Инструкция по эксплуатации опель вектра а 1988 1995

4A

General

Fuel tank capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.0 litres

Fuel octane rating:

Leaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 RON (4-star)

Unleaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 RON (Premium)

Carburettor type (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pierburg 2E3

Air cleaner element

Application:

Round type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W103

Square type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U512

14 NV engine

Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925 ± 25 rpm

Idle mixture (CO content) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5%

Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2200 to 2600 rpm

Choke valve gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 3.5 mm

Choke pull-down gap:

“Small” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 to 2.1 mm

“Large” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 to 2.9 mm

Idle fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Idle air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Primary Secondary

Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.0 mm 24.0 mm

Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X95 X110

Chapter 4 Part A:

Fuel and exhaust systems — carburettor models

Accelerator pump — testing, removal and refitting . . . . . . . . . . . . . . .18

Air cleaner inlet air temperature control — description and testing . . . .4

Air cleaner — removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Automatic choke unit — removal, refitting and adjustment . . . . . . . . .19

Automatic choke vacuum pull-down units — removal, refitting and

adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Carburettor — general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Carburettor — removal, overhaul and refitting . . . . . . . . . . . . . . . . . . .13

Carburettor filter — removal and refitting . . . . . . . . . . . . . . . . . . . . . . .21

Fuel level sender unit — removal and refitting . . . . . . . . . . . . . . . . . . . .8

Fuel pump — removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Fuel pump — testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Fuel system — precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Fuel tank — removal, examination and refitting . . . . . . . . . . . . . . . . . . .7

Fuel vapour separator (1.6 and 1.8 litre models) — removal and

refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Idle cut-off solenoid (1.8 litre models) — description and testing . . . .25

Idle speed and mixture — adjustment . . . . . . . . . . . . . . . . . . . . . . . . .14

Idle speed increase valve — testing . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Inlet manifold — removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .26

Needle valve and float — removal, inspection and refitting . . . . . . . . .15

Power valve diaphragm — removal and refitting . . . . . . . . . . . . . . . . .17

Secondary throttle valve vacuum diaphragm — testing, removal and

refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Throttle cable — removal, refitting and adjustment . . . . . . . . . . . . . . .11

Throttle pedal — removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .10

Throttle position sensor (automatic transmission models) — removal

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Throttle valve dashpot (automatic transmission models) —

adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4A•1

Specifications

Contents

Easy, suitable for

novice with little

experience

Fairly easy, suitable

for beginner with

some experience

Fairly difficult,

suitable for competent

DIY mechanic

Difficult, suitable for

experienced DIY

mechanic

Very difficult,

suitable for expert DIY

or professional

Degrees of difficulty

5

4

3

2

1

16 SV engine

Idle speed

Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925 ± 25 rpm

Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825 ± 25 rpm (in ‘park’ or ‘neutral’)

Idle mixture (CO content) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5%

Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 to 2400 rpm

Choke valve gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 3.5 mm

Choke pull-down gap:

Up to 1990:

“Small” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 to 1.7 mm

“Large” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 to 2.3 mm

From 1990:

“Small” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 1.7 mm

“Large” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 to 2.2 mm

Idle fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Idle air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.5

Primary Secondary

Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.0 mm 24.0 mm

Main jet:

Up to 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X95 X105

From 1990 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X92.5 X105

18 SV engine

Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925 ± 25 rpm

Idle mixture (CO content) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5%

Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900 to 2300 rpm

Choke valve gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 3.5 mm

Choke pull-down gap:

“Small” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 ± 0.2 mm

“Large” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 ± 0.2 mm

Idle fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.5

Idle air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.5

Primary Secondary

Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.5 125

Torque wrench settings Nm lbf ft

Exhaust manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16

Exhaust downpipe-to-manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18

Exhaust fixings except flexible joint bolts . . . . . . . . . . . . . . . . . . . . . . . . 25 18

Exhaust flexible joint bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9

Fuel pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13

Fuel tank mounting strap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15

Inlet manifold nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16

1 General description

The fuel system on all carburettor models

comprises a fuel tank, a fuel pump, a vapour

separator (1.6 and 1.8 litre models only), a

downdraught carburettor, and a thermostati-

cally-controlled air cleaner.

The fuel tank is mounted under the rear of

the vehicle, forward of the rear suspension.

The tank is ventilated to the atmosphere, and

has a simple filler pipe and a fuel gauge

sender unit.

The fuel pump is a mechanical diaphragm

type, actuated by a pushrod bearing on the

camshaft.

The fuel vapour separator is used to

stabilise the fuel supply to the carburettor.

Vapour is purged from the carburettor fuel

supply, thus improving hot starting qualities.

The carburettor is a Pierburg 2E3 type, a full

description of which is given in Section 12.

The air cleaner has a wax or vacuum-

controlled air inlet supplying a blend of hot

and cold air to suit the prevailing engine

operating conditions. A fuller description is

given in Section 4.

All engines available within the Cavalier

range can be operated on unleaded petrol —

see Chapter 5.

2 Fuel system — precautions

1 Certain adjustment points in the fuel system

are protected by tamperproof caps, plugs or

seals. In some territories, it is an offence to

drive a vehicle with broken or missing

tamperproof seals. Before disturbing a

tamperproof seal, check that no local or

national laws will be broken by doing so, and

fit a new tamperproof seal after adjustment is

complete, where required by law. Do not

break tamperproof seals on a vehicle that is

still under warranty.

2 When working on fuel system components,

scrupulous cleanliness must be observed,

and care must be taken not to introduce any

foreign matter into fuel lines or components.

Carburettors in particular are delicate

instruments, and care should be taken not to

disturb any components unnecessarily.

Before attempting work on a carburettor,

ensure that the relevant spares are available.

Full overhaul procedures for carburettors have

not been given in this Chapter. Complete

stripdown of a carburettor is unlikely to cure a

fault that is not immediately obvious, without

introducing new problems. If persistent

problems are met, it is recommended that the

advice of a Vauxhall dealer or carburettor

specialist is sought. Most dealers will be able

to provide carburettor re-setting and servicing

facilities, and if necessary it should be

possible to buy a reconditioned carburettor.

3 Refer to Chapter 5, for precautions to be

observed when working on vehicles fitted with

an engine management system.

4A•2 Fuel and exhaust systems — carburettor models

3 Air cleaner — removal and

refitting

2

Removal

1 Remove the air cleaner element, as

described in Chapter 1.

2 Release the crankcase ventilation hose

from the plastic clip on the left-hand side of

the air cleaner body.

3 Disconnect the inlet duct from the hot air

hose on the exhaust manifold (see

illustration), and lift the air cleaner body from

the carburettor.

4 With 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.

5 Remove the seal from under the air cleaner

body.

Refitting

6 Check the hot air hose for condition, and

renew it if necessary.

7 Fit a new air cleaner body-to-carburettor

seal.

8 Connect the crankcase ventilation hose to

the stub on the underside of the body, and

connect the vacuum hose for the air

temperature control flap.

9 Locate the body on the carburettor, and at

the same time locate the inlet duct on the hot

air hose on the exhaust manifold.

10 Engage the crankshaft ventilation hose in

the plastic clip.

11 Refit the air cleaner element, referring to

Chapter 1 if necessary.

4 Air cleaner inlet air

temperature control —

description and testing

3

Description

1 The air cleaner is thermostatically-

controlled, to provide air at the most suitable

temperature for combustion with minimum

exhaust emission levels.

2 The optimum air temperature is achieved

by drawing in cold air from an inlet at the front

of the vehicle, and blending it with hot air

drawn 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

3 To 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.

4 Temporarily refit the cover on the vacuum

type.

5 Run the engine until it reaches its normal

operating temperature.

6 On 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.

7 If 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.

5 Fuel pump — testing

2

Note: Refer to Section 2 before proceeding

1 Disconnect the ignition coil LT lead.

2 Place 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.

3 Have 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.

4 No spare parts are available for the pump,

and if faulty, the unit must be renewed.

6 Fuel pump — removal and

refitting

3

Note: Refer to Section 2 before proceeding

Removal

1 The fuel pump is located at the rear right-

hand end of the camshaft housing.

2 Disconnect the battery negative lead.

3 Disconnect 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 model

4.2 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.

4 Unscrew the two securing bolts, and

withdraw the pump from the camshaft

housing (see illustration).

5 Recover the plastic insulating block.

Refitting

6 Refitting is a reversal of removal, but ensure

that the fuel hoses are reconnected to their

correct locations as noted during removal,

and tighten the securing bolts to the specified

torque.

7 Run the engine and check for leaks on

completion. If leakage is evident, stop the

engine immediately and rectify the problem

without delay. Note that the engine may take

a longer time than usual to start when the

pump has been removed, as the pump refills

with fuel.

7 Fuel tank — removal,

examination and refitting

4

Note: Refer to Section 2 before proceeding

Removal

1 Disconnect the battery negative lead.

2 Siphon out any remaining fuel in the tank

through the filler pipe. Siphon the fuel into a

clean metal container that can be sealed.

3 Chock the front wheels, then jack up the

rear of the vehicle, and support securely on

axle stands (see “Jacking and Vehicle

Support”) placed under the body side

members.

4 Disconnect the exhaust system front

flexible joint. Suspend the front section of the

exhaust system with wire or string from the

underbody.

5 Disconnect the rear section of the exhaust

system from its rubber mountings, and allow it

to rest on the rear suspension torsion beam. It

is advisable to support the rear section of the

exhaust at its front end, with wire or string

from the underbody, to avoid straining the

system.

6 Unclip the handbrake cable from the

bracket on the left-hand fuel tank securing

strap.

7 Disconnect the fuel hoses from the fuel

level sender unit located in the right-hand side

of the fuel tank. Make a note of the hose

positions for use when refitting. Be prepared

for fuel spillage, and take adequate fire

precautions. Plug the open ends of the hoses,

to prevent dirt ingress and further fuel loss.

8 Disconnect the wiring plug from the fuel

level sender unit.

9 Disconnect the filler and vent hoses from

the rear of the fuel tank.

10 Support the weight of the fuel tank on a

jack with an interposed block of wood.

11 Unscrew the securing bolts from the tank

mounting straps, then remove the straps and

lower the tank sufficiently to enable the

disconnection of the remaining vent hose.

12 With the aid of an assistant, withdraw the

tank sideways from the right-hand side of the

vehicle. Note that as the tank is withdrawn,

some residual fuel may be released.

Examination

13 If the tank contains sediment or water, it

may be cleaned out using two or three rinses

with clean fuel. Shake vigorously using

several changes of fuel, but before doing so,

remove the fuel level sender unit, as

described in Section 8. This procedure should

be carried out in a well-ventilated area, and it

is vital to take adequate fire precautions —

refer to the “Safety first!” Section at the

beginning of this manual for further details.

14 Any repairs to the fuel tank should be

carried out by a professional. Do not under

any circumstances attempt to weld or solder a

fuel tank. Removal of all residual fuel vapour

requires several hours of specialist cleaning.

Refitting

15 Refitting is a reversal of removal, ensuring

that all hoses are reconnected to their correct

locations as noted during removal.

16 On completion, fill the fuel tank, then run

the engine and check for leaks. If leakage is

evident, stop the engine immediately and

rectify the problem without delay. Note that

the engine may take a longer time than usual

to start when the fuel tank has been removed,

as the pump refills with fuel.

8 Fuel level sender unit —

removal and refitting

3

Note: Refer to Section 2 before proceeding

Removal

1 Disconnect the battery negative lead.

2 Siphon out any remaining fuel in the tank

through the filler pipe. Siphon the fuel into a

clear metal container that can be sealed.

3 Chock the front wheels, then jack up the rear

of the vehicle, and support securely on axle

stands (see “Jacking and Vehicle Support”)

placed under the body side members.

4 The sender unit is located in the right-hand

side at the fuel tank.

5 Make alignment marks on the sender unit

and the fuel tank, so that the sender unit can

be refitted in its original position.

6 Disconnect the fuel hoses from the sender

unit. Be prepared for fuel spillage, and take

adequate fire precautions. Plug the open ends

of the hoses, to prevent dirt ingress and

further fuel loss.

7 Disconnect the wiring plug from the fuel

level sender unit.

8 To remove the sender unit, engage a flat

piece of metal as a lever between two of the

slots on the sender unit rim, and turn it anti-

clockwise.

9 Withdraw the unit carefully, to avoid

bending the float arm.

10 Recover the sealing ring.

Refitting

11 Refitting is a reversal of removal,

remembering the following points.

12 Examine the condition of the sealing ring,

and renew if necessary.

13 Ensure that the marks made on the

sender unit and fuel tank before removal are

aligned.

14 Ensure that the hoses are reconnected to

their correct locations as noted during

removal.

15 On completion, fill the fuel tank, then run

the engine and check for leaks. Also check

that the fuel gauge reads correctly. If leakage

is evident, stop the engine immediately and

rectify the problem without delay. Note that

the engine may take a longer time than usual

to start when the sender unit has been

removed, as the fuel pump refills with fuel.

9 Fuel vapour separator (1.6

and 1.8 litre models) —

removal and refitting

3

Note: Refer to Section 2 before proceeding

Removal

1 The fuel vapour separator is located on a

bracket attached to the side of the

carburettor.

2 Note the locations of the three fuel hoses,

labelling them if necessary for use when

refitting, then disconnect the hoses from the

vapour separator. 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.

3 Remove the two securing screws, and lift

the vapour separator from its bracket.

4 Check the body of the separator for cracks

or leaks before refitting, and renew if

necessary.

Refitting

5 Refitting is a reversal of removal, but ensure

that the three fuel hoses are connected to

their correct locations as noted during

removal.

6 Run the engine and check the hose

connections for leaks on completion. If

leakage is evident, stop the engine

immediately and rectify the problem without

delay.

4A•4 Fuel and exhaust systems — carburettor models

6.4 Withdrawing the fuel pump and plastic

insulating block — 1.6 litre model

10 Throttle pedal — removal and

refitting

3

Removal

1 Working inside the vehicle, remove the

lower trim panel from the driver’s footwell.

2 Slide the cable retainer from the bracket on

the top of the pedal, and disconnect the cable

end from the pedal.

3 Extract the circlip from the right-hand end

of the pedal pivot shaft, then slide out the

pivot shaft from the left-hand side of the pivot

bracket (see illustration). Recover the pivot

bushes and the pedal return spring.

4 Examine the pivot bushes for wear, and

renew if necessary.

Refitting

5 Refitting is a reversal of removal, but on

completion check the throttle mechanism for

satisfactory operation, and check the throttle

cable adjustment, as described in Section 11.

11 Throttle cable — removal,

refitting and adjustment

3

Removal

1 Remove the air cleaner, on early models.

On later models, disconnect the air trunking

from the air cleaner, then disconnect the

vacuum pipe and breather hose from the air

box. Extract the three securing screws and lift

off the air box, complete with air trunking (see

illustration).

2 Extract the clip from the cable end fitting at

the bracket on the carburettor, then slide the

cable end grommet from the bracket (see

illustrations).

3 Slide the cable end from the throttle valve

lever on the carburettor.

4 Working inside the vehicle, remove the

lower trim panel from the driver’s footwell.

5 Slide the cable retainer from the bracket on

the top of the pedal, and disconnect the cable

end from the pedal.

6 Make a careful note of the cable routing,

then withdraw the cable through the bulkhead

into the engine compartment.

Refitting

7 Refitting is a reversal of removal,

remembering the following points.

8 Ensure that the cable is correctly routed, as

noted before removal.

9 Ensure that the bulkhead grommet is

correctly seated in its hole.

Adjustment

10 On completion, check the throttle

mechanism for satisfactory operation, and if

necessary adjust the cable, as described in

the following paragraphs.

11 Two points of cable adjustment are

provided. A stop screw is located on the

pedal arm to control the fully released position

of the pedal stop (see illustration). A clip is

located on a threaded section of the cable

sheath at the bracket on the carburettor, to

adjust the cable free play.

12 The cable should be adjusted so that

when the throttle pedal is released, there is

very slight free play in the cable at the

carburettor end.

13 Check that when the throttle pedal is fully

depressed, the throttle valve is fully open.

Adjust the position of the clip on the cable

sheath, and the pedal stop screw, to achieve

the desired results.

12 Carburettor — general

1 The Pierburg 2E3 carburettor is of twin-

venturi, fixed-jet sequential throttle type. The

primary throttle valve operates alone except

at high engine speeds and loads, when the

secondary throttle valve is operated, until at

full-throttle, both are fully open. This

arrangement allows good fuel economy

during light acceleration and cruising, but also

gives maximum power at full-throttle. The

secondary throttle valve is vacuum-operated,

according to the vacuum produced in the

primary venturi. The primary throttle barrel

and venturi diameters are smaller than their

secondary counterparts. The carburettor is a

complicated instrument, with various

refinements and sub-systems added to

achieve improved driveability, economy and

exhaust emission levels (see illustrations).

Fuel and exhaust systems — carburettor models 4A•5

11.2A Extract the throttle cable end

clip . . .

12.1A Side view of carburettor, showing

accelerator pump (1) and main choke pull-

down diaphragm unit (2)

11.11 Throttle pedal stop screw11.2B . . .and slide the grommet from the

bracket

11.1 Removing an air box securing screw10.3 Throttle pedal pivot assembly. Circlip

arrowed

4A

2 A separate idle system operates

independently from the main jet system,

supplying fuel by way of the mixture control

screw.

3 The main jets are calibrated to suit engine

requirements at mid-range throttle openings.

To provide the necessary fuel enrichment at

full throttle, a vacuum-operated power valve is

used. The valve provides extra fuel under the

low vacuum conditions associated with wide

throttle openings.

4 To provide an enriched mixture during

acceleration, an accelerator pump delivers

extra fuel to the primary main venturi. The

accelerator pump is operated mechanically by

a cam on the throttle linkage.

5 A fully automatic choke is fitted, operated

by a coolant and electrically heated bi-metal

coil. When the engine is cold, the bi-metal coil

is fully wound up, holding the choke plate

(fitted to the primary barrel) closed. As the

engine warms up, the bi-metal coil is heated

and therefore unwinds, progressively opening

the choke plate. A vacuum operated pull-

down system is employed, whereby, if the

engine is under choke but is only cruising (i.e.

not under heavy load) the choke plate is

opened against the action of the bi-metal coil.

The pull-down system prevents an over-rich

mixture, which reduces fuel economy and

may cause unnecessary engine wear when

the engine is cold. A secondary pull-down

solenoid is fitted, which operates in

conjunction with the main diaphragm unit to

modify the pull-down characteristics,

improving fuel economy.

6 1.8 litre models are fitted with an idle cut-off

solenoid. This is an electrically operated valve,

which interrupts the idle mixture circuit when

the ignition is switched off, this preventing

engine “run-on”.

13 Carburettor — removal,

overhaul and refitting

3

Note: Refer to Section 2 before proceeding.

New gasket(s) must be used when refitting the

carburettor. A tachometer and an exhaust gas

analyser will be required to check the idle

speed and mixture on completion

Removal

1 Disconnect the battery negative lead.

2 Remove the air cleaner, on early models.

On later models, disconnect the air trunking

from the air cleaner, then disconnect the

vacuum pipe and breather hose from the air

box. Extract the three securing screws and lift

off the air box, complete with air trunking.

3 On 1.4 litre models, disconnect the fuel

supply hose from the carburettor, and on 1.6

and 1.8 litre models, disconnect the fuel

supply and return hoses from the vapour

separator. Be prepared for fuel spillage, and

take adequate fire precautions. Plug the ends

of the hoses, to prevent dirt ingress and

further fuel spillage.

4 Extract the clip from the throttle cable end

fitting at the bracket on the carburettor, then

slide the cable end grommet from the bracket,

and slide the cable end from the throttle valve

lever.

5 Disconnect the coolant hoses from the

automatic choke housing noting their

locations, as an aid to refitting. Be prepared

for coolant spillage, and plug the hoses, or

secure them with their ends facing upwards,

to prevent further coolant loss.

6 Disconnect the vacuum pipes from the front

of the carburettor, noting their locations and

routing for use when refitting (see

illustration).

7 Disconnect the choke heater wire and any

additional wiring.

8 Unscrew the three securing nuts, and

withdraw the carburettor from the inlet

manifold studs.

9 Recover the gasket(s) and insulator block

that fit between the carburettor and the inlet

manifold.

Overhaul

10 With the carburettor removed from the

vehicle, drain the fuel from the float chamber

and vapour separator (where applicable).

Clean the outside of the carburettor, then

remove the top cover (Section 15).

11 Blow through the jets and drillings with

compressed air, or air from a foot pump — do

not probe them with wire. If it is wished to

remove the jets, unscrew them carefully with

well-fitting tools.

12 Remove the fuel filter gauze from the inlet

union, refer to Section 21, for details. Vauxhall

recommend that it is renewed whenever the

carburettor is cleaned.

4A•6 Fuel and exhaust systems — carburettor models

12.1B Side view of carburettor, showing automatic choke

housing (1), vapour separator (2) and secondary throttle valve

vacuum diaphragm (3)

12.1C Side view of carburettor, showing secondary choke pull-

down solenoid (1) and power valve (2)

13.6 Disconnecting the air box vacuum

pipe from the carburettor — 1.6 litre model

Aerosol cans of carburettor

cleaner are widely available

and can prove useful in

helping to clean internal

passages of stubborn obstructions.

13 Clean any foreign matter from the float

chamber. Renew the float, the float needle

valve and seat if wear is evident, or if the float

is punctured or otherwise damaged. Check

that the needle valve closes completely before

the float reaches the top of its movement. See

Section 15, for details of float level checking.

14 Renew the diaphragms in the part-load

enrichment valve and in the accelerator pump.

If additional pump or valve parts are supplied

in the overhaul kit, renew these parts also.

15 Further dismantling is not recommended.

Pay particular attention to the throttle opening

mechanism arrangement if it is decided to

dismantle it; the interlocking arrangement is

important.

16 Reassemble in the reverse order to

dismantling. Use new gaskets and seals

throughout; lubricate linkages with a smear of

molybdenum based grease.

Refitting

17 Carry out the following procedure before

refitting.

a) Position the fast idle adjustment screw on

the highest step of the fast idle cam.

b) Use a gauge rod or twist drill of the

specified diameter to measure the

opening of the primary throttle valve.

c) Adjust if necessary at the fast idle

adjustment screw.

d) Note that this is a preliminary adjustment;

final adjustment of the fast idle speed

should take place with the engine running.

18 Refitting is a reversal of removal, but

renew the gasket(s).

19 After refitting, carry out the following

checks and adjustments.

20 Check the throttle cable free play and

adjust if necessary, as described in Section 11.

21 Check and if necessary top-up the

coolant level, as described in Chapter 3.

22 Check and if necessary adjust the idle

speed and mixture, as described in Section 14.

14 Idle speed and mixture —

adjustment

3

Note: Refer to Section 2 before proceeding.

To carry out the adjustments, an accurate

tachometer and an exhaust gas analyser (CO

meter) will be required

1 To check the idle speed and mixture

adjustment, the following conditions must be

met:

a) The engine must be at normal operating

temperature

b) All electrical consumers (cooling fan,

heater blower, headlamps, etc.) must be

switched off

c) The ignition timing and spark plug gaps

must be correctly adjusted — see Chapters

1 and 5

d) The throttle cable free play must be

correctly adjusted — see Section 11

e) The air inlet trunking must be free from

leaks, and the air filter must be clean

f) On automatic models, always select

position, “P”.

2 Connect a tachometer and an exhaust gas

analyser to the vehicle, according to the

equipment manufacturer’s instructions.

3 Start the engine, and run it at 2000 rpm for

approximately 30 seconds, then allow it to

idle. If the idle speed is outside the specified

limits, adjust by means of the throttle stop

screw (see illustration).

4 When the idle speed is correct, check the

CO level in the exhaust gas. If it is outside the

specified limits, adjust by means of the idle

mixture adjustment screw. In production, the

screw is covered by a tamperproof plug;

ensure that no local or national laws are being

broken before removing the plug (see

illustration).

5 On automatic models, when position “D” is

selected (all electrical systems switched off),

the idle speed should not drop perceptibly. If

it does, the vehicle should be taken to a

Vauxhall dealer for the idle-up system to be

checked using special Vauxhall test

equipment.

6 With the idle mixture correct, readjust the

idle speed if necessary.

7 If the cooling fan cuts in during the

adjustment procedure, stop the adjustments,

and continue when the cooling fan stops.

8 When both idle speed and mixture are

correctly set, stop the engine and disconnect

the test equipment.

9 Fit a new tamperproof plug to the idle

mixture adjustment screw, where this is

required by law.

15 Needle valve and float —

removal, inspection and

refitting

4

Note: Refer to Section 2 before proceeding. A

new carburettor top cover gasket must be

used on reassembly. A tachometer and an

exhaust gas analyser will be required to check

the idle speed and mixture on completion

Removal

1 Disconnect the battery negative lead.

2 Remove the round air cleaner, on

applicable models. On other models,

disconnect the air trunking from the air

cleaner, then disconnect the vacuum pipe and

breather hose from the air box. Extract the

three securing screws and lift off the air box,

complete with air trunking.

3 Thoroughly clean all external dirt from the

carburettor.

4 Disconnect the fuel supply hose at the

carburettor. Be prepared for fuel spillage, and

take adequate fire precautions. Plug the end

of the hose, to prevent dirt ingress and further

fuel spillage.

5 Identify the automatic choke coolant hose

locations as an aid to refitting, then

disconnect the hoses. Be prepared for

coolant spillage, and either plug the hoses, or

secure them with their ends facing upwards,

to prevent further coolant loss.

6 Disconnect the choke heater wiring plug.

7 Disconnect the lower vacuum hoses from

the choke pull-down unit.

8 Remove the four carburettor top cover

securing screws, noting their locations, as two

lengths of screw are used (see illustration).

9 Lift off the top cover and recover the

gasket.

Inspection

10 Hold the cover vertically, so that the float

is hanging from its pivot. Then tilt the cover

until the float needle valve is just closed — the

needle spring must not be compressed by the

weight of the float.

11 Measure the distance, dimension x (see

illustration), from the bottom of the float to

the gasket surface on the top cover’s

Fuel and exhaust systems — carburettor models 4A•7

15.8 Carburettor top cover securing

screws (arrowed)

14.4 Tamperproof plug (arrowed) covering

idle mixture adjustment screw

14.3 Carburettor idle speed adjustment

(throttle stop) screw (arrowed)

4A

underside. If the distance measured exceeds,

or is less than, that specified, the float weight

is incorrect and the float must be renewed.

12 When the float level is known to be

correct, reassemble the carburettor, using a

new top cover gasket. Check the idle speed

and mixture settings as described in Section

14.

13 Using a pin punch, tap the float retaining

pin from the base of the top cover, and lift out

the float and needle valve.

14 Inspect the components for damage, and

renew as necessary. Check the needle valve

for wear, and check the float for leaks by

shaking it to see if it contains petrol.

15 Clean the mating faces of the carburettor

body and top cover.

Refitting

16 Refitting is a reversal of removal,

remembering the following points.

17 After refitting, check the float and needle

valve for full and free movement.

18 Use a new gasket between the top cover

and the carburettor body.

19 Ensure that all hoses, pipes and wires are

correctly reconnected.

20 On completion, check and if necessary

top-up the coolant level, as described in

Chapter 3, and check and if necessary adjust

the idle speed and mixture, as described in

Section 14.

16 Secondary throttle valve

vacuum diaphragm — testing,

removal and refitting

3

Note: The diaphragm unit must be renewed in

its entirety, as no spares are available

Testing

1 If a vacuum source incorporating a gauge is

available, apply approximately 300 mbars (9 in

Hg) to the diaphragm unit, at the hose nearest

the carburettor body. Close off the vacuum

source, and check that the vacuum is held. If

there is a leak, rectify or renew the leaking

component. Alternately, testing of a suspect

vacuum unit must be by the substitution of a

known good item.

Removal

2 Remove the air cleaner, on early models.

On later models, disconnect the air trunking

from the air cleaner, then disconnect the

vacuum pipe air breather hose from the air

box. Extract the three securing screws and lift

off the air box, complete with air trunking.

3 Disconnect the vacuum pipe from the

diaphragm unit.

4 Prise the diaphragm operating rod balljoint

from the secondary throttle valve linkage.

5 On 1.6 and 1.8 litre models, remove the two

securing screws and lift the vapour separator

from the bracket. Move the vapour separator

to one side, taking care not to strain the fuel

hoses.

6 Remove the three securing screws, and

withdraw the diaphragm unit complete with its

bracket from the carburettor body.

Refitting

7 Refitting is a reversal of removal.

17 Power valve diaphragm —

removal and refitting

3

Note: Refer to Section 2 before proceeding

Removal

1 Disconnect the battery negative lead.

2 Remove the air cleaner, on early models.

On later models, disconnect the air trunking

from the air cleaner, then disconnect the

vacuum pipe and breather hose from the air

box. Extract the three securing screws and lift

off the air box, complete with air trunking.

3 Thoroughly clean all external dirt from the

area around the power valve housing.

4 Remove the two securing screws, and lift

off the power valve cover, spring, and

diaphragm assembly.

Refitting

5 Clean the mating faces of the cover and

housing.

6 Locate the spring on the cover and

diaphragm assembly, ensuring that it is

correctly seated, then press the diaphragm

assembly and cover together. Note that the

vacuum hole in the diaphragm must align with

the corresponding holes in the housing flange

and cover.

7 Further refitting is a reversal of removal, but

ensure that the diaphragm is correctly seated

(see illustration).

18 Accelerator pump — testing,

removal and refitting

3

Note: Refer to Section 2 before proceeding

Testing

1 It will be necessary to feed the float

chamber with fuel from a small reservoir

during this test.

2 Position the primary barrel over an accurate

measuring glass. Fully open and close the

throttle ten times, taking approximately one

second for each opening, and pausing for

three seconds after each return stroke. Make

sure that the fast idle cam is not restricting

throttle travel at either end.

3 Measure the quantity of fuel delivered, and

compare this with the specified value.

4A•8 Fuel and exhaust systems — carburettor models

15.11 Measuring the float level “X”

17.7 Carburettor power valve components

1 Cover

2 Spring

3 Diaphragm

assembly

4 If adjustment is necessary, release the

clamp screw and turn the cam plate in the

desired direction. Tighten the clamp screw,

and recheck the pump delivery (see

illustration).

Removal

5 Proceed as described in Section 17,

paragraphs 1 and 2.

6 Thoroughly clean all external dirt from the

area around the accelerator pump housing.

7 Remove the four securing screws and lift off

the accelerator pump cover. Recover the

diaphragm, spring, valve retainer and valve.

Note the orientation of the valve retainer.

Refitting

8 Clean the mating faces of the cover and

housing.

9 Check the condition of the valve, and renew

if necessary.

10 Begin refitting by locating the valve, valve

retainer and spring in the housing. Note that

the valve retainer can only be fitted in one

position. The larger diameter of the spring

should rest against the valve retainer.

11 Locate the diaphragm on the housing,

ensuring that the spring is correctly seated,

and refit the cover. Tighten the cover securing

screws progressively to avoid distorting the

diaphragm (see illustration).

12 Further refitting is a reversal of removal.

19 Automatic choke unit —

removal, refitting and

adjustment

3

Note: Refer to Section 2 before proceeding. A

tachometer and an exhaust gas analyser will

be required to check the idle speed and

mixture on completion. If the coolant housing

is removed, new O-rings will be required for

refitting

Removal

1 Proceed as described in Section 17,

paragraphs 1 and 2.

2 Note the position of the bi-metal housing

alignment marks as an aid to refitting, if

necessary making additional marks for clarity,

then remove the three securing screws and lift

off the bi-metal housing. Place the housing to

one side, taking care not to strain the coolant

hoses or electric choke heater wiring.

3 Remove the three screws securing the

choke housing to the carburettor body, and

withdraw the choke assembly, taking care not

to bend the choke operating rod.

4 If it is necessary to remove the bi-metal

housing for renewal, continue as follows;

otherwise go on to paragraph 8.

5 Identify the automatic choke coolant hose

locations as an aid to refitting, then

disconnect the hoses. Be prepared for

coolant spillage, and either plug the hoses, or

secure them with their ends facing upwards,

to prevent further loss of coolant.

6 Disconnect the wiring from the electric

choke heater, and withdraw the bi-metal

housing.

7 The coolant housing can be separated from

the bi-metal housing by unscrewing the

central securing bolt. Recover the O-rings

from under the bolt head, and from the rim of

the coolant housing.

Refitting

8 Begin refitting by locating the choke

assembly on the carburettor body, ensuring

that the lever on the choke assembly engages

with the choke operating rod. Tighten the

three securing screws.

9 Check and if necessary adjust the choke

valve gap and the fast idle cam position, as

described in paragraphs 15 to 19, of this

Section.

10 Connect the bi-metal spring to the choke

lever, position the bi-metal housing on the

choke housing, and loosely fit the securing

screws. Align the marks on the bi-metal

housing and the choke housing as noted

during removal, then tighten the securing

screws.

11 Where applicable, refit the coolant

housing to the bi-metal housing, using new O-

rings if necessary, and reconnect the coolant

hoses and electric choke heater wiring.

12 Further refitting is a reversal of removal,

remembering the following points.

13 If the coolant hoses have been

disconnected, check the coolant level, as

described in Chapter 3.

14 Check and if necessary adjust the fast idle

speed, as described in paragraphs 25 to 34,

of this Section.

Adjustment

Choke valve gap

15 With the bi-metal housing removed as

described in paragraphs 2 to 4, of this

Section, continue as follows.

16 Press the choke operating lever fully

clockwise, and retain it in position with a

rubber band.

17 Move the throttle lever to the fully open

position, and measure the choke valve gap

between the lower side of the choke plate and

the wall of the primary barrel. Check that the

gap is as given in the Specifications.

18 If necessary, adjust the choke valve gap

by bending the “adjuster segment (2)” If the

gap is too small, enlarge gap “B”, by levering

with a screwdriver. If the gap is too large,

decrease gap “B” using a pair of pliers (see

illustration).

19 If no further adjustments are to be carried

out, refit the bi-metal housing, as described in

paragraphs 10 to 14, of this Section.

Fuel and exhaust systems — carburettor models 4A•9

18.11 Carburettor accelerator pump components

1 Cover with operating lever

2 Diaphragm

3 Spring

4 Valve

5 Air passage

18.4 Accelerator pump delivery adjustment: “+” to

increase, “-” to reduce

4A

Fast idle cam position

20 With the bi-metal housing removed, and

the choke valve gap “B”, correctly set,

continue as follows.

21 Open the throttle valve, then close the

choke valve using light finger pressure on the

choke drive lever (see illustration). Close the

throttle valve.

22 Check that the fast idle speed adjustment

screw is resting against the stop on the

second highest step of the fast idle cam.

23 If adjustment is required, first check that

the choke return spring is correctly

positioned, then adjust by bending the

adjustment lever.

24 Refit the bi-metal housing, as described in

paragraphs 10 to 14 of this Section.

Fast idle speed

Note: To carry out the adjustment, an

accurate tachometer and an exhaust gas

analyser (CO meter) will be required

25 Check the idle speed and mixture, as

described in Section 14. The idle speed must

be correct before attempting to check or

adjust the fast idle speed.

26 With the engine at normal operating

temperature, and a tachometer connected

according to the equipment manufacturer’s

instructions, continue as follows.

27 Position the fast idle speed adjustment

screw on the second highest step of the fast

idle cam (see illustration).

28 Start the engine without touching the

throttle pedal, and check that the fast idle

speed is as specified. If adjustment is

required, stop the engine and continue as

follows.

29 Remove the tamperproof cap from the

fast idle speed adjustment screw, ensure that

no local or national laws are being broken by

doing so (see illustration).

30 Ensure that the adjustment screw is still

resting on the second highest step of the fast

idle cam, then start the engine, again without

touching the throttle pedal.

31 Turn the adjustment screw using a

screwdriver, until the specified fast idle speed

is obtained.

32 If the cooling fan cuts in during the

adjustment procedure, stop the adjustments,

and continue when the cooling fan stops.

33 On completion of adjustment, stop the

engine and disconnect the tachometer.

34 Fit a new tamperproof cap to the fast idle

speed adjustment screw, where this is

required by law.

20 Automatic choke vacuum

pull-down units — removal,

refitting and adjustment

3

Main diaphragm unit

Note: Refer to Section 2 before proceeding. A

new star clip must be used when refitting the

diaphragm unit. Test vacuum units as

described in Section 16, paragraph 1.

Removal

1 Proceed as described in Section 17,

paragraphs 1 and 2.

2 Disconnect the diaphragm unit vacuum

pipes.

3 Using a pin punch, tap out the roll pin

securing the diaphragm unit to the carburettor

top cover.

4 Note the position of the bi-metal housing

alignment marks as an aid to refitting, if

necessary making additional marks for clarity,

then remove the three securing screws, and

lift off the bi-metal housing. Place the housing

to one side, taking care not to strain the

coolant hoses or electric choke heater wiring.

4A•10 Fuel and exhaust systems — carburettor models

19.18 Choke valve gap adjustment

1 Choke operating lever

2 Adjuster segment

B Choke valve gap

19.21 Fast idle cam adjustment

1 Fast idle cam

2 Adjustment lever

3 Choke drive lever

4 Fast idle speed adjustment screw

19.29 Tamperproof cap (arrowed) fast idle speed adjustment

screw

19.27 Fast idle speed adjustment

3 Fast idle speed adjustment screw

4 Screw positioned on second highest step of cam

5 Remove the three screws securing the

choke assembly to the carburettor body.

Allow the choke assembly to drop down, but

do not disconnect the choke linkage.

6 Remove the star clip that secures the

diaphragm unit to the carburettor top cover,

and withdraw the diaphragm unit.

Refitting

7 Refitting is a reversal of removal, but use a

new star clip to secure the diaphragm unit to

the carburettor top cover. Before refitting the

air box to the top of the carburettor, check

and if necessary adjust the choke pull-down,

as follows.

Vacuum pull-down

Adjustment

8 With the air cleaner or air box removed from

the top of the carburettor, as described in

Section 17, paragraph 2, continue as follows.

9 Note the position of the bi-metal housing

alignment marks as an aid to refitting, if

necessary making additional marks for clarity,

then remove the three securing screws, and

lift off the bi-metal housing. Place the housing

to one side, taking care not to strain the

coolant hoses or electric choke heater wiring.

10 Position the fast idle speed adjustment

screw on the highest step of the fast idle cam,

and check that the choke valve is closed.

11 Move the pull-down arm towards the

diaphragm unit by pushing on the adjustment

screw until resistance is felt. Hold the arm in

this position.

12 Using a drill shank of appropriate

diameter, or a similar item, measure the

clearance between the lower side of the

choke plate and the wall of the primary barrel

(see illustrations). Check that the clearance

is as given for the “small” choke pull-down

gap in the Specifications.

13 If adjustment is necessary, turn the

adjustment screw in the appropriate direction,

using an Allen key, until the clearance is

correct.

14 Now push the pull-down arm towards the

diaphragm unit as far as its stop, and hold the

arm in this position.

15 As before measure the clearance between

the lower side of the choke plate and the wall

of the primary barrel. Check that the

clearance is as given for the “large” choke

pull-down gap in the Specifications.

16 If adjustment is necessary, turn the

adjustment screw in the appropriate direction

until the clearance is correct.

17 Connect the bi-metal spring to the choke

lever, position the bi-metal housing on the

choke housing and loosely fit the securing

screws. Align the marks on the bi-metal

housing and the choke housing as noted

during removal, then tighten the securing

screws.

18 Refit the air box to the top of the

carburettor on completion.

Secondary pull-down solenoid

Removal

19 This unit operates in conjunction with the

main diaphragm unit.

20 To remove the solenoid unit, first continue

as described in Section 17, paragraphs 1 and

2.

21 Disconnect the diaphragm unit vacuum

pipe.

22 Disconnect the wiring plug, then unscrew

the securing screw, and withdraw the

solenoid unit and its mounting bracket from

the carburettor. Note that the securing screw

also secures the wiring plug earth lead (see

illustration).

Refitting

23 Refitting is a reversal of removal, but

ensure that the wiring plug earth lead is in

place under the solenoid bracket securing

screw.

21 Carburettor filter — removal

and refitting

3

Removal

1 A small tubular filter gauze is fitted into the

carburettor top cover’s fuel inlet union to

remove any particles of dirt from the fuel.

2 To ensure a clean fuel supply and to

prevent the risk of misfiring, poor starting or

other problems due to a restricted fuel supply,

this filter must be cleaned and/or renewed at

the interval specified in Chapter 1.

3 To reach the filter, remove the air cleaner or

air box, as applicable, then disconnect and

plug the hose from the fuel pump or vapour

separator to the top cover union.

4 Remove the filter by hooking it out with a

small screwdriver, or by snaring it with a long

thin screw (3 mm thread size, screwed

approximately 5 mm into the filter).

5 If the filter is blocked or heavily fouled, or if

it is torn, distorted or damaged in any way, it

must be renewed. If it is fit for further use,

clean it using a jet of compressed air or by

brushing away particles of dirt with an old soft

toothbrush. Then flushing it in clean solvent,

taking care not to allow any overspray to get

into your eyes; if petrol is used, take care to

prevent the risk of fire.

Fuel and exhaust systems — carburettor models 4A•11

20.12B Checking the vacuum pull-down gap using a twist drill

20.22 Secondary choke pull-down

solenoid securing screw and earth lead

20.12A Choke vacuum pull-down adjustment

1 Adjustment screw 2 Diaphragm unit A Twist drill

4A

Refitting

6 On refitting the filter, press it into the union

until it catches (see illustration). The

remainder of the reassembly procedure is the

reverse of removal.

22 Throttle valve dashpot

(automatic models) —

adjustment

2

1 Remove the air cleaner or air box, refer to

Section 3.

2 Ensure that the lever (see illustration) is in

the idling position.

3 Slacken the locknut and unscrew the

dashpot until a gap of 0.05 mm (0.002 in)

exists between the lever and the dashpot tip.

Then screw the dashpot downwards 2.5 full

turns and tighten the locknut.

4 Refit all removed components.

23 Throttle position sensor

(automatic transmission

models) — removal and refitting

2

Removal

1 Disconnect the battery earth lead.

2 Disconnect the wiring plug from the sensor.

3 Either unscrew the two securing screws

and withdraw the sensor from its bracket, or

unbolt the bracket.

Refitting

4 Refitting is the reverse of the removal

procedure, noting the following points.

a) Install the sensor when the throttle valve

is fully closed and ensure that the

adapter, “1” (see illustration), seats

correctly on the throttle valve spindle.

b) Tighten the screws carefully.

24 Idle speed increase valve —

testing

2

1 Certain models are fitted with an idle speed

increase valve that is attached to the side of

the carburettor.

2 To test the operation of this valve first

remove the air filter and vacuum hose.

3 With the valve’s plug connected, have

someone turn the ignition on (but do not start

the engine). A mechanical shifting noise

should be heard. If not replace the unit.

4 After refitting replace the vacuum hose and

air filter.

25 Idle cut-off solenoid (1.8 litre

models) — description and

testing

2

Note: Refer to Section 2 before proceeding

Description

1 On 1.8 litre models, the carburettor is fitted

with an idle cut-off solenoid. This is an

electrically operated valve, which interrupts

the idle mixture circuit when the ignition is

switched off, thus preventing the engine from

running-on (see illustration).

2 The idle cut-off solenoid is energised all the

time that the ignition is switched on. A

defective solenoid, or a break in its power

supply, will cause the engine to stall or idle

roughly, although it will run normally at speed.

Testing

3 If the operation of the solenoid is suspect,

first check that battery voltage is present at

the solenoid terminal when the ignition is

switched on. Use a 12 volt test lamp or similar

test device.

4 If no voltage is present, then the fault lies in

the wiring to the solenoid. If voltage is

present, the solenoid can be tested as

follows.

5 With the solenoid unscrewed from the

carburettor, connect the body of the solenoid

to the negative terminal of a 12 volt battery.

When the battery positive terminal is

connected to the solenoid centre terminal,

there should be an audible click, and the

needle at the tip of the solenoid should

retract.

6 A defective idle cut-off solenoid must be

renewed.

26 Inlet manifold — removal and

refitting

3

Note: Refer to Section 2 before proceeding. A

new manifold gasket must be used on refitting

Removal

1 Disconnect the battery negative lead.

2 Drain the cooling system, as described in

Chapter 3.

3 Proceed as described in Section 13,

paragraphs 2 to 7 inclusive, ignoring the

reference to coolant spillage in paragraph 5.

4A•12 Fuel and exhaust systems — carburettor models

21.6 Refitting the carburettor fuel filter

23.4 Throttle position sensor — models with automatic

transmission

1 Adapter 2 Sensor

22.2 Adjusting the throttle valve dashpot — models with

automatic transmission

1 Lever 2 Locknut 3 Dashpot

4 Disconnect the coolant hose from the rear

of the manifold (see illustration).

5 Where applicable, disconnect the camshaft

cover breather hose from the rear of the

manifold (see illustration).

6 Unscrew the union and disconnect the

brake servo vacuum hose from the manifold.

7 On 1.4 and 1.6 litre models, disconnect the

wiring from the temperature gauge sender.

8 Unscrew and remove the top alternator

mounting nut and bolt.

9 On 1.4 and 1.6 litre models, disconnect and

remove the stub hose that connects the

crankcase breather tube to the rear of the

camshaft housing.

10 Make a final check to ensure that all

relevant hoses, pipes and wires have been

disconnected.

11 Unscrew the securing nuts, and withdraw

the manifold from the cylinder head (see

illustration). Note the position of the rear

engine lifting bracket, which is secured by one

of the manifold nuts, and recover the manifold

gasket.

12 It is possible that some of the manifold

studs may be unscrewed from the cylinder

head when the manifold securing nuts are

unscrewed. In this event, the studs should be

screwed back into the cylinder head once the

manifold has been removed, using two

manifold nuts locked together.

13 If desired, the carburettor can be removed

from the manifold, referring to Section 13, if

necessary.

Refitting

14 Refitting is a reversal of removal,

remembering the following points.

15 If the carburettor has been removed from

the manifold, refit it, using a new gasket.

16 If the alternator mounting bracket has

been unbolted from the manifold, refit it

before refitting the manifold, as access to the

securing bolt is extremely limited once the

manifold is in place.

17 Refit the manifold using a new gasket,

and ensure that the engine lifting bracket is in

place under the relevant manifold nut. Tighten

the nuts to the specified torque.

18 Ensure that all relevant hoses, pipes and

wires are correctly reconnected.

19 Refill the cooling system, as described in

Chapter 3.

20 Check the throttle cable free play and

adjust if necessary, as described in Section

11.

21 If the carburettor has been disturbed,

check and if necessary adjust the idle speed

and mixture, as described in Section 14.

Fuel and exhaust systems — carburettor models 4A•13

26.5 . . .and the camshaft cover breather

hose (arrowed) from the inlet manifold —

1.6 litre model

26.11 Withdrawing the inlet manifold —

1.6 litre model

26.4 Disconnecting the coolant hose . . .

4A

25.1 Carburettor idle cut-off solenoid

(arrowed) — 1.8 litre models

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 settings Nm 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 . . . .43

Headlamp 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

experience

Fairly easy, suitable

for beginner with

some experience

Fairly difficult,

suitable for competent

DIY mechanic

Difficult, suitable for

experienced DIY

mechanic

Very difficult,

suitable for expert DIY

or professional

Degrees of difficulty

5

4

3

2

1

1 General 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.

2 Electrical 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 both

the 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 a

breakdown 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•2 Body 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.

to-metal contact between components, due

to flexible rubber mountings, etc.

To check whether a component is properly

earthed, disconnect the battery, and connect

one lead of an ohmmeter to a known good

earth point. Connect the other lead to the wire

or earth connection being tested. The

resistance reading should be zero; if not,

check the connection as follows.

If an earth connection is thought to be

faulty, dismantle the connection, and clean

back to bare metal both the bodyshell and the

wire terminal or the component earth

connection mating surface. Be careful to

remove all traces of dirt and corrosion, then

use a knife to trim away any paint, so that a

clean metal-to-metal joint is made. On

reassembly, tighten the joint fasteners

securely; if a wire terminal is being refitted,

use serrated washers between the terminal

and the bodyshell, to ensure a clean and

secure connection. When the connection is

remade, prevent the onset of corrosion in the

future by applying a coat of petroleum jelly or

silicone-based grease.

3 Fuses and relays — general

Fuses

1 Fuses are designed to break a circuit when

a predetermined current is reached, to protect

the components and wiring which could be

damaged by excessive current flow. Any

excessive current flow will be due to a fault in

the circuit, usually a short-circuit (Section 2).

2 The main fuses and relays are located in a

panel at the lower right-hand side of the facia,

under a hinged cover (see illustration).

3 The circuits protected by the various fuses

and relays are marked on the inside of the

panel cover.

4 A blown fuse can be recognised from its

melted or broken wire.

5 To remove a fuse, first ensure that the

relevant circuit is switched off. Then open the

cover and pull the relevant fuse or relay from the

panel (see illustration). If desired, the lower

end of the panel can be tilted forwards, after

releasing the retaining clips to improve access.

6 Before renewing a blown fuse, trace and

rectify the cause, and always use a fuse of the

correct rating. Never substitute a fuse of a

higher rating, or make temporary repairs using

wire or metal foil, as more serious damage or

even fire could result.

7 Spare fuses are provided in the blank

terminal positions in the fusebox.

8 Note that the fuses are colour-coded, see

Specifications. Refer to the wiring diagrams

for details of the fuse ratings and the circuits

protected.

Relays

9 A relay is an electrically operated switch,

which is used for the following reasons:

a) A relay can switch a heavy current

remotely from the circuit in which the

current is flowing, allowing the use of

lighter-gauge wiring and switch contacts.

b) A relay can receive more than one control

input, unlike a mechanical switch.

c) A relay can have a timer function — for

example, the intermittent wiper relay.

10 Most of the relays are located at the rear

of the main fusebox (remove the securing

screws and pull the fusebox forwards to

improve access). The rear wiper motor relay is

located in the tailgate, behind the tailgate trim

panel. On some models, additional engine-

related relays are located in the relay box

mounted on the left-hand side of the engine

compartment.

11 On certain models, additional relays are

located in a box at the left-hand rear of the

engine compartment (see illustration).

12 If a circuit or system controlled by a relay

develops a fault, and the relay is suspect,

operate the system. If the relay is functioning, it

should be possible to hear it “click” as it is

energised. If this is the case, the fault lies with

the components or wiring of the system. If the

relay is not being energised, then either the

relay is not receiving a main supply or a

switching voltage, or the relay itself is faulty.

Testing is by the substitution of a known good

unit, but be careful — while some relays are

identical in appearance and in operation, others

look similar but perform different functions.

13 To remove a relay, first ensure that the

relevant circuit is switched off. The relay can

then simply be pulled out from the socket,

and pushed back into position.

4 Ignition switch and lock

cylinder — removal and

refitting

3

Removal

1 Disconnect the battery negative lead.

2 Turn 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.

3 Remove the three securing screws from the

underside of the lower column shroud, then

remove both the upper and lower shrouds.

4 To remove the lock cylinder, insert the

ignition key and turn it to position “II”.

5 Insert a thin rod into the hole in the lock

housing, then press the rod to release the

detent spring, and pull out the lock cylinder

using the key.

6 The ignition switch is secured to the

steering lock housing by two grub screws.

Disconnect the wiring plug, and remove the

screws to extract the switch (see illustration).

Removal of the steering wheel, may aid

removal. Refer to Chapter 10 or Section 57, as

applicable. It is recommended that the switch

and the lock cylinder are not both removed at

the same time, so that their mutual alignment

is not lost.

Refitting

7 Refitting is a reversal of removal.

Body electrical systems 12•3

3.11 Relays in engine compartment box —

2.0 litre SRi model shown

4.6 Removing an ignition switch securing

screw

3.5 Removing a fuse —

2.0 litre model shown

3.2 Main fuses and relays in facia panel —

2.0 litre SRi model shown

12

5 Direction indicator/lighting

switch — removal and refitting

2

Removal

1 Disconnect the battery negative lead.

2 Turn 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.

3 Remove the three securing screws from the

underside of the lower column shroud, then

remove both the upper and lower shrouds.

4 Disconnect the wiring plug from the switch.

5 Depress the switch retaining clip, and

withdraw the switch from the housing.

Refitting

6 Refitting is a reversal of removal.

6 Wash/wipe switch — removal

and refitting

2

Proceed as described in Section 5.

7 Facia panel switches —

removal and refitting

2

1 Disconnect the battery negative lead.

Lighting switch

Removal

2 Turn 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).

3 Press 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).

4 Note that the switch assembly cannot be

dismantled, and if any part of the switch is

faulty, the complete assembly must be

renewed.

Refitting

5 Refitting is a reversal of removal.

Push-button switches

Removal

6 First 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

7 Refitting is a reversal of removal.

Headlamp aim adjustment

switch

8 The procedure is as described for push-

button switches.

Hazard warning switch

Removal

9 Using a screwdriver, carefully prise the cap

from the switch (see illustration).

10 Using a screwdriver with a piece of card

under the blade to avoid damage to the facia

trim, prise the ventilation nozzle from the

facia.

11 Prise the switch from the facia and

disconnect the wiring (see illustration).

Refitting

12 Refitting is a reversal of removal.

Heater blower motor switch

Removal

13 Remove the heater control panel, as

described in Chapter 11.

14 Disconnect the wiring plug from the

switch, if not already done.

15 Prise the switch out from the rear of the

heater control panel.

Refitting

16 Refitting is a reversal of removal, but refer

to Chapter 11, when refitting the heater

control panel.

12•4 Body 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 facia

7.9 Prising the cap from the hazard

warning flasher switch

7.6 Prising a push-button switch from the

facia

7.3A Press the switch securing clips

towards the switch spindle . . .

8 Electric door mirror switch —

removal and refitting

2

Removal

1 Disconnect the battery negative lead.

2 Prise the plastic surround from the door

interior handle.

3 Free 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.

4 Note 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.

5 Prise the switch from the door trim panel,

and feed the wiring through the panel.

Refitting

6 Refitting is a reversal of removal, but ensure

that the wiring is correctly routed, so as not to

foul the door interior handle mechanism.

9 Sunroof operating switch —

removal and refitting

2

Removal

1 Disconnect the battery negative lead.

2 Prise the courtesy lamp from the roof trim

panel, and disconnect the wiring.

3 Remove the two trim panel securing

screws, and withdraw the trim panel from the

roof, disconnecting the wiring from the

sunroof operating switch.

4 Release the securing clips, then pull the

switch from the rear face of the trim panel.

Refitting

5 Refitting is a reversal of removal.

10 Courtesy lamp switch —

removal and refitting

2

Removal

1 Disconnect the battery negative lead.

2 Open the door and remove the switch

securing screw.

3 Withdraw the switch from the door pillar,

and pull the wiring out sufficiently to prevent it

from springing back into the pillar.

4 Disconnect the wiring and remove the

switch.

Refitting

5 Refitting is a reversal of removal.

11 Luggage compartment lamp

switch — removal and refitting

2

Removal

1 Disconnect the battery negative lead.

2 Open the boot lid or tailgate, as applicable,

and remove the switch securing screw.

3 Withdraw the switch from the body panel,

and pull the wiring out sufficiently to prevent it

from springing back into the body.

4 Disconnect the wiring and remove the

switch.

Refitting

5 Refitting is a reversal of removal.

12 Brake lamp switch — removal

and refitting

2

Removal

1 Disconnect the battery negative lead.

2 Remove the lower trim panel from the

driver’s footwell.

3 Disconnect the wiring plug from the brake

lamp switch, then twist the switch

anti-clockwise and remove it from its bracket.

Refitting

4 Refitting is a reversal of removal.

13 Handbrake “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.

14 Oil pressure warning lamp

switch — removal and refitting

3

Removal

1 Disconnect the battery negative lead.

2 The 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).

3 In 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.

4 Disconnect 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

5 Refitting 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.

15 Cigarette lighter — removal

and refitting

2

Removal

1 Disconnect the battery negative lead.

2 Slide 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.

3 To 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

4 Refitting is a reversal of removal.

16 Clock — removal and refitting

2

Removal

1 Disconnect the battery negative lead.

2 Using a thin-bladed screwdriver, carefully

prise the clock from the facia panel.

3 Disconnect the wiring plugs and withdraw

the clock (see illustration).

Refitting

4 Refitting is a reversal of removal.

17 Heated 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.

18 Instrument panel — removal

and refitting

3

Removal

1 Disconnect the battery negative lead.

2 Remove the steering wheel, (Chapter 10).

3 Remove the steering column shrouds, and

the instrument panel upper and lower trim

panels, (Chapter 11).

4 Remove the single upper, and two lower,

instrument panel securing screws (see

illustration).

5 Carefully 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).

6 If desired, the instrument panel can be

dismantled, with reference to Section 19.

Refitting

7 Refitting 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.

19 Instrument panel

components — removal and

refitting

3

1 With the instrument panel removed, as

described in Section 18, continue as follows.

Panel illumination and warning

lamp bulbs

Removal

2 Twist the relevant bulbholder clockwise,

and withdraw it from the printed circuit board

on the rear of the instrument panel (see

illustration).

3 The bulbs are integral with the bulbholders,

and must be renewed as a unit.

Refitting

4 Refitting is a reversal of removal.

Voltage stabiliser

Removal

5 Remove 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

6 Refitting is a reversal of removal.

Fuel and temperature gauges —

“low series” models

Removal

7 Pull the trip meter reset pin from the front of

the panel.

8 Release the two retaining clips at the top of

the panel, and remove the panel shroud (see

illustration).

9 Unscrew the two securing nuts, and

withdraw the relevant gauge through the front

of the instrument panel.

12•6 Body 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

shroud

19.5 Instrument panel voltage stabiliser

(arrowed)

19.2 Withdrawing an instrument panel

illumination lamp bulb

18.4 Unscrewing a lower instrument panel

securing screw

Refitting

10 Refitting is a reversal of removal.

Fuel and temperature gauge

assembly — “high series” models

11 The procedure is as described in

paragraphs 7 to 10 inclusive, except that the

gauge assembly is secured by four nuts.

Tachometer

12 The procedure is as described in

paragraphs 7 to 10 inclusive except that the

tachometer is secured by three nuts (see

illustration).

Speedometer

Removal

13 Proceed as described in paragraphs 7

and 8.

14 Extract the four securing screws from the

rear of the panel (see illustration).

Refitting

15 Refitting is a reversal of removal.

Printed circuit board

Removal

16 Remove all bulbs and instruments, and

the voltage stabiliser, as described previously

in this Section.

17 Carefully peel the printed circuit board

from the instrument panel.

Refitting

18 Refitting is a reversal of removal, but

ensure that the printed circuit board is seated

correctly on the rear of the instrument panel.

20 Trip computer components —

removal and refitting

2

1 Disconnect the battery lead.

Display module

Removal

2 Using a thin-bladed screwdriver, carefully

prise the module from the facia panel.

3 Disconnect the wiring plug and withdraw

the module.

Refitting

4 Refitting is a reversal of removal.

Display module illumination bulb

Removal

5 Remove the display module, as described

previously in this Section.

6 Using 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

7 Refitting is a reversal of removal.

Operating switch

Removal

8 Remove the rear section of the centre

console, as described in Chapter 11.

9 Release the wiring plug from the switch

using a screwdriver.

10 Lift the switch, then pull it down and out

from the centre console.

Refitting

11 Refitting is a reversal of removal.

Outside air temperature sensor

Removal

12 The sensor is located at the left-hand end

of the front bumper (see illustration).

13 Prise the cover cap from the bumper, then

unclip the sensor, and disconnect the wiring

plug.

Refitting

14 Refitting is a reversal of removal.

21 Check control system

components — removal and

refitting

3

1 Disconnect the battery negative lead.

Warning lamp bulbs

2 The warning lamp bulbs are located in the

instrument panel, and removal and refitting

are described in Section 19.

Control module

Removal

3 The control module is located behind the

passenger side of the facia, above the

glovebox.

4 Remove the glovebox assembly, as

described in Chapter 11.

5 Disconnect the control module wiring plug,

then release the control module from its

mounting and withdraw the unit.

Refitting

6 Refitting is a reversal of removal.

Coolant level sensor

Removal

7 The coolant level sensor is integral with the

coolant expansion tank cap.

8 Disconnect the wiring from the top of the

cap, then unscrew the cap and withdraw it

from the expansion tank.

9 If faulty, the complete cap assembly must

be renewed.

Refitting

10 Refitting is a reversal of removal.

Washer fluid level sensor

Removal

11 The sensor is mounted in the side of the

fluid reservoir.

12 Disconnect 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

13 Refitting is a reversal of removal.

Body electrical systems 12•7

20.6 Removing the trip computer display

module illumination bulb

20.12 Trip computer outside air

temperature sensor location (arrowed)

19.14 Speedometer securing screws

(arrowed)

19.12 Tachometer securing nuts (arrowed)

12

Brake fluid level sensor

14 The procedure is as described for the

coolant level sensor in paragraphs 7 to 10

inclusive.

Engine oil level sensor

Removal

15 Apply the handbrake, jack up the front of

the vehicle, and support securely on axle

stands (see “Jacking and Vehicle Support”)

positioned under the body side members.

16 On DOHC models, remove the engine

undershield, as described in Chapter 11.

17 Disconnect the sensor wiring plug.

18 Unscrew the three or four sensor securing

screws, as applicable, and withdraw the

sensor, manipulating the float through the hole

in the sump (see illustration). Recover the

sealing ring. Be prepared for some oil spillage.

19 Examine the condition of the sealing ring,

and renew if necessary.

Refitting

20 Refitting is a reversal of removal. On

completion, check, and if necessary top-up,

the engine oil level.

Bulb failure sensor

Removal

21 The bulb failure sensor is mounted behind

the fuse/relay panel in the facia.

22 Release the retaining clips from the lower

end of the fuse/relay panel, and tilt it forwards.

23 Reach up behind the fuse/relay panel, and

pull the sensor from its socket.

Refitting

24 Refitting is a reversal of removal.

22 Horn(s) — removal and refitting

2

1 On models with a single horn, the horn is

located in front of the radiator. On models

with twin horns, the horns are located beneath

the washer fluid reservoir, at the left-hand end

of the front bumper.

Single horn

Removal

2 Disconnect the battery negative lead.

3 Remove the radiator grille panel, with

reference to Chapter 11.

4 Disconnect the wiring from the rear of the

horn.

5 Reach up behind the mounting bracket, and

unscrew the single nut securing the horn to the

bracket (see illustration). Withdraw the horn.

Refitting

6 Refitting is a reversal of removal.

Twin horns

Removal

7 Disconnect the battery negative lead.

8 Apply the handbrake, then jack up the front

of the vehicle, and support securely on axle

stands (see “Jacking and Vehicle Support”)

positioned under the body side members.

9 Remove the securing screws, and withdraw

the plastic cover (where fitted) from the

bumper/front wing to expose the horns.

10 Remove the bolt securing the horn

mounting bracket to the bracket below the

washer fluid reservoir (see illustration).

11 Withdraw the horns and disconnect the

wiring.

12 If desired, the horns can be unbolted from

the bracket.

Refitting

13 Refitting is a reversal of removal.

23 Interior lamps — removal and

refitting

2

Removal

1 Disconnect the battery negative lead.

2 Using a thin-bladed screwdriver, prise the

lamp from its location and disconnect the

wiring (see illustration).

Refitting

3 Refitting is a reversal of removal.

24 Interior lamp bulbs — renewal

1

1 Disconnect the battery negative lead.

Courtesy lamp

Note: Some later models are fitted with

courtesy lamps for the rear seat passengers,

as well as front.

Removal

2 Using a thin-bladed screwdriver, prise the

lamp from its location and disconnect the

wiring.

3 On models fitted with a courtesy lamp with

integral map reading lamps, the lens must be

levered from the housing for access to the

bulbs.

12•8 Body electrical systems

21.18 Engine oil level sensor — DOHC model

22.10 Horn mounting bracket securing

bolt (arrowed) — twin horned model

23.2 Withdrawing the courtesy lamp

22.5 Horn viewed from behind with radiator removed — single

horned model

4 Remove the courtesy lamp bulbs by

carefully prising it from its location using a

thin-bladed screwdriver. Where applicable,

the map reading lamp bulbs are a push fit in

the bulbholders.

Refitting

5 Refitting is a reversal of removal.

Glovebox lamp

Removal

6 Using a thin-bladed screwdriver, prise the

lamp from its location and disconnect the

wiring.

7 Carefully prise the bulb from the lamp.

Refitting

8 Refitting is a reversal of removal.

Luggage compartment,

underbonnet and kerb lamps

Removal

9 Using a thin-bladed screwdriver, prise the

lamp from its location; disconnect the wiring.

10 Carefully prise the bulb from the lamp

(see illustration).

Refitting

11 Refitting is a reversal of removal

Cigarette lighter illumination lamp

Removal

12 Slide the ashtray/cigarette lighter

assembly from the facia, then disconnect the

wiring and pull the bulbholder from the rear of

the cigarette lighter housing.

13 The bulb is a push fit in the bulbholder.

Refitting

14 Refitting is a reversal of removal.

Clock illumination lamp

15 Remove the clock, (Section 16).

16 Twist the bulbholder and pull it from the

rear of the clock (see illustration).

17 The bulb is a push fit in the bulbholder.

Trip computer display module

illumination lamp

18 Refer to Section 20.

Heater control panel

illumination lamp

Removal

19 Remove the heater control panel, as

described in Chapter 11.

20 Pull the bulbholder from the rear of the

control panel (see illustration).

21 The bulb is a push fit in the bulbholder.

Refitting

22 Refitting is a reversal of removal.

Facia panel switch illumination

lamp

23 If a bulb fails in one of the facia panel

switches, the complete switch assembly must

be renewed, as described in Section 7, as no

individual spare parts are available.

Vanity mirror illumination lamp

Removal

24 Lower the sunvisor and, using a

thin-bladed screwdriver, prise out the mirror

and diffuser assembly. Pull the bulb(s) from

the spring contacts.

Refitting

25 Refitting is a reversal of removal.

25 Headlamp unit — removal and

refitting

2

Removal

1 Remove the radiator grille panel, as

described in Chapter 11.

2 Remove the front indicator lamp unit, as

described in Section 29.

3 Remove the cover from the rear of the

headlamp unit, and disconnect the wiring

plugs from the bulbs.

4 If applicable, disconnect the wiring plug

from the headlamp aim adjustment motor.

5 Remove the three securing screws, and

withdraw the headlamp unit (see

illustrations). Feed the wiring through the

headlamp casing as it is removed.

6 If required, the headlamp lens can be

removed by releasing the spring clips around

its edge.

Refitting

7 Refitting is a reversal of removal.

8 On completion, have the headlamp

alignment checked, with reference to

Section 27.

Body electrical systems 12•9

24.20 Heater control panel illumination

lamp bulbholder withdrawn

25.5C Withdrawing a headlamp unit25.5B Unscrewing an upper headlamp

securing screw

25.5A Unscrewing the lower headlamp

securing screw

24.16 Removing the clock illumination

lamp bulbholder

24.10 Removing the underbonnet lamp

bulb

12

27 Headlamps — alignment

2

1 Correct 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.

2 Accurate alignment should be carried out

using optical beam setting equipment.

3 In 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.

4 All 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.

28 Headlamp dim-dip system —

general, removal and refitting

3

General

1 The 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).

2 The control unit uses the oil pressure

warning lamp circuit to ensure that, when the

engine 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.

3 To 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

4 If 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.

5 If 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

6 Refitting is the reverse of the removal

procedure.

26 Headlamp aim adjustment

motor — removal and refitting

3

Removal

1 Remove the headlamp, (Section 25).

2 Twist the motor clockwise to release it from

the headlamp, then carefully disconnect the

motor from the balljoint (see illustrations).

Refitting

3 Refitting is a reversal of removal, but ensure

that the motor is correctly engaged with the

balljoint.

12•10 Body 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 screw

27.3A Headlamp alignment adjustment screws — models without

electric aim adjustment

A Vertical adjustment screw B Horizontal adjustment screw

26.2B Headlamp aim adjuster balljoint

(arrowed)

29 Front indicator lamp unit —

removal and refitting

2

Removal

1 Disconnect the battery negative lead.

2 Remove the single indicator lamp unit

securing screw, which is accessible through

the hole in the upper body panel (see

illustration).

3 Pull the lamp unit forwards to release it

from the body, then disconnect the wiring

plug (see illustration).

Refitting

4 Refitting is a reversal of removal.

30 Side repeater lamp — removal

and refitting

2

Removal

1 Disconnect the battery negative lead.

2 Remove the wheel arch liner, as described

in Chapter 11.

3 Working in the engine compartment,

disconnect the wiring plug, and detach the

earth lead from the body panel.

4 Working under the wheel arch, depress the

retaining tabs and manipulate the lamp

through the outside of the wing, pulling the

wiring and the grommet from the inner wing

panel.

5 The lens can be removed from the lamp by

twisting it to release the retaining clips.

6 Check the condition of the rubber sealing

ring, and renew if necessary.

Refitting

7 Refitting is a reversal of removal.

31 Front foglamp — removal,

refitting and adjustment

3

Removal

1 Disconnect the battery negative lead.

2 Removing (if necessary) the radiator grille

panel, as described in Chapter 11, disconnect

the appropriate foglamp wiring plug.

3 Apply the handbrake, jack up the front of

the vehicle and support it securely on axle

stands (see “Jacking and Vehicle Support”)

positioned under the body side members.

4 If removing the driver’s side foglamp,

remove the securing screws and withdraw the

plastic cover from the bumper/front wing to

expose the lamp mountings.

5 Unscrew the three securing bolts and

withdraw the lamp and wiring, the two bottom

bolts are obvious, but the third is well hidden

at the top of the lamp.

Refitting

6 Refitting is a reversal of removal, but on

completion check the foglamp adjustment.

Adjustment

7 The vertical aim of the foglamps can be

adjusted by turning the adjuster screw at the

rear of the lamp in the required direction. It will

be necessary to remove the plastic cover

(driver’s side only) from the bumper/front wing

to expose the adjuster screw (see

illustration).

32 Rear lamp unit — removal and

refitting

2

Removal

1 Disconnect the battery negative lead.

2 Working in the luggage compartment,

remove the cover from the rear of the lamp.

3 Release the top and bottom retaining clips,

and pull the bulbholder from the lamp.

Disconnect the wiring plug.

4 Remove the securing screws, and withdraw

the lamp unit from outside the vehicle.

5 Note that the lens cannot be renewed

separately, and if damaged, the complete

lamp unit must be renewed.

Refitting

6 Refitting is a reversal of removal.

33 Number plate lamp — removal

and refitting

2

Removal

1 Disconnect the battery negative lead.

2 Using a thin-bladed screwdriver, carefully

prise the lamp surround from the bumper.

3 Pull the lamp from the bumper, and

disconnect the wiring.

Refitting

4 Refitting is a reversal of removal.

34 Exterior lamp bulbs — renewal

1

Note: The glass envelopes of the headlamp

and foglamp bulbs must not be touched with

the fingers. If the glass is accidentally

touched, it should be washed with methylated

spirits and dried with a soft cloth. Failure to

observe this procedure may result in

premature bulb failure

1 Disconnect the battery negative lead.

Headlamps

Removal

2 Working in the engine compartment,

release the retaining clip, and remove the

cover from the rear of the headlamp (see

illustration).

Body electrical systems 12•11

31.7 Foglamp aim adjustment screw

(arrowed)

34.2 Removing the cover from the rear of

the headlamp

29.3 Disconnecting the front indicator

lamp unit wiring plug

29.2 Unscrewing the front indicator lamp

unit securing screw

12

3 Pull the wiring plug from the base of the bulb,

then release the spring clip, grasp the bulb by

its contacts and carefully withdraw it (see

illustrations). Do not touch the bulb glass.

Refitting

4 Refitting is a reversal of removal.

Sidelamps

Removal

5 Working in the engine compartment,

release the retaining clip, and remove the

cover from the rear of the headlamp.

6 Pull the wiring plug from the bulbholder,

then pull the bulbholder from the headlamp

(see illustration).

7 The bulb is a push fit in the bulbholder (see

illustration).

Refitting

8 Refitting is a reversal of removal.

Front indicator lamp

Removal

9 Working in the engine compartment,

disconnect the wiring plug from the

bulbholder.

10 Twist the bulbholder anti-clockwise, and

pull it from the lamp unit (see illustration).

11 The bulb is a bayonet fit in the bulbholder

(see illustration).

Refitting

12 Refitting is a reversal of removal.

Front indicator side repeater

lamp

Removal

13 Twist the lamp lens anti-clockwise, and

pull it from the lamp.

14 The bulb is a push fit in the lamp (see

illustration).

Refitting

15 Refitting is a reversal of removal, but

ensure that the rubber sealing ring is correctly

seated between the lens and the body panel.

Front foglamp

Removal

16 To improve access, apply the handbrake,

jack up the front of the vehicle, and support

securely on axle stands (see “Jacking and

Vehicle Support”) positioned under the body

side members.

17 Remove the securing screws, and

withdraw the plastic cover (driver’s side only)

from the bumper/front wing to expose the

foglamp.

18 Remove the security screw, and withdraw

the cover from the base of the lamp (see

illustration).

19 Release the spring clip, using a

screwdriver if necessary, then grasp the bulb

by its contacts and carefully withdraw it. Do

not touch the bulb glass (see illustration).

20 Pull the wiring plug from the base of the

bulb.

Refitting

21 Refitting is a reversal of removal.

Rear lamp unit

Removal

22 Working in the luggage compartment,

remove the cover from the rear of the lamp.

23 Release the top and bottom retaining

clips, and pull the bulbholder from the lamp,

12•12 Body electrical systems

34.3A Release the spring clip . . . 34.6 Pull the sidelamp bulbholder from the

headlamp . . .

34.18 Removing a front foglamp cover

securing screw

34.10 Withdraw the front indicator lamp

bulbholder (lamp removed) . . .

34.07 . . . then pull the bulb from the

bulbholder

34.14 Removing a front indicator side

repeater lamp bulb

34.11 . . . then remove the bulb

34.3B . . . and withdraw the headlamp bulb

taking care not to strain the wiring (see

illustration).

24 The bulbs are a bayonet fit in the bulbholder

(see illustration). Note that the brake/tail lamp

bulb has offset bayonet pins so that it can only

be fitted in one position; ensure that the correct

type of replacement is obtained.

Refitting

25 Refitting is a reversal of removal.

Rear number plate lamp

Removal

26 Using a thin-bladed screwdriver, carefully

prise the lamp surround from the bumper.

27 Pull the lamp from the bumper, taking

care not to strain the wiring, and unclip the

lens (see illustration).

28 The bulb is a bayonet fit in the lamp (see

illustration).

Refitting

29 Refitting is a reversal of removal.

35 Wiper blades — renewal

1

Removal

1 The wiper blades should be renewed when

they no longer clean the glass effectively.

2 Lift the wiper arm away from the glass. On

some models it may be more convenient to do

this with the bonnet open.

3 With the blade at 90° to the arm, depress

the spring clip and slide the blade from the

hook (see illustration).

4 If necessary, extract the two metal inserts

and unhook the wiper rubber.

Refitting

5 Refitting is a reversal of removal, but where

applicable, make sure that the cut-outs in the

metal inserts securing the rubber to the blade

face each other.

36 Wiper arms — removal and

refitting

2

Windscreen and rear window

wipers

Removal

1 The wiper motor should be in its parked

position before removing the wiper arm. Mark

the position of the blade on the glass with

adhesive tape as a guide to refitting.

2 Lift the hinged covers, and remove the nuts

and washers securing the arms to the

spindles.

3 Prise the arms from the spindles, using a

screwdriver if necessary. Take care not to

damage the paintwork.

Refitting

4 Refitting is a reversal of removal. Note that

the passenger side wiper arm is longer than

that fitted to the driver’s side. Ensure that the

arms are fitted to their correct locations, as

incorrect installation can cause the blades to

foul one another when being used (see

illustration).

Headlamp wipers

5 The procedure is as described in

paragraphs 1 to 4, but the washer hose must

be disconnected from the stub on the body

panel.

37 Washer nozzles — removal

and refitting

1

Models up to 1990

Removal

1 To remove a nozzle, carefully prise it from

its location using a thin-bladed screwdriver.

Take care not to damage the paintwork.

Body electrical systems 12•13

34.24 . . . then remove the relevant bulb

36.4 Windscreen wiper arms —

1992-on models

35.3 Removing a wiper blade

34.28 . . . then remove the bulb34.27 Unclip the lens from the rear

number plate lamp . . .

34.23 Release the rear lamp unit

bulbholder retaining clips . . .

34.19 Withdrawing a foglamp bulb

12

2 Disconnect the washer hose and withdraw

the nozzle.

Refitting

3 To refit, reconnect the washer hose to the

nozzle, and push the nozzle into its locating

hole.

4 The nozzles can be adjusted by inserting a

pin into the jet, and swivelling it to the

required position.

1991-on models

5 The nozzles on all later models are fitted

with twin jets.

6 On some later models, the nozzles are

heated; the circuit is fed through fuse 29 and

is live whenever the ignition is switched on.

Current is regulated by a Positive

Temperature Coefficient (PTC) resistor that

takes outside temperature into account.

38 Windscreen wiper motor and

linkage — removal and refitting

3

Removal

1 Disconnect the battery negative lead.

2 Remove the wiper arms, as described in

Section 36.

3 Remove the windscreen cowl panel, as

described in Chapter 11.

4 Disconnect the wiring plug from the motor

(see illustration).

5 Unscrew the three bolts securing the

motor/linkage assembly to the body, then

withdraw the assembly (see illustrations).

6 If desired, the motor can be removed from

the linkage by unscrewing the three securing

bolts. Do not attempt to dismantle the linkage.

Refitting

7 Refitting is a reversal of removal.

39 Tailgate wiper motor —

removal and refitting

3

Removal

1 Disconnect the battery negative lead.

2 Remove the wiper arm, as described in

Section 36.

3 Extract the securing screws, and remove

the rear tailgate trim panel.

4 Disconnect the motor wiring plug.

5 Unscrew the two motor securing bolts,

noting the earth leads under the bolt heads

(see illustration).

6 Manipulate the motor assembly from the

tailgate.

Refitting

7 Refitting is a reversal of removal, ensuring

that the cut-out in the drive spindle rubber

seal engages with the notch in the drive

spindle (see illustration).

40 Headlamp wiper motor —

removal and refitting

3

Removal

1 Disconnect the battery negative lead.

2 Remove the wiper arm, as described in

Section 36.

3 Remove the headlamp, as described in

Section 25.

4 Disconnect the motor wiring plug.

5 Unscrew the two bolts securing the motor

mounting bracket to the body panel, then

withdraw the motor (see illustrations).

Refitting

6 Refitting is a reversal of removal.

12•14 Body electrical systems

38.4 Disconnecting the windscreen wiper

motor wiring plug

38.5B . . . then withdraw the assembly

40.5B . . . and withdraw the motor40.5A Unscrew the headlamp wiper motor

securing bolts . . .

39.7 Cut-out in tailgate wiper motor drive

spindle rubber seal must engage with

notch in drive spindle

39.5 Tailgate wiper motor assembly. Note

earth leads under heads of securing bolts

38.5A Unscrew the windscreen wiper

motor/linkage assembly securing bolts . .

41 Washer fluid reservoir —

removal and refitting

2

1 Disconnect the battery negative lead.

Models without headlamp wash

Removal

2 Disconnect the wiring from the washer

pump.

3 Disconnect the washer fluid hose from the

pump. Be prepared for fluid spillage.

4 Remove the screw(s) securing the reservoir

to the body, and withdraw the reservoir.

Refitting

5 Refitting is a reversal of removal.

Models with headlamp wash

Removal

6 On models with headlamp wash, the

reservoir is in two sections, the upper section,

which can be removed from the engine

compartment, and the lower section, which

must be removed from under the wheel arch.

7 Disconnect the wiring from the headlamp

wash non-return valve in the top of the

reservoir.

8 Disconnect the washer fluid hoses from the

non-return valve. Be prepared for fluid spillage.

9 Remove the screw securing the upper

section of the reservoir to the wing panel.

10 Loosen the plastic collar securing the

upper section of the reservoir to the lower

section, then withdraw the upper section of

the reservoir from the engine compartment.

11 To remove the lower section of the

reservoir, continue as follows.

12 Apply the handbrake, then jack up the

front of the vehicle, and support on axle

stands (see “Jacking and Vehicle Support”)

positioned under the body side members.

13 Remove the securing screws, and

withdraw the plastic cover from the

bumper/front wing to expose the lower

section of the reservoir.

14 Remove the horns, (Section 22).

15 Remove the wheel arch liner, (Chapter 11).

16 Disconnect the wiring and the fluid hoses

from the washer pump. Be prepared for fluid

spillage.

17 Unscrew the bolts securing the

horn/reservoir support bracket and the

reservoir to the body, then withdraw the

bracket and the reservoir (see illustration).

Refitting

18 Refitting is a reversal of removal.

42 Washer pump — removal and

refitting

2

1 Disconnect the battery negative lead.

Models without headlamp wash

Removal

2 Disconnect the wiring and the fluid hose

from the pump. Be prepared for fluid spillage.

3 Pull the pump from the reservoir, being

prepared for fluid spillage if the reservoir still

contains fluid.

4 Examine the condition of the sealing

grommet, and renew if necessary, and clean the

gauze filter at the end of the pump pick-up tube.

Refitting

5 Refitting is a reversal of removal.

Models with headlamp wash

6 Apply the handbrake, then jack up the front

of the vehicle, and support on axle stands

positioned under the body side members.

7 Remove the securing screws, and withdraw

the plastic cover from the bumper/front wing

to expose the lower section of the fluid

reservoir.

8 Remove the wheel arch liner, (Chapter 11).

9 Proceed as described in paragraphs 2 to 5

inclusive.

43 Headlamp washer fluid

non-return valve — removal

and refitting

2

Removal

1 The valve is located on a bracket attached

to the upper section of the washer fluid

reservoir (see illustration).

2 Disconnect the battery negative lead.

3 Disconnect the wiring and the fluid hoses

from the valve. Be prepared for fluid spillage.

4 Remove the screw securing the valve

bracket to the reservoir, and withdraw the

valve.

Refitting

5 Refitting is a reversal of removal.

44 Electric window components

— removal and refitting

3

Note: Whenever any of the electric window

components are removed, after refitting the

components, the electric window controls

must be programmed, as described in

Section 45.

1 Disconnect the battery negative lead.

Rear door-mounted switches

Removal

2 Prise the plastic surround from the door

interior handle.

3 Carefully prise the switch from its location,

and disconnect the wiring plug.

Refitting

4 Refitting is a reversal of removal, but make

sure that the wiring is routed so that it does

not foul the electric window or lock operating

components.

Body electrical systems 12•15

43.1 Headlamp washer fluid non-return valve (arrowed)41.17 Horn/washer fluid reservoir support bracket securing bolt

(arrowed) — model with headlamp wash

12

Centre console-mounted

switches

Removal

5 The switches must be removed as a

complete assembly, and cannot be

dismantled. If one of the switches is faulty, the

complete assembly must be renewed.

6 Remove the rear section of the centre

console, as described in Chapter 11.

7 Release the securing clips, and withdraw

the switch assembly through the top of the

centre console.

Refitting

8 Refitting is a reversal of removal.

Operating motors

9 Remove the door window regulator, as

described in Chapter 11.

10 To remove the motor assembly from the

front door window regulator, unscrew the

three motor securing nuts, and the single

screw securing the pulse pick-up unit to the

regulator assembly. Withdraw the motor,

complete with the pulse pick-up unit. Note

that if the motor or pick-up unit is/are faulty,

the two components must be renewed as an

assembly, as no spare parts are available (see

illustration).

11 The motor assembly fitted to the rear door

window regulator is an integral part of the

regulator, and no attempt should be made at

dismantling. If faulty, the complete

motor/regulator assembly must be renewed,

as no spares are available.

45 Electric window controls —

programming

1

1 Whenever the battery is disconnected, or any

of the electric window components are removed,

on completion of work, the electric window

controls must be programmed as follows.

2 Close all doors, and switch on the ignition.

3 Close one of the windows by pressing the

relevant operating switch. Press and hold the

switch for a further five seconds after the

relevant window has fully closed.

4 Repeat the procedure for the remaining

window(s).

46 Central door locking

components — removal and

refitting

3

1 Disconnect the battery negative lead.

Electronic control module

Removal

2 The module is mounted in the driver’s

footwell, behind the side trim panel.

3 Remove the driver’s footwell side trim

panel, as described in Chapter 11.

4 Unscrew the two securing nuts, and lift the

module from the body panel (see

illustration).

5 Depress the retaining clip to release the

wiring plug, then withdraw the module.

Refitting

6 Refitting is a reversal of removal.

Operating switch

Removal

7 The operating switch takes the form of a

microswitch, mounted inside the door at the

rear of the exterior handle assembly.

8 Remove the door inner trim panel, as

described in Chapter 11.

9 Peel back the plastic insulating sheet

sufficiently to gain access to the exterior

handle.

10 Unclip the microswitch from the rear edge

of the exterior handle assembly, and

disconnect the switch wiring plug from the

door wiring harness, then withdraw the switch

(see illustration).

Refitting

11 Refitting is a reversal of removal.

Door lock operating motor

Removal

12 Remove the door lock, as described in

Chapter 11.

13 Disconnect the lock operating rod from

the motor.

14 Remove the two securing screws, and

withdraw the motor from the lock assembly.

Refitting

15 Refitting is a reversal of removal.

Tailgate/boot lid lock operating

motor

Removal

16 On Hatchback models, extract the

securing screws and remove the rear tailgate

trim panel.

17 Remove the two securing screws, and

manipulate the motor to disconnect the lock

operating rod.

18 Withdraw the motor and disconnect the

wiring plug (see illustration).

Refitting

19 Refitting is a reversal of removal.

Fuel filler flap lock operating

motor

Removal

20 Remove the right-hand rear quarter trim

panels, as described in Chapter 11.

21 Disconnect the wiring plug from the rear

of the motor (see illustration).

12•16 Body electrical systems

44.10 Front door electric window motor

securing nuts and pulse pick-up securing

screw (arrowed)

46.10 Central door locking operating

microswitch (arrowed) in driver’s door

46.18 Disconnecting the wiring plug from

the tailgate lock operating motor —

Hatchback model

46.4 Unscrewing a central door locking

control module securing nut

22 Unscrew the two screws securing the

motor to the mounting bracket, then

manipulate the motor to disconnect the lock

operating rod. Withdraw the motor.

Refitting

23 Refitting is a reversal of removal.

47 Aerial — removal and refitting

3

Removal

1 On models with an electric aerial,

disconnect the battery negative lead.

2 Remove the left-hand rear quarter trim

panel, as described in Chapter 11.

3 Remove the screw securing the earth

lead(s) to the body panel (see illustration).

4 Remove the screw securing the aerial

bracket to the body panel, then ensure that

the aerial is fully retracted, and pull it through

the grommet in the bodywork into the luggage

compartment. Disconnect the wiring plug on

models with an electric aerial, and disconnect

the aerial lead (see illustrations).

Refitting

5 Refitting is a reversal of removal, but ensure

that the rubber grommet is correctly seated in

the bodywork.

48 Aerial mast, electric —

removal and refitting

3

Removal

1 The mast on “factory fitted”, fully automatic

electric aerials, can be replaced separately.

2 Extend the aerial as far as possible, by

switching on the radio.

3 Unscrew the mounting nut.

4 Pull the sprung sleeve upwards and clear of

its base.

5 The assembly can now be removed from

the clutch mechanism, by pulling the

assembly upwards.

Refitting

6 Insert the ball end of the mast assembly

into the base.

7 Carefully push the mast assembly down as

far as possible, until it engages into the clutch

mechanism (see illustration).

8 Switch the radio off to retract the aerial.

9 If the aerial does not fully retract into its

base, guide the remaining mast into the base

by hand.

10 Insert the sprung sleeve into the base and

tighten the mounting nut.

11 Check the aerial works properly by turning

the radio on and off a few times.

49 Speakers — removal and

refitting

2

1 Disconnect the battery negative lead.

Facia-mounted speaker

Removal

2 Using a thin-bladed screwdriver, carefully

prise the speaker from the top of the facia

panel. Take care not to damage the facia trim

(see illustration)

3 Disconnect the wiring and withdraw the

speaker. If desired, the plastic trim panel can

be unclipped from the top of the speaker.

Refitting

4 Refitting is a reversal of removal.

Front door-mounted speaker

Removal

5 Remove the door inner trim panel, as

described in Chapter 11.

Body electrical systems 12•17

47.4A Unscrewing the radio aerial bracket

securing screws — electric aerial

49.2 Removing a facia-mounted speaker

(viewed through windscreen)

48.7 Push the mast assembly down, until it

engages in the clutch mechanism

47.4B Disconnecting the aerial lead —

electric aerial

47.3 Radio aerial earth lead securing

screw (arrowed) — electric aerial

46.21 Disconnecting the wiring plug from

the fuel filler flap operating motor —

Hatchback model

12

Always clean the aerial mast

in an upwards direction. This

should minimise dirt being

forced down, into the mast

sections.

Always clean the aerial mast

in an upwards direction. This

should minimise dirt being

forced down, into the mast

sections.

6 Remove the three securing screws, and

withdraw the speaker from the door.

Disconnect the wiring plug (see illustration).

Refitting

7 Refitting is a reversal of removal, but note

that the speaker can only be fitted one way

up, so that the lug on the bottom of the

speaker rim engages with the corresponding

hole in the door skin.

Rear speaker — Hatchback

models

Removal

8 Remove the upper rear quarter trim panel,

as described in Chapter 11.

9 Remove the four securing screws, and

withdraw the speaker.

Refitting

10 Refitting is a reversal of removal.

Rear speaker Saloon models

Removal

11 Carefully prise the trim cover from the

parcel shelf, to expose the speaker.

12 Remove the four securing screws,

withdraw the speaker and disconnect the

wiring.

Refitting

13 Refitting is a reversal of removal.

50 Radio/cassette player —

removal and refitting

2

Removal

1 All the radio/cassette players fitted to the

Cavalier range have DIN standard fixings. Two

special tools, obtainable from in-car

entertainment specialists, are required for

removal.

2 Disconnect the battery negative lead.

3 Unscrew the four grub screws from the

corners of the radio cassette player, using an

Allen key or hexagon bit (see illustration).

4 Insert the tools into the holes exposed by

removal of the grub screws, and push them

until they snap into place. Pull the tools

outwards to release the unit (see illustration).

5 Pull the unit forwards, and withdraw it from

the facia.

Refitting

6 To refit the radio/cassette player, simply

push the unit into the facia until the retaining

lugs snap into place, then refit the grub

screws.

51 Sunroof motor — removal and

refitting

3

Removal

1 Ensure that the sunroof is fully closed.

2 Disconnect the battery negative lead.

3 Prise the courtesy lamp from the roof trim

panel, and disconnect the wiring.

4 Remove the two trim panel securing

screws, and withdraw the trim panel from the

roof, disconnecting the wiring from the

sunroof operating switch.

5 Disconnect the wiring plugs from the motor.

6 Unscrew the securing nut, and withdraw

the motor assembly.

Refitting

7 Refitting is a reversal of removal.

52 Speedometer cable — removal

and refitting

3

Removal

1 Remove the instrument panel, as described

in Section 18.

2 Pull the cable through the bulkhead into the

engine compartment, noting its routing.

3 Working in the engine compartment,

unscrew the securing sleeve and disconnect

the speedometer cable from the top of the

transmission (see illustration).

4 The cable can now be withdrawn from the

vehicle, noting its routing so that it can be

refitted in the same position.

Refitting

5 Refitting is a reversal of removal, ensuring

that the cable is correctly routed. Make sure

that the cable is not kinked or twisted

between the instrument panel and the

bulkhead as the instrument panel is refitted.

Note that the cable should be routed to the

right of the steering column support bracket.

12•18 Body electrical systems

49.6 Withdrawing a front door-mounted

speaker — wiring plug arrowed

50.4 . . . and withdraw the radio/cassette player using the special

tools

52.3 Speedometer cable securing sleeve (arrowed) at

transmission — SOHC model

50.3 Unscrew the grub screws . . .

53 Anti-theft alarm — general

1 Certain models are fitted with an anti-theft

alarm as standard equipment.

2 The alarm system is triggered by door,

bonnet and boot lid/tailgate mounted

switches, and by ultrasonic sensors mounted

inside the passenger compartment (see

illustration).

3 The alarm features a self-diagnostic

function, and any faults should be referred to

a Vauxhall dealer, who will have access to the

necessary specialist diagnostic equipment.

54 Anti-theft alarm system

components — removal and

refitting

4

Control unit

Removal

1 Disconnect the battery negative lead.

2 Remove the driver’s side lower facia panel

as described in Chapter 11.

3 If necessary, remove the footwell side trim

panel as described in Chapter 11.

4 Undo the control unit retaining bolt,

disconnect the wiring plug and remove the

unit from its location.

Refitting

5 Refitting is a reversal of removal.

Ultrasonic sensor

6 Disconnect the battery negative lead.

7 Remove the centre body pillar trim panel as

described in Chapter 11.

8 Carefully release the ultrasonic sensor trim

panel and withdraw it downwards.

9 Release the ultrasonic sensor from its

location, disconnect the wiring plug and

remove the unit from the car.

Refitting

10 Refitting is a reversal of removal.

Bonnet contact unit

Removal

11 Disconnect the battery negative lead.

12 Using a screwdriver, depress the catch at

the base of the contact unit and withdraw the

contact from its location.

13 Disconnect the contact wiring and remove

the unit.

Refitting

14 Refitting is a reversal of removal.

55 Airbag — general

All 1993 Cavalier models are available with

an airbag that is designed to prevent serious

chest and head injuries to the driver during an

accident. A similar bag for the front seat

passenger is also available on certain models.

Sensors in the centre of the car measure the

vehicle deceleration rate and pass these

signals to a microprocessor. This unit

analyses the sensor data and compares the

information with pre-programmed values

stored in its memory, triggering the airbag if

the deceleration is severe. The airbag is

inflated in 50 milliseconds by a gas generator

that forces the bag out of the module cover in

the centre of the steering wheel.

No repairs are possible on the airbag unit or

its associated parts. The contents of the

following Sections are confined to removal

and refitting of the airbag, purely for access to

other non-related components.

Should a fault be suspected on the airbag

unit, indicated by the warning light on the

instrument panel, or if the car has been

involved in an accident, however minor,

consult a Vauxhall dealer immediately. Do not

attempt to dismantle any of the airbag

components or carry out any work

whatsoever, other than the procedures

described in the following Sections.

On vehicles fitted with a passenger side

airbag, do not fit accessories in the airbag

zone. Items like telephones, cassette storage

boxes, additional mirrors, etc., can be ripped off

and cause serious injury, if the airbag inflates.

Body electrical systems 12•19

12

53.2 Anti-theft alarm system component

locations

(Calibra model shown — component locations

identical on Cavalier)

1 Control unit

2 Ultrasonic sensor

with LED

3 Ultrasonic sensor

with probe

4 Radio contact

5 Bonnet contact unit

6 Horn

7 Relay

Warning: Before starting any

work on airbag or related

components, disconnect the

battery. Cover the battery’s

terminals and wait a minimum of 1

minutes as a precaution against

accidental firing of the airbag unit. This

period ensures that any stored energy in

the back-up capacitor is dissipated.

Handle the airbag unit with extreme care

as a precaution against personal injury,

and always hold it with the cover facing

away from the body. If in doubt

concerning any proposed work involving

the airbag unit or its control circuitry,

consult a Vauxhall dealer or other

qualified specialist.

56 Airbag unit, drivers side —

removal and refitting

4

Note: On power steering models in particular,

it will be advantageous to jack up the front of

the car and support it on axle stands placed

under the body side members, so that the

steering wheel can be turned more easily.

Removal

1 Disconnect the battery negative lead and

cover the battery terminal. Wait a minimum of 1

minute.

2 With the steering wheel positioned in the

straight-ahead position, turn it 90° clockwise

so that the left-hand spoke is accessible from

the rear.

3 Using a Torx type socket, undo the first

airbag retaining bolt from the rear of the

steering wheel (see illustration).

4 Turn the steering wheel 180° anti-clockwise

so that the right-hand spoke is accessible

from the rear.

5 Undo the second retaining bolt from the

rear of the steering wheel.

6 Return the steering wheel to the

straight-ahead position then carefully lift up

the airbag unit.

7 Disconnect the wiring plug and remove the

airbag from the car.

Refitting

8 Refitting is a reversal of removal.

57 Steering wheel (with airbag)

— removal and refitting

4

Note: Read warning at the beginning of

Section 55, before starting work. A

two-legged puller will be required for this

operation. Note also that the steering wheel is

a very tight fit on the shaft.

Removal

1 Remove the airbag unit as described

previously.

2 Ensure that the steering wheel is in the

straight ahead position.

3 From the centre of the steering wheel

unscrew the two screws securing the airbag

contact unit.

4 Using a screwdriver, prise back the tabs on

the lockwasher securing the steering wheel

retaining nut.

5 Unscrew and remove the steering wheel

retaining nut and the lockwasher.

6 Make alignment marks between the

steering wheel and the end of the column

shaft.

7 A suitably small two-legged puller must

now be fitted to the steering wheel in order to

pull it from the column shaft.

8 Once the steering wheel has been released

from the column shaft, disconnect the horn

wiring and remove the steering wheel.

Refitting

9 Begin refitting by positioning the steering

wheel on the column shaft, ensuring that the

marks made on removal are aligned, and that

the wheel correctly engages with the airbag

contact unit. It may be necessary to tap the

steering wheel fully home on the column shaft

using a metal tube and socket.

10 Reconnect the horn wiring.

11 Refit the lockwasher and the steering

wheel retaining nut, and tighten the nut to the

specified torque. Bend up the lockwasher to

secure.

12 Refit the two screws securing the airbag

contact unit.

13 Refit the airbag as described previously.

58 Airbag contact unit — removal

and refitting

4

Note: Read warning at the beginning of

Section 55, before starting work.

Removal

1 Remove the airbag and the steering wheel

as described previously.

2 Remove the steering column upper and

lower shrouds, referring to Chapter 10, if

necessary.

3 Disconnect the contact unit wiring plug

below the steering column and withdraw the

contact unit from the column, noting its fitted

position as a guide to reassembly (see

illustration).

Refitting

4 Before refitting the contact unit, ensure that

the front wheels are in the straight-ahead

position.

5 Place the contact unit on the column in the

correct position as noted during removal.

6 Route the wiring harness under the steering

column lock/ignition switch and connect the

wiring plug.

7 Refit the steering column shrouds.

8 Refit the steering wheel and airbag as

described previously.

59 Airbag unit, passengers side

— removal and refitting

4

Note: Read warning at the beginning of

Section 55, before starting work.

Removal

1 Disconnect the battery, cover the terminals

and wait at least 1 minute.

2 Remove the glovebox assembly. Refer to

Chapter 11, for further details if necessary.

3 Remove the right hand ventilation air duct.

12•20 Body electrical systems

58.3 Airbag contact unit retaining screws

56.3 Airbag, steering wheel and contact unit details

Warning: Read warning at the

beginning of Section 55, before

starting work.

Warning: Stand the unit with the

cover uppermost and do not

expose it to heat sources in

excess of 100ºC. Do not attempt

to open or repair the airbag unit, or apply

any voltage to it. Do not use any airbag

unit that is visibly damaged or has been

tampered with.

4 Disconnect the plug connections.

5 Unbolt the six M6 nuts from the two side

brackets.

6 Remove the airbag unit (see illustration).

Refitting

4 Refitting is a reversal of removal.

60 Bracket, passenger airbag

unit — removal and refitting

5

Note: Read warning at the beginning of

Section 55, before starting work. This process

involves removal of the windscreen, refer to

Chapter 11, before starting work.

Removal

1 Remove the passenger side airbag unit as

described in Section 59.

2 Remove the airbag unit cover.

3 Remove the water deflector from in front of

the windscreen.

4 Remove the windscreen.

5 The brackets can now be unbolted.

Refitting

4 Refitting is a reversal of removal.

61 Airbag control unit — removal

and refitting

4

Note: Read warning at the beginning of

Section 55, before starting work.

Removal

1 Disconnect the battery negative lead and

cover the battery terminal to prevent

accidental reconnection.

2 Remove the centre console rear section as

described in Chapter 11.

3 Disconnect the control unit wiring plug,

then undo the three nuts and remove the unit

from the car (see illustration).

Refitting

4 Refitting is a reversal of removal.

62 Wiring diagrams — general

1 The wiring diagrams are of the current flow

type, each circuit being shown in the simplest

possible fashion. Note that since the diagrams

were originally written in German (to the DIN

standard), all wire colours and abbreviations

used on the diagrams themselves are in

German. Refer to the information given

overleaf for clarification.

2 The bottom line of the diagram represents

the “earth” or negative connection; the

numbers below this line are track numbers,

enabling circuits and components to be

located using the key.

3 The lines at the top of the diagram

represent “live feed” or positive connection

points. The line marked “30” is live at all

times, that marked “15” is live only when the

ignition is switched on.

4 Numbers on the diagram that are framed in

square boxes at the end of a wire show the

track reference number in which that wire is

continued. At the point indicated will be

another framed number referring back to the

circuit just left.

5 As an example of how to use the diagrams,

trace with the help of the following text the

reversing lamp switch circuit located between

track reference numbers 496 and 498 on the

1991 model year diagram on page 12•40.

6 Starting at the top of track 497, the supply

for the circuit comes from the line “15”,

showing that the circuit is fed only when the

ignition is switched on, through fuse 22 (F22,

rated at 10 amps). Note that this fuse can also

protect the feed for several other circuits,

some of which may not be applicable to the

vehicle being worked on.

7 If the vehicle in question has a manual

transmission (MT), the circuit continues along

a black wire of 0.75 mm cross-section (as

shown by “SW 0.75” in the wire path), through

terminal 12 of connector X5 to the reversing

lamp switch S7. From the switch the circuit

continues along a white wire, with a black

tracer and of 0.75 mm cross-section (WSSW

0.75), through terminal 2 of connector X5 and

terminal 1 of connector X6, to the reversing

lamp bulbs (E17 and E18). The circuit is

completed by a brown wire from each

bulbholder to earth; in this case the “earth”

wire simply attaches the component to the

nearest piece of metal bodywork, but in other

cases earthing is achieved by the component

mounting and no wire is needed. The diagram

shows, as simply as possible, that when the

switch contacts (which are normally open) are

closed by the driver selecting reverse gear,

current is allowed to flow to earth through the

switch and bulbs causing the reversing lamps

to light.

8 If the vehicle in question has automatic

transmission (AT), the circuit differs in that the

“live feed” goes from fuse 22 to terminal “F” of

the transmission selector lever position switch

connector X46 (track reference number 773).

When position “R” is selected, terminals “F”

and “G” are connected so that the circuit feed

continues (back to track reference number

496, the “RFS/reversing lamp” circuit) along

the same route described above for manual

transmission models.

Body electrical systems 12•21

61.3 Airbag control unit details59.6 Removing the passenger side airbag

12

12•22 Body electrical systems

Explanations of abbreviations used in wiring diagrams

ABS Anti-lock braking system

AC Air conditioning

AZV Trailer hitch

AT Automatic transmission

ATC Automatic temperature control

BR Trip (on-board) computer

CC Check control system

CRC Cruise control

D Diesel

DS Theft protection

DT Turbo Diesel

DWA Anti-theft warning system

DZM Tachometer

EFC Electric folding roof (Convertible)

EKS Pinch guard (electric windows)

EMP Radio

EUR Euronorm (emission control standard)

engine

EZ + El Plus ignition system (with self-

diagnosis)

EZV Ecotronic

FH Electric windows

GB Great Britain

HS Heated rear window

HW Rear window wiper

HZG Heating

HRL Luggage compartment lamp

INS Instrument panel

IRL Courtesy lamps

KAT Catalytic converter

KBS Wiring harness

KV Contact breaker distributor

L3.1 Bosch Jetronic fuel injection system

LCD Liquid crystal display (LCD)

instruments

LHD Left-hand drive

4WD Four-wheel-drive

LWR Headlamp aim adjustment

M1.5 Bosch Motronic M1.5 engine

management system

M2.5 Bosch Motronic M2.5 engine

management system

MOT Motronic (general)

MT Manual gearbox

MUL Multec fuel injection system

N Norway

NS Front foglamps

NSL Rear foglamps

OEL Oil level/pressure check system

OPT Optional equipment

PBSL Park and brake shift block

(automatic transmission, selector

lever in position ‘P’)

P/N Park/neutral (automatic transmission)

POT Potentiometer

RC Rear suspension level control

system

RFS Reversing lamps

RHD Right-hand drive

S Sweden

SD Sunroof

SH Heated seats

SRA Headlamp washers and wipers

TANK Fuel level sender unit

TD Turbo Diesel

TEMP Temperature gauge

TFL Daytime driving lamps

TKS Courtesy lamp (door pillar) switches

TSZI Transistorised ignition (inductive-

triggered) system

VGS Carburettor

WEG Odometer frequency/roadspeed

sensor

WHR Rear suspension level control

system

WS Warning buzzer

ZV Central locking

ZYL Cylinder

Colour codes

BL Blue

HBL Light blue

BR Brown

GE Yellow

GR Grey

GN Green

RT Red

WS White

SW Black

LI Lilac

VI Violet

Wiring identification

Example: GEWS 1.5

GE — Wire basic colour

WS — Wire tracer colour

1.5 — Wire cross-section in mm

2

Note: Not all items shown are fitted to all models. Refer to Section 62 (Chapter 12) for details of diagram usage.

Wiring diagrams 12•23

12

Key to wiring diagrams for 1989 models

E1 Sidelamp — left 406

E2 Tail lamp — left 302, 380, 407

E3 Number plate lamp 413

E4 Side lamp right 409

E5 Tail lamp right 382, 410

E6 Engine compartment lamp 416

E7 Headlamp main beam — left 437

E8 Headlampmain beam — right 438

E9 Headlampdipped beam — left 384, 439

E10 Headlamp dipped beam — right 386, 440

E11 Instrument illumination lamps 328 to 329

E12 Gear selector lever illumination lamp (automatics) 799

E13 Luggage compartment lamp 485

E14 Courtesy lamp 487

E15 Glovebox lamp 599

E16 Cigarette lighter illumination lamp 598

E17 Reversing lamp — left 497

E18 Reversing lamp — right 498

E19 Heated rearwindow 572

E20 Front foglamp — left 448

E21 Front foglamp — right 447

E24 Rear foglamp — left 454

E25 Seat heater — front left 575

E30 Seat heater — front right 579

E32 Clock illumination lamp 552

E38 Trip computer illumination lamp 539

E39 Rear foglamp — right 455

E41 Courtesy lamp (with delay) 488 to 490

E50 Kerb lamp — driver’s door 635

E51 Kerb lamp — passenger door 653

F1 to Fuse (in fusebox) Various

F30

F32 Fuse — mixture preheating (not UK) 232

F33 Fuse — electronic carburettor (not UK) 201

F34 Fuse (in relay box, engine compartment) 834

F35 Voltage stabiliser 302

F36 Fuse — fuel filter heating (Diesel models) 866

G1 Battery 101

G2 Alternator 110

G3 Battery — Diesel models 846

G6 Alternator — Diesel models 850 to 852

H2 Horn 591

H3 Direction indicator warning lamp 318, 320

H4 Oil pressure warning lamp 310

H5 Brake fluid level warning lamp 313

H6 Hazard warning flasher warning lamp 470

H7 Alternator charge warning lamp 310

H8 Headlamp main beam warning lamp 322

H9 Brake lamp — left 388

H10 Brake lamp — right 390

H11 Direction indicator lamp — front left 472

H12 Direction indicatorlamp — rear left 473

H13 Direction indicator lamp — front right 481

H14 Direction indicator lamp — rear right 482

H16 Glow plug warning lamp (Diesel models) 323

H17 Trailer direction indicator warning lamp 321

H18 Horns (twin) 592, 593

H19 Headlamps-on warning buzzer 494, 495

H21 Handbrake-on warning lamp 315

H23 Radio/cassette player 585, 586

H25 Door mirror heater warning lamp 678

H26 ABS warning lamp 319

H30 Engine fault warning lamp 324

H33 Direction indicator side repeater lamp — left 476

H34 Direction indicator side repeater lamp — right 478

H42 Automatic transmission warning lamp 325

H45 Four-wheel-drive warning lamp 327

H46 Catalytic converter temperature warning lamp (not UK) 329

K1 Relay-heated rear window 571 to 572

K5 Relay — front foglamps 448 to 450

K6 Relay — air conditioning (not UK) 801 to 802

K7 Relay — air conditioning blower (not UK) 808 to 809

K8 Relay — intermittent windscreen wipe 503 to 506

K9 Relay — headlamp wash 522 to 523

K10 Relay — direction indicator/hazard warning flashers 467 to 469

K20 HEI ignition control unit 122 to 124

K25 Relay — glow plugs (Diesel models) 856 to 859

K30 Relay — intermittent rear window wipe 515 to 517

K35 Relay — door mirror heater 683 to 685

K37 Central locking control unit 606 to 612

K45 Relay — mixture preheating (not UK) 231 to 232

K47 Relay — surge arrester (ABS) 702 to 703

K50 ABS control unit 707 to 721

K51 Relay — cooling fan 830 to 831

K54 Electronic carburettor control unit (not UK) 203 to 226

K55 Relay — electronic carburettor (not UK) 203 to 206

K57 Fuel injection control unit (not UK) 139 to 161

K58 Relay — fuel pump (not UK) 162 to 163

K59 Relay — daytime running lamps (not UK) 420 to 426

K61 Motronic M4.1 control unit 170 to 194

K62 Dim-dip control unit 428 to 432

K63 Relay — horn 593 to 594

K64 Relay — air conditioning blower (not UK) 802 to 803

K67 Relay — cooling fan 827 to 828

K68 Relay — fuel injection system 294 to 299, 196 to 199

K69 Motronic M2.5 control unit 267 to 297

K71 Ride control unit (not UK) 739 to 754

K80 Relay — fuel filter heater (Diesel models) 865 to 866

K82 Relay — engine revolution 862 to 863

K83 Four-wheel-drive control unit 725 to 731

No Description Track No Description Track

12•24 Wiring diagrams

K84 MSTS ignition control unit 247 to 256

K85 Automatic transmission control unit 771 to 797

K86 Check control unit 370 to 392

K87 Relay — auxiliary cooling fan 833 to 834

K88 Catalytic converter temperature control unit (not UK) 760 to 762

K89 Relay — rear fog lamps 444 to 447

K90 Relay — air conditioning compressor (not UK) 820 to 821

K93 Relay — air conditioning compressor (not UK) 821 to 822

L1 Ignition coil 121 to 122, 133 to 134, 174 to 175,

225 to 226, 243 to 244, 261 to 262

M1 Starter motor 105 to 106

M2 Windscreen wiper motor 501 to 504

M4 Cooling fan motor 113

M6 Headlamp wiper motor — left 525 to 527

M7 Headlamp wiper motor — right 529 to 531

M8 Rear window wiper motor 513 to 515

M13 Sunroof motor 692 to 694

M18 Central locking motor — driver’s door 607 to 610

M19 Central locking motor — left rear door 622 to 624

M20 Central locking motor — right rear door 626 to 628

M21 Fuel pump 163, 196, 299

M26 Electric aerial motor 584 to 585

M30 Door mirror motor and heater — driver’s door 674 to 676

M31 Door mirror motor and heater — passenger door 680 to 682

M32 Central locking motor — passengerdoor 614to617

M33 Idle speed adjuster 146 to 149, 183 to 184, 277 to 278

M37 Central locking motor — boot lid/tailgate 618 to 621

M39 Headlamp aim adjustment motor — left 557 to 560

M40 Headlamp aim adjustment motor — right 561 to 564

M41 Central locking motor — fuel filler flap 623 to 625

M43 Ride control actuator — front left (not UK) 739 to 741

M44 Ride control actuator — front right (not UK) 743 to 745

M45 Ride control actuator — rear left (not UK) 747 to 749

M46 Ride control actuator — rear right (not UK) 751 to 753

M47 Electric window motor — front left 636 to 640

M48 Electric window motor — front right 654 to 658

M49 Electric window motor — rear left 642 to 646

M50 Electric window motor — rear right 660 to 664

M55 Washer fluid pump 518 to 519

P1 Fuel gauge 304

P2 Coolant temperature gauge 306

P3 Clock 551

P4 Fuel level sender unit 304

P5 Coolant temperature sensor 306

P7 Tachometer 308

P8 Oil pressure gauge 341

P9 Voltmeter 339

P10 Oil pressure sensor 341

P11 Airflow meter (Motronic M4.1) 185 to 189

P12 Coolant temperature sensor 178, 272

P13 Trip computer outside air temperature sensor 542 to 543

P14 Distance sensor (not UK) 336 to 337

P17 ABS wheel sensor — front left 707

P18 ABS wheel sensor — front right 710

P19 ABS wheel sensor — rear left 712

P20 ABS wheel sensor — rear right 714

P21 Speedometer frequency sensor (not UK) 332

P23 Pressure sensor 249 to 250

P24 Oil temperature sensor 251

P24 Automatic transmission fluid temperature sensor 795

P27 Brake pad wear sensor — front left 375

P28 Brake pad wear sensor — front right 375

P29 Inlet manifold temperature sensor (not UK) 207 to 208

P30 Coolant temperature sensor 209 to 210, 150

P31 Throttle position sensor (not UK) 209 to 211

P32 Oxygen sensor — heated (not UK) 193 to 194, 291 to 292

P33 Oxygen sensor 157

P34 Throttle position sensor 158 to 160, 780

P35 Crankshaft speed/position sensor 189 to 191, 223 to 225,

281 to 282

P39 Trailer bulb failure sensor 392 to 394

P43 Electronic speedometer 336

P44 Air mass meter (Motronic M2.5) 294 to 296

P45 Automatic transmission input speed sensor 787 to 788

P46 Knock sensor 284 to 285

P47 Distributor ‘Hall-effect’ sensor (Motronic M2.5) 287 to 288

P48 Automatic transmission distance sensor 785 to 786

P50 Catalytic converter temperature sensor (not UK) 761 to 762

R2 Carburettor preheating 116, 228

R3 Cigarette lighter 596 to 597

R5 Glow plugs (Diesel models) 858 to 859

R7 Mixture preheating (not UK) 232

R12 Automatic choke 117

R15 Mixture adjustment potentiometer (not UK) 155 to 157

R19 Cooling fan motor resistor 828, 848

S1 Ignition switch 102 to 106, 851 to 852

S2.1 Lighting switch 404 to 407

S2.2 Courtesy lamp switch 487

S2.3 Instrument illumination lamp dimmer 328

S3 Heater blower switch 837 to 844

S4 Heated rear window switch 570 to 571

S5.2 Dipped beam switch 438, 439

S5.3 Direction indicator switch 480 to 482

S5.4 Sidelamp switch 401 to 402

S7 Reversing lamp switch 497

S8 Brake lamp switch 462

S9.2 Windscreen wiper switch 501 to 504

S9.5 Rear window wash/wiper switch 516 to 518

S10 Automatic transmission switch 770 to 776

S11 Brake fluid level warning sensor 313

S13 Handbrake-on warning switch 315

S14 Oil pressure switch 310

S15 Luggage compartment lamp switch 485

S17 Passenger door courtesy lamp switch 490

Key to wiring diagrams for 1989 models (continued)

No Description Track No Description Track