transmission OPEL CALIBRA 1988 Service Workshop Manual

REF•24Glossary of Technical Terms
automatic transmission, a switch that
prevents starting if the vehicle is not in Neutral
or Park.
StrutSee MacPherson strut.
TTappetA cylindrical component which
transmits motion from the cam to the valve
stem, either directly or via a pushrod and
rocker arm. Also called a cam follower.
ThermostatA heat-controlled valve that
regulates the flow of coolant between the
cylinder block and the radiator, so maintaining
optimum engine operating temperature. A
thermostat is also used in some air cleaners in
which the temperature is regulated.
Thrust bearingThe bearing in the clutch
assembly that is moved in to the release levers
by clutch pedal action to disengage the
clutch. Also referred to as a release bearing.
Timing beltA toothed belt which drives the
camshaft. Serious engine damage may result
if it breaks in service.
Timing chainA chain which drives the
camshaft.
Toe-inThe amount the front wheels are
closer together at the front than at the rear. On
rear wheel drive vehicles, a slight amount of
toe-in is usually specified to keep the front
wheels running parallel on the road by
offsetting other forces that tend to spread the
wheels apart.
Toe-outThe amount the front wheels are
closer together at the rear than at the front. Onfront wheel drive vehicles, a slight amount of
toe-out is usually specified.
ToolsFor full information on choosing and
using tools, refer to the Haynes Automotive
Tools Manual.
TracerA stripe of a second colour applied to
a wire insulator to distinguish that wire from
another one with the same colour insulator.
Tune-upA process of accurate and careful
adjustments and parts replacement to obtain
the best possible engine performance.
TurbochargerA centrifugal device, driven by
exhaust gases, that pressurises the intake air.
Normally used to increase the power output
from a given engine displacement, but can
also be used primarily to reduce exhaust
emissions (as on VW’s “Umwelt” Diesel
engine).
UUniversal joint or U-jointA double-pivoted
connection for transmitting power from a
driving to a driven shaft through an angle. A U-
joint consists of two Y-shaped yokes and a
cross-shaped member called the spider.
VValveA device through which the flow of
liquid, gas, vacuum, or loose material in bulk
may be started, stopped, or regulated by a
movable part that opens, shuts, or partiallyobstructs one or more ports or passageways.
A valve is also the movable part of such a
device.
Valve clearanceThe clearance between the
valve tip (the end of the valve stem) and the
rocker arm or tappet. The valve clearance is
measured when the valve is closed.
Vernier caliperA precision measuring
instrument that measures inside and outside
dimensions. Not quite as accurate as a
micrometer, but more convenient.
ViscosityThe thickness of a liquid or its
resistance to flow.
VoltA unit for expressing electrical “pressure”
in a circuit. One volt that will produce a current
of one ampere through a resistance of one
ohm.
WWeldingVarious processes used to join metal
items by heating the areas to be joined to a
molten state and fusing them together. For
more information refer to the Haynes
Automotive Welding Manual.
Wiring diagramA drawing portraying the
components and wires in a vehicle’s electrical
system, using standardised symbols. For
more information refer to the Haynes
Automotive Electrical and Electronic Systems
Manual.

AABS components- 9•2, 9•16
Accelerator cable- 4A•5, 4B•9
Accelerator pedal- 4A•5
Acknowledgements- 0•4
Aerial- 12•17
Air cleaner- 1•3, 1•13, 4A•3, 4B•4
Air box- 4B•5
Air pump/cut off valve- 4C•2
Air temp control- 4B•5
Air vents- 3•8
Airbag- 12•19
Airflow meters- 4B•12
Alternator- 5•5
Alternator V-belt check- 1•12
Anti theft alarm- 12•19
Anti-roll bars- 10•8, 10•13, 10•17
Antifreeze mixture- 0•12, 0•17, 1•2, 3•3
ATF- 0•17, 1•2, 1•11, 7B•3
Automatic choke unit- 4A•9
Automatic transmission- 7B•1 et seq
cooler pipes and hoses - 7B•5
ECU - 7B•5
fault diagnosis - REF•12, REF•16
fluid - 0•17, 1•2, 1•11, 7B•3
kickdown switch - 7B•3
removal and refitting - 7B•6
selector control cable - 7B•4
speed sensors - 7B•6
starter inhibitor switch - 7B•3
temperature sensor - 7B•5
BBattery- 0•6, 0•15, 5•5
Bearings (engine)- 2A•31
Bleeding the brakes- 9•3
Bleeding the power steering- 10•22
Blower motor- 3•7
Body damage- 11•2
Body electrical systems - 12•1 et seq
Bodywork and fittings- 11•1 et seq
Bonnet- 11•4
Bonnet lock/release cable- 11•4
Boot lid- 11•4
Boot lid lock- 11•5
Bores- 2A•33
Brake checks- 1•12,
Braking system- 9•1 et seq
ABS components - 9•2, 9•16
backplate - 9•12
bleeding the brakes - 9•3
brake caliper - 9•8
brake disc - 9•10
brake drum - 9•11
brake fluid pipes and hoses - 9•18
brake lamp switch - 12•5
brake pads - 9•4
brake pedal - 9•21
brake shoes - 9•6
disc shield - 9•13
fault diagnosis - REF•12, REF•17
fluid - 0•13, 0•17handbrake adjustment - 9•18
handbrake cables - 9•19
handbrake lever - 9•20
master cylinder - 9•13
pressure valves - 9•18
vacuum servo unit - 9•15
wheel cylinder - 9•11
Bulbs- 12•2, 12•7, 12•11
Bumpers- 11•11
CCables:
bonnet release - 11•4
clutch - 6•2
handbrake - 9•19
selector automatic transmission - 7B•4
speedometer - 12•18
throttle - 4A•5, 4B•9
Caliper (brake)- 9•8
Camber- 10•1, 10•24
Camshaft- 2A•19, 2B•6
Camshaft housing- 2A•18
Camshaft oil seals- 2A•18
Capacities- 1•2
Carbon canister- 4C•4
Carburettor- 4A•5, 4A•11
Carpets- 11•2
Castor- 10•1, 10•24
Catalytic converter- 4C•3
Central door locking- 12•16
Centre console- 11•18
Cigarette lighter- 12•5
Clock- 12•6
Clutch- 6•1 et seq
cable - 6•2
fault diagnosis - REF•12, REF•15
pedal - 6•3
release bearing - 6•6
removal, inspection and refitting - 6•3
Coil- 5•9
Coil spring (rear)- 10•12, 10•15
Compression test- 2A•8
Computer components- 12•7
Connecting rods- 2A•29
Contents- 0•2
Control units- 4B•16, 7B•5
Conversion factors- REF•2
Coolant- 0•12, 0•17, 1•2, 3•3
Cooling, heating and ventilation systems-
3•1 et seq
blower motor - 3•7
coolant level sensor - 3•5
coolant pump - 3•4
cooling fan - 3•5
draining - 3•2
expansion tank - 3•5
fan switch - 3•6
fault diagnosis - REF•12, REF•15
filling - 3•2
flushing - 3•2
heater control panel - 3•6
heater matrix - 3•7
radiator - 3•3temperature gauge sender - 3•6
thermostat - 3•4
vents - 3•8
Courtesy lamp switch- 12•5
Crankcase ventilation system- 2A•7
Crankshaft- 2A•31
Crankshaft oil seals- 2A•26, 2B•6, 2B•9
Cylinder bores- 2A•33
Cylinder head- 2A•19, 2A•22, 2B•7DDents- 11•2
Depressurising fuel system- 4B•5
Differential bearing oil seal- 7A•3
Dimensions and weights- REF•1
Disc (brake)- 9•10
Distributor- 5•10
Door- 11•6
handle - 11•7
inner trim panel - 11•6
lock key battery - 1•13
mirror - 11•11
Driveshafts- 8•1 et seq
fault diagnosis - REF•12, REF•16
gaiter - 8•4
joint renewal - 8•4
Drum (brake)- 9•11
EEarth fault finding- 12•2
ECU’s - 4B•16, 7B•5
EGR components- 4C•2
Electric windows- 12•15
Electrical fault finding- 12•2
Electrical system (body)- 12•1 et seq
Electrical system- 0•14, 5•2
Electrical system fault diagnosis- REF•12,
REF•18
Electronic control units- 4B•16, 7B•5
Engine:
bearings - 2A•31
camshaft - 2A•19, 2B•6
camshaft housing - 2A•18
camshaft oil seals - 2A•18, 2B•6
codes - 2A•1, 2B•1
compartment - 0•10, 1•5
compression test - 2A•8
connecting rods - 2A•29
crankcase ventilation - 2A•7
crankshaft - 2A•31
crankshaft oil seals - 2A•26, 2B•6, 2B•9
cylinder bores - 2A•33
cylinder head - 2A•19, 2A•22, 2B•7
dismantling - 2A•12
DOHC - 2B•1 et seq
electrical systems - 5•1 et seq
fault diagnosis - REF•12, REF•13
flexplate (automatic transmission) - 2A•26
flywheel - 2A•26
main and big-end bearings - 2A•31
mountings (engine/transmission) - 2A•12,
2B•3
Index REF•25
REF
Note:References throughout this index are in the form - “Chapter number” • “page number”

oil and filter renewal - 0•17, 1•2, 1•9
oil cooler - 2B•10
oil level - 0•12
oil pump - 2A•28, 2B•9
piston rings - 2A•30
piston/connecting rod - 2A•29
removal - 2A•8, 2B•3
SOHC - 2A•1 et seq
sump - 2A•27, 2B•9
timing belt - 2A•13, 2B•3, 2B•6
undershield - 11•13
valve lifters - 2A•24, 2B•9
valves - 2A•5, 2B•2
Environmental considerations- REF•4
Exhaust manifold- 4C•5
Exhaust system check- 1•11, 4C•5
Expansion tank- 3•5
FFan (radiator)- 3•5
Fault diagnosis- REF•12 et seq
automatic transmission - REF•12, REF•16
braking system - REF•12, REF•17
clutch - REF•12, REF•15
cooling system - REF•12, REF•15
driveshafts - REF•12, REF•16
electrical system - REF•12, REF•18
engine - REF•12, REF•13
fuel and exhaust systems - REF•12, REF•15
manual transmission - REF•12, REF•16
steering - REF•12, REF•17
suspension - REF•12, REF•17
Flexplate (automatic transmission)- 2A•26
Flushing (cooling system)- 3•2
Flywheel- 2A•26
Foglamp- 12•11
Fuel and exhaust (carburettor) systems-
4A•1 et seq
Fuel and exhaust (fuel injection) systems-
4B•1 et seq
Fuel and exhaust systems - emissions-
4C•1 et seq
Fuel and exhaust systems:
accelerator cable - 4A•5
accelerator pedal - 4A•5
air box - 4B•5
air cleaner - 1•3, 1•13, 4A•3, 4B•4
air pump/cut off valve - 4C•2
air temperature control - 4B•5
airflow meters - 4B•12
automatic choke - 4A•9
carbon canister - 4C•4
carburettor - 4A•5, 4A•11
catalytic converter - 4C•3
control unit - 4B•16
depressurising fuel system - 4B•5
EGR components - 4C•2
exhaust manifold - 4C•5
exhaust system check - 1•11, 4C•5
fault diagnosis - REF•12, REF•15
filler cap - 11•13
fuel filters - 1•3, 1•14, 4B•6
fuel flow damper - 4B•8
fuel injector(s) - 4B•13
fuel level sender unit - 4A•4, 4B•8
fuel pressure regulator - 4B•10
fuel pump - 4A•3, 4B•6fuel tank - 4A•4, 4B•7
fuel vapour separator - 4A•4
idle speed/mixture adjustment - 4A•7,
4A•12, 4B•9, 4B•11
inlet manifold - 4A•12, 4B•17
knock sensor - 4B•17
lambda sensor - 4C•4
manifolds - 4A•12, 4B•17, 4C•5
mixture (CO) - 4A•7, 4A•12, 4B•9
oxygen sensor - 4C•4
Pierburg 2E3 - 4A•5
potentiometer - 4B•12, 4B•16
throttle cable - 4A•5
throttle pedal - 4A•5
Fuses- 12•1, 12•3
GGear selector linkage- 7A•2
Gearbox - see Manual or Automatic
transmission
Gearbox oil- 0•17, 1•2, 1•15
Gearchange lever- 7A•3
Glass- 11•9
Glossary of technical terms- REF•20
Glove compartment- 11•18
HHandbrake adjustment- 9•18
Handbrake cables- 9•19
Handbrake lever- 9•20
Handles (door)- 11•7
Hazard warning switch- 12•4
Headlamp alignment- 12•10
Headlamp unit- 12•9
Headlining- 11•19
Heater blower motor switch- 12•4
Heater control panel- 3•6
Heater matrix- 3•7
Heating systems- 3•1 et seq
Horn- 12•8
Hose and fluid leak check- 0•9, 1•9
Hoses brake- 9•18
IIdle speed/mixture/adjustment- 4A•7,
4A•12, 4B•9, 4B•11
Ignition coil- 5•9
Ignition switch- 12•3
Ignition system- 5•2
Igniton timing- 5•2, 5•13
Indicator lamps- 12•11
Indicator switch- 12•4
Injector(s)- 4B•13
Inlet manifold- 4A•12, 4B•17
Input shaft (clutch) oil seal- 7A•4
Instrument panel- 12•6
Interior lamps- 12•8
Interior trim panels- 11•14
Introduction to the Vauxhall Cavalier- 0•4
JJacking and vehicle support- REF•5
Jump starting- 0•7
KKickdown switch - 7B•3
Knock sensor- 4B•17
LLambda sensor- 4C•4
Lamps- 12•8, 12•9
Leaks- 0•9, 1•9
Light switch- 12•4
Locks bonnet- 11•4
Locks door- 11•8
Locks tailgate- 11•6
Lubricants and fluids- 0•17
MMain and big-end bearings- 2A•31
Maintenance - see Routine maintenance
Maintenance schedule- 1•4
Manifolds- 4A•12, 4B•17, 4C•5
Manual transmission- 7A•1 et seq
differential bearing oil seals - 7A•3
fault diagnosis - REF•12, REF•16
gear selector linkage - 7A•2
gearbox oil - 0•17, 1•2, 1•15
gearchange lever - 7A•3
input shaft (clutch) oil seal - 7A•4
overhaul -7A•5
removal and refitting - 7A•4
reversing lamp switch - 7A•6
speedometer drive - 7A•6
Master cylinder (brake)- 9•13
Mirrors- 11•11
Mixture (CO)- 4A•7, 4B•9
MOT test checks- REF•8
Mountings (engine/transmission)- 2A•12,
2B•3
NNumber plate lamp- 12•11
OOil change- 0•17, 1•2, 1•9
Oil cooler- 2B•10
Oil filter- 1•2, 1•9
Oil pressure warning lamp switch- 12•5
Oil pump- 2A•28, 2B•9
Oil seals:
differential bearing - 7A•3
general - REF •4
camshaft - 2A•18, 2B•6
crankshaft - 2A•26, 2B•6, 2B•9
Oils- 0•17, 1•2
Open-circuit, finding - 12•2
Oxygen sensor- 4C•4
PPads (brake)- 9•4
Paintwork damage- 11•2
Parts- REF•3
Pedals
brake - 9•21
clutch - 6•3
throttle - 4A•5
REF•26Index