 MOT test checks REF•9 Exhaust system Front and rear suspension and The same general checks apply to vehicles wheel bearings fitted with other suspension types, such as Start the engine. With your assistant torsion bars, hydraulic displacer units, etc. holding a rag over the tailpipe, check the Starting at the front right-hand side, grasp Ensure that all mountings and attachments are entire system for leaks.
  • Page 227 MOT test checks REF•10 for smoke emissions from the exhaust tailpipe. If the idle speed is obviously much too high, or if dense blue or clearly-visible black smoke comes from the tailpipe for more than 5 seconds, the vehicle will fail. As a rule of thumb, blue smoke signifies oil being burnt (engine wear) while black smoke signifies unburnt fuel (dirty air cleaner element, or other...
  • Page 228 Fault diagnosis REF•11 Engine Automatic transmission Fluid leakage Engine fails to rotate when attempting to start Transmission fluid brown, or has burned smell Engine rotates, but will not start General gear selection problems Engine difficult to start when cold Transmission will not downshift (kickdown) with accelerator fully Engine difficult to start when hot depressed Starter motor noisy or excessively-rough in engagement...

  • Page 229: Fault Diagnosis

    Fault diagnosis REF•12 headings denoting various components or systems, such as Engine, Cure the disease, not the symptom. Substituting a flat battery with a Cooling system, etc. The Chapter and/or Section which deals with the fully-charged one will get you off the hard shoulder, but if the problem is also shown in brackets.

  • Page 230: Cooling System

    Fault diagnosis REF•13 Blocked carburettor jet(s) or internal passages - carburettor Oil pressure warning light illuminated with engine models (Chapter 4A). running Blocked injector/fuel injection system fault - fuel-injected models Low oil level, or incorrect oil grade (Chapter 1). (Chapter 4B). Faulty oil pressure sensor (Chapter 5A).

  • Page 231: Manual Gearbox

    Fault diagnosis REF•14 Fuel and exhaust systems Excessive fuel consumption Fuel leakage and/or fuel odour Damaged or corroded fuel tank, pipes or connections (Chapter 4A Air filter element dirty or clogged (Chapter 1). or 4B). Choke mechanism faulty - carburettor models (Chapter 4A). Carburettor float chamber flooding (float height incorrect) (Chapter 4A).

  • Page 232: Automatic Transmission

    Fault diagnosis REF•15 Automatic transmission Note: Due to the complexity of the automatic transmission, it is difficult a) Engine starting in gears other than Park or Neutral. for the home mechanic to properly diagnose and service this unit. For b) Indicator on gear selector lever pointing to a gear other than the problems other than the following, the vehicle should be taken to a one actually being used.

  • Page 233: Suspension And Steering

    Fault diagnosis REF•16 Judder felt through brake pedal or steering wheel Brakes binding when braking Seized brake caliper or wheel cylinder piston(s) (Chapter 9). Excessive run-out or distortion of front discs or rear discs/drums Incorrectly-adjusted handbrake mechanism (Chapter 9). (Chapters 1 and 9). Faulty master cylinder (Chapter 9).
  • Page 234 Fault diagnosis REF•17 Internal fault in alternator or voltage regulator (Chapter 5A). Wiper blades fail to clean the glass effectively Broken, disconnected, or loose wiring in charging circuit (Chapter Wiper blade rubbers worn or perished (Chapter 1). 5A). Wiper arm tension springs broken, or arm pivots seized (Chapter 12).
  • Page 235 Glossary of Technical terms REF•18 would tend to clog the radiator and coolant Bearing The curved surface on a shaft or in a passages and reduce cooling efficiency. bore, or the part assembled into either, that ABS (Anti-lock brake system) A system, Anti-seize compound A coating that...
  • Page 236 Glossary of Technical terms REF•19 Camshaft A rotating shaft on which a series Catalytic converter A silencer-like device in Crocodile clip See Alligator clip of cam lobes operate the valve mechanisms. the exhaust system which converts certain pollutants in the exhaust gases into less The camshaft may be driven by gears, by harmful substances.
  • Page 237 Glossary of Technical terms REF•20 Feeler blade A thin strip or blade of hardened electrode in a spark plug. Also refers to the steel, ground to an exact thickness, used to spacing between the points in a contact EGR valve A valve used to introduce exhaust check or measure clearances between parts.
  • Page 238 Glossary of Technical terms REF•21 Overhead cam (ohc) engine An engine with the ozone in the upper atmosphere. the camshaft(s) located on top of the cylinder Rocker arm A lever arm that rocks on a shaft Jump start Starting the engine of a vehicle head(s).
  • Page 239 Glossary of Technical terms REF•22 automatic transmission, switch that front wheel drive vehicles, a slight amount of obstructs one or more ports or passageways. prevents starting if the vehicle is not in Neutral toe-out is usually specified. A valve is also the movable part of such a or Park.
  • Page 240 Index REF•23 Note: References throughout this index are in the form - “Chapter number” • “page number” Bulbs - 12•2, 12•6 radiator - 3•2 direction indicator - 12•7 switches - 3•5 thermostat - 3•2 foglamp - 12•7, 12•8 headlamp - 12•7 vents &...

  • Page 241: Hose And Fluid Leak Check

    Index REF•24 Engine/transmission mountings - 2A•11 Environmental considerations - REF•4 Exhaust manifold - 4A•19, 4B•14 Exhaust system - 1•14, 4A•20, 4B•14 Gearbox - see Manual or Automatic transmission Kickdown cable - 7B•2 Exterior mirror - 11•10 Gearbox oil - 0•17, 1•17, 7A•1, 7A•2 Gearchange lever - 7A•2 Gearchange linkage - 7A•2 Glass - 11•8, 11•10...

  • Page 242: Road Test

    Index REF•25 Speedometer cable - 12•6 Timing - 5B•5, 5C•7 Speedometer drive - 7A•4 Timing chain/sprockets - 2A•14 Starter inhibitor - 7B•2 Timing gear - 2A•9 Starter motor - 5A•4 Toe setting - 10•1, 10•15 Pads (brake) - 9•4, 9•5 Starting system - 5A•3 Tools and working facilities - REF•5 Paintwork damage - 11•2...
  • Page 243 Preserving Our Motoring Heritage < The Model J Duesenberg Derham Tourster. Only eight of these magnificent cars were ever built – this is the only example to be found outside the United States of America Almost every car you’ve ever loved, loathed or desired is gathered under one roof at the Haynes Motor Museum.

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