OPEL CALIBRA 1988 Service Repair Manual

12Unscrew and remove the top alternator
mounting nut and bolt.
13Make a final check to ensure that all
relevant hoses, pipes and wires have been
disconnected.
14Unscrew the securing nuts, and withdraw
the manifold from the cylinder head. Recover
the gasket (see illustrations).
15It 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.
16If desired, the ancillary components can
be removed from the manifold, referring to the
relevant Chapter.
Refitting
17Refitting is a reversal of removal,
remembering the following points.
18Where applicable refit any ancillary
components to the manifold, with reference to
relevant Sections of Chapters 4A or 4B.
19If 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.
20Refit the manifold using a new gasket,
and tighten the securing nuts to the specified
torque.
21Ensure that all relevant hoses, pipes and
wires are correctly reconnected.
22On completion, check and if necessary
top-up the coolant level, (Chapter 3).
23Check and if necessary adjust the throttle
cable free play, as described in Chapters 4A
or 4B, as applicable.
24If any of the fuel system components have
been disturbed or renewed, check and if
necessary adjust the idle mixture, as
described in Chapters 4A or 4B, as applicable.
39Inlet manifold (SOHCwith
Multec) - removal and refitting
3
Removal
1Depressurise the fuel system Section 8).
2Remove the air box (see Section 5).
3Disconnect the battery negative lead.
4Either remove the throttle body assembly
(see Section 32), or disconnect the throttle
cable, wiring, fuel and vacuum hoses and
pipes to allow the manifold to be removed
with the throttle body.
5Drain the cooling system (see Chapter 3).
6Continue as described in Chapter 4A,
Section 26, paragraph 4 onwards.
Refitting
7Refitting is the reverse of the removal
procedure; renew all gaskets and seals
disturbed.
40Inlet manifold (DOHC
models) - removal and
refitting
3
Removal
1Disconnect the battery negative lead.
2Disconnect the wiring plug from the air
mass meter. Recover the sealing ring.
3Loosen the clamp screw securing the air
trunking to the right-hand end of the air mass
meter.
4Using an Allen key or hexagon bit, unscrew
the four bolts securing the air box to the
throttle body. Lift the air box from the throttle
body, and disconnect the hose from the base
of the air box then withdraw the air box/air
mass meter assembly.
5Disconnect the wiring plug from the throttle
position sensor.
6Slide the throttle cable end from the throttle
valve lever. Then pull the cable end grommet
from the bracket on the inlet manifold and
move the throttle cable to one side out of the
way.
7Disconnect the two breather hoses from the
rear of the camshaft cover. Disconnect the
larger hose from the throttle body, and
remove the hose completely.
8Position a wad of rag beneath one of the
fuel hose unions on the fuel rail, to absorb the
fuel that will be released as the union is
disconnected.
9Slowly loosen the fuel hose union, to
gradually relieve the pressure in the fuel feed
line, then disconnect the hose from the fuel
rail. Be prepared for fuel spillage, and take
adequate fire precautions. Plug the end of the
fuel hose, to prevent dirt ingress and further
fuel leakage.
10Repeat paragraphs 9 and 10 for the
remaining fuel hose-to-fuel rail union.
11Disconnect the vacuum pipe from the top
of the fuel pressure regulator.
12Disconnect the wiring harness housing
from the fuel injectors and move it to one side,
taking care not to strain the wiring. Pull up on
the wiring harness housing, and compress the
wiring plug retaining clips to release the
housing from the injectors.
13Unscrew the union nut, and disconnectthe brake servo vacuum hose from the left-
hand side of the inlet manifold (see
illustration).
14Unscrew the retaining nut, and remove
the fuel hose bracket from the left-hand side
of the throttle body.
15Unscrew the securing nuts, and
disconnect the earth leads from the fuel rail
securing studs at either end of the fuel rail.
16Unscrew the securing bolt, and remove
the cable/hose bracket from the left-hand end
of the inlet manifold.
17Remove the idle speed adjuster, as
described in Section 22.
18Unscrew and remove the top alternator
mounting nut and bolt.
19Make a final check to ensure that all
relevant hoses, pipes and wires have been
disconnected.
20Unscrew the securing nuts, and withdraw
the manifold from the cylinder head. Recover
the gasket.
21It 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.
22If desired, the ancillary components can
be removed from the manifold, with reference
to the relevant Sections of Chapters 4A or 4B.
Refitting
23Refitting is a reversal of the removal
procedure.
4B•18Fuel and exhaust systems - fuel injection models
38.14A Unscrew the securing nuts
40.13 Brake servo vacuum hose
connection at inlet manifold (arrowed) -
DOHC models
38.14B ...and withdraw the inlet manifold -
SOHC models

1
Chapter 1
Routine maintenance and servicing
Air cleaner element - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Air inlet temperature control check . . . . . . . . . . . . . . . . . . . . . . . . . .28
Alternator V-belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Automatic transmission check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . . .7
Automatic transmission fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . .38
Bodywork check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Brake pad check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Brake shoe check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Clutch cable check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Distributor and HT lead check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Door lock key battery - replacement . . . . . . . . . . . . . . . . . . . . . . . . .24
Driveshaft gaiter check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Engine oil and filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Handbrake linkage check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Headlamp alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Hose and fluid leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Idle speed and mixture - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .9
Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Intensive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Lock and hinge check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Manual transmission fluid check . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Power steering fluid check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Power steering pump drivebelt check . . . . . . . . . . . . . . . . . . . . . . . .18
Radiator inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Rear suspension level control system check . . . . . . . . . . . . . . . . . . .19
Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Spark plug renewal (SOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Spark plug renewal (DOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Steering and suspension check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Throttle linkage maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1•1
Contents
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321

Lubricants and fluids
Refer to “Weekly Checks”
Capacities
Engine oil
Including filter:
1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.0 litres
1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 litres
1.8 and 2.0 litre SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.0 litres
20 XEJ and C 20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 litres
X 20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.0 litres
Quantity of oil required to raise level on dipstick from “MIN” to “MAX”:
1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.8 litre
All other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 litre
Cooling system (approx.)
1.4 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6 litres
1.6 litre models (except C 16 NZ2) - manual transmission . . . . . . . . . .5.8 litres
1.6 litre models (except C 16 NZ2) - automatic transmission . . . . . . . .5.6 litres
C 16 NZ2, 1.8 and 2.0 litre SOHC models - manual transmission . . . . .7.2 litres
C 16 NZ2, 1.8 and 2.0 litre SOHC models - automatic transmission . . .7.1 litres
DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2 litres
Transmission
Manual transmission codes:
F10 and F13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6 litres
F16, F18 and F20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9 litres
Automatic - at fluid change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.0 to 3.5 litres
Difference between dipstick MAX and MIN marks -approximate:
+ 20°C side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.25 litre
+ 80°C side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.40 litre
Power steering fluid
Approximately . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 litre
Fuel tank
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63.0 ±2 litres
Washer fluid
Without headlamp washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6 litres
With headlamp washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 litres
Engine
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion G102
Cooling system
Antifreeze mixture:
28% antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Protection down to -15°C (5°F)
50% antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Protection down to -30°C (-22°F)
Note:
Refer to antifreeze manufacturer for latest recommendations.
Fuel system
Note:Ignition timing adjustment is not possible on some models, shown for information only.
For further details refer to Chapters 4A or 4B, as applicable.
Idle speed:
14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .925 ±25 rpm
16 SV
Manual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .925 ±25 rpm
Automatic transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . .825 ±25 rpm
18 SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .925 ±25 rpm
C 16 NZ and X 16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .850 ±80 rpm
C 16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .880 ±80 rpm
C 18 NZ
Manual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .880 ±80 rpm
Automatic transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . .830 ±80 rpm
20 NE, C 20 NE and 20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 ±80 rpm
20 XEJ and C 20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .940 ±80 rpm
X 20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .850 ±160 rpm
1•2Servicing Specifications

Idle mixture CO content:
All carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5 to 1.5%
20 NE and 20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0 max.
20 XEJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.7 to 1.2%
All other injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.3 % (at 2800 to 3200 rpm)
Air filter element:
1.4 and 1.6 litre ‘round type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion W103
1.6 and 1.8 litre ‘square type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion U512
1.8 litre ‘round type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion type not available
2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion U554
Fuel filter:
1.6, 1.8 and 2.0 litre ‘in-line’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion L201
Ignition system:
Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refer to Chapter 5
Spark plugs
SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion RN9YCC or RN9YC
DOHC models:
except C20 XE and X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion RC9MCC *
C20 XE and X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vauxhall P/N 90444724 (FR8LDC)
Plug gap:
RN9YCC and RC9MCC * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.8 mm
RN9YC * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.7 mm
FR8LDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.7 to 0.8 mm
* Information on spark plug types and electrode gaps is as recommended by Champion Spark Plug. Where alternative types are used, refer to the
manufacturer’s recommendations
Brakes
Minimum pad friction material thickness (including backing plate):
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.0 mm
Minimum shoe friction material thickness:
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5 mm above rivet heads
Tyres
Tyre size:
51/2 J x 13 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 R13-82T
51/2 J x 14 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175/70 R14-82T, 195/60 R14-85H, or 195/60 R14-85V
6J x 15 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195/60 R15-87V or 205/55 R15-87V
PressuresSee “Weekly checks”
Torque wrench settingsNmlbf ft
Automatic transmission drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4533
Roadwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11081
Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2518
Engine oil (sump) drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5541
Servicing Specifications 1•3
1
The maintenance intervals in this manual
are provided with the assumption that you,
not the dealer, will be carrying out the work.
These are the minimum maintenance intervals
recommended by the manufacturer for
vehicles driven daily. If you wish to keep your
vehicle in peak condition at all times, you may
wish to perform some of these procedures
more often. We encourage frequent
maintenance, because it enhances the
efficiency, performance and resale value of
your vehicle.
If the vehicle is driven in dusty areas, used
to tow a trailer, or driven frequently at slow
speeds (idling in traffic) or on short journeys,more frequent maintenance intervals are
recommended. Vauxhall recommend that the
service intervals are halved for vehicles that
are used under these conditions.
When the vehicle is new, it should be
serviced by a factory-authorised dealer
service department, to preserve the factory
warranty.
Maintenance is essential for ensuring safety
and for getting the best in terms of
performance and economy from your vehicle.
Over the years, the need for periodic
lubrication -oiling, greasing, and so on -has
been drastically reduced, if not eliminated.
This has unfortunately tended to lead someowners to think that because no action is
required, components either no longer exist,
or will last for ever. This is certainly not the
case; it is essential to carry out regular visual
examination comprehensively to spot any
possible defects at an early stage before they
develop into major expensive repairs.
The following service schedules are a list of
the maintenance requirements, and the
intervals at which they should be carried out,
as recommended by the manufacturers.
Where applicable, these procedures are
covered in greater detail near the beginning of
each relevant Chapter.
Maintenance schedule

1•4Maintenance schedule
Every 250 miles (400 km) or weekly
MRefer to “Weekly checks”
Basic service, every 9000 miles
(15 000 km) or 12 months -
whichever comes sooner
Along with the items in “Weekly checks”, carry out the
following:
MRenew the engine oil and oil filter (Section 3).
MCheck all hoses and other components for fluid
leaks (Section 4).
MCheck the steering and suspension components
(Section 5).
MCheck the condition of the driveshaft rubber
gaiters (Section 6).
MCheck the automatic transmission fluid level (if
applicable), (Section 7).
MCheck the radiator for blockage (e.g. dead insects)
and clean as necessary (Section 8).
MCheck and adjust the idle speed and mixture (if
applicable), (Section 9).
MCheck the throttle linkage and lubricate if
necessary (Section 10).
MCheck the exhaust system for corrosion, leaks and
security (Section 11).
MCheck all wiring for condition and security
(Section 12).
MCheck and adjust the ignition timing (if applicable),
(Section 13).
MRenew the brake fluid (Section 14).
MCheck the brake pad friction material for wear
(Section 15).
MCheck the handbrake linkage (Section 16).
MCheck the power steering fluid level (if applicable),
(Section 17).
MCheck the power steering pump drivebelt (if
applicable), (Section 18).
MCheck the rear suspension level control system
height, if fitted (Section 19).
MCheck the bodywork (Section 20).
MLubricate all locks and hinges (Section 21).
MCheck the alternator V-belt (Section 22).
MCheck the headlamp alignment (Section 23).
MReplace battery in the door-lock key (if applicable),
(Section 24).
MCarry out a road test (Section 25).
Note: Vauxhall specify that an Exhaust Emissions Test should be
carried out at least annually. However, this requires special
equipment, and is performed as part of the MOT test (refer to the
end of the manual).
Full service, every 18 000 miles
(30 000 km) or 24 months -
whichever comes sooner
Along with the ‘basic service’, carry out the following:
MRenew the coolant (Section 26).
MRenew the air cleaner element (Section 27).
MCheck the operation of the air cleaner air inlet
temperature control (carburettor models only),
(Section 28).
MRenew the fuel filter (Section 29).
MRenew the spark plugs (SOHC only), (Section 30) *.
MInspect and clean the distributor cap and HT leads
(Section 31).
MCheck the clutch cable adjustment (Section 32).
MCheck the manual transmission oil level (Section 33).
MCheck the automatic transmission (Section 34).
MCheck the brake drum shoe for wear (Section 35).
Major service, every 36 000 miles
(60 000 km) or 48 months -
whichever comes sooner
Along with the ‘full service’, carry out the following:
MRenew timing belt (Section 36).
MRenew the spark plugs (DOHC models only),
(Section 37).
MRenew automatic transmission fluid (Section 38) *.
* Note: If a vehicle is used for heavy-duty work (e.g. taxi work,
caravan/trailer towing, mostly short-distance, stop-start city driving)
the fluid must be changed every 36 months or 27 000 miles (45 000
km), whichever occurs first.

Maintenance - component location 1•5
1
Underbonnet view of a 1989 1.6 L model (16 SV engine)
1 VIN plate
2 Air cleaner casing *
3 Suspension strut top
4 Coolant expansion tank
5 Brake fluid reservoir
6 Fuel pump
7 Steering rack
8 Octane rating plug
9 Washer fluid reservoir
10 Battery
11 Ignition coil
12 Distributor (Bosch type)
13 Cooling fan motor
14 Engine oil level dipstick
15 Oil filter
16 Oil filler cap
* Refer to Chapter 4A for
alternative type
Underbonnet view of a 1991 model Cavalier 1.6 L (C16 NZ engine)
1 Air cleaner casing
2 Suspension strut top
3 Coolant expansion tank
4 Brake fluid reservoir
5 Air box
6 Exhaust gas recirculation valve
7 Steering gear
8 Octane coding plug
9 Washer fluid reservoir
10 Battery
11 Ignition coil
12 Distributor
13 Cooling fan motor
14 Engine oil level dipstick
15 Engine oil filter
16 Oxygen sensor
17 Engine oil filler cap

1•6Maintenance - component location
Underbonnet view of a 1989 2.0 SRi model (20 SEH engine)
1 VIN plate
2 Air cleaner casing
3 Airflow meter
4 Suspension strut top
5 Coolant expansion tank
6 Brake fluid reservoir
7 Throttle body
8 Relay box
9 Octane rating plug
10 Washer fluid reservoir
11 Battery
12 Power steering fluid reservoir
13 Power steering fluid hoses
14 Distributor cap
15 Engine oil level dipstick
16 Idle speed adjuster
17 Fuel pressure regulator
18 Oil filler cap
19 Thermostat housing
Underbonnet view of a 1990 GSi 2000 model (20 XEJ engine)
1 VIN plate
2 Air cleaner casing
3 Suspension strut top
4 Coolant expansion tank
5 Brake fluid reservoir
6 Air mass meter
7 Fuel pressure regulator
8 Relay box
9 Anti-theft alarm horn
10 ABS hydraulic modulator
11 Washer fluid reservoir
12 Power steering fluid reservoir
13 Battery
14 Distributor
15 Engine oil level dipstick
16 Oil filler cap

Maintenance - component location 1•7
1
Front underbody view of a 1989 1.6 L model (16 SV engine)
1 Brake caliper
2 Subframe
3 Oil filter
4 Clutch cover plate
5 Suspension lower arm
6 Differential cover plate
7 Engine oil drain plug
8 Driveshaft gaiter
9 Exhaust pipe
10 Anti-roll bar securing nut
Rear underbody view of a 1989 2.0 SRi model (semi-independent rear suspension)
1 Torsion beam
2 Trailing arm
3 Anti-roll bar
4 Shock absorber
5 Coil spring
6 Exhaust expansion box
7 Fuel flow damper
8 Fuel filter
9 Fuel tank securing strap
10 Handbrake cable

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

test (refer to Chapter 2A) will provide valuable
information regarding the overall performance
of the main internal components. Such a test
can be used as a basis to decide on the
extent of the work to be carried out. If, for
example, a compression test indicates serious
internal engine wear, conventional
maintenance as described in this Chapter will
not greatly improve the performance of the
engine. It may also prove a waste of time and
money, unless extensive overhaul work is
carried out first.
The following series of operations are those
most often required to improve the
performance of a generally poor-running
engine:Primary operations
a)Clean, inspect and test the battery (See
“Weekly Checks”)
b)Check all the engine related fluids (See
“Weekly Checks”)
c)Check the condition and tension of the
auxiliary drivebelt (Sections 18 and 22, as
appropriate).
d)Renew the spark plugs (Sections 30 and
37, as appropriate).
e)Inspect the distributor cap, rotor arm and
HT leads, as applicable (Section 31).
f)Check the condition of the air filter, and
renew if necessary (Section 27).
g)Check the fuel filter (Section 29).
h)Check the condition of all hoses, and
check for fluid leaks (Section 4).i)Check the idle speed and mixture
settings, as applicable (Section 9).
5If the above operations do not prove fully
effective, carry out the following secondary
operations:
Secondary operations
All items listed under “Primary operations”,
plus the following:
a)Check the charging system (Chapter 5).
b)Check the ignition system (Chapter 5).
c)Check the fuel system (Chapters 4A and
4B).
d)Renew the distributor cap and rotor arm
(Section 31).
e)Renew the ignition HT leads (Section 31).
3Engine oil and filter - renewal
2
1Ideally, the oil should be drained with the
engine hot, just after the vehicle has been
driven.
2On DOHC models, remove the engine
undershield to expose the sump drain plug
and the oil filter.
3Place a container beneath the oil drain plug
at the rear of the sump.
4Remove the oil filler cap from the camshaft
cover, then using a socket or spanner,
unscrew the oil drain plug, and allow the oil to
drain (see illustration). Take care to avoid
scalding if the oil is hot.
5Allow ten to fifteen minutes for the oil to
drain completely, then move the container
and position it under the oil filter.6On 1.8 and 2.0 litre models, improved
access to the oil filter can be gained by
jacking up the front of the vehicle and
removing the right-hand roadwheel (see
illustration). Ensure that the handbrake is
applied, and that the vehicle is securely
supported on axle stands (see “Jacking and
Vehicle Support”). Note that further oil may
drain from the sump as the vehicle is raised.
7Using a strap wrench or a filter removal tool
if necessary, slacken the filter and unscrew it
from the mounting. Alternatively, if the filter is
very tight, a screwdriver can be driven
through the filter casing and used as a lever.
Discard the filter.
8Wipe the mating face on the filter mounting
with a lint-free rag, then smear the sealing ring
of the new filter with clean engine oil of the
specified grade.
9Screw the new filter into position and
tighten it by hand only, do not use any tools.
10Where applicable, refit the roadwheel and
lower the vehicle to the ground. Fully tighten
the roadwheel bolts with the vehicle resting on
its wheels.
11Examine the condition of the oil drain plug
sealing ring and renew if necessary, then refit
the drain plug and tighten it to the specified
torque. 12Refill the engine through the filler on the
camshaft cover, using the specified grade and
quantity of oil. Fill until the level reaches the
“MAX” mark on the dipstick, allowing time for
the oil to drain through the engine to the
sump.
13Refit the oil filler cap, then start the engine
and check for leaks. Note that the oil pressure
warning lamp may stay illuminated for a few
seconds when the engine is started as the oil
filter fills with oil.
14Stop the engine and recheck the oil level,
topping-up if necessary.
15On DOHC models, refit the engine
undershield.
16Dispose of the old engine oil safely; do not
pour it down a drain.
4Hose and fluid leak check
1
1Visually inspect the engine joint faces,
gaskets and seals for any signs of water or oil
leaks. Pay particular attention to the areas
around the camshaft cover, cylinder head, oil
filter and sump joint faces. Remember that,
over a period of time, some very slight
seepage from these areas is to be expected -
what you are really looking for is any
indication of a serious leak. Should a leak be
found, renew the offending gasket or oil seal
by referring to the appropriate Chapters in this
manual.
Every 9000 miles or 12 months 1•9
3.6 Oil filter viewed through right-hand
wheel arch - SOHC model3.4 Sump drain plug location -
2.0 litre DOHC model
(engine undershield removed)
1
Basic service, every 9000 miles (15 000 km) or 12 months
As the drain plug releases
from the threads, move it
away quickly so the stream
of oil, running out of the
sump, goes into the container not up
your sleeve (see illustration).
Note: It is
antisocial and
illegal to dump oil
down the drain.
To find the
location of your
local oil recycling
bank, call this
number free.