battery location OPEL VECTRA 1988 Service Repair Manual

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

4Unscrew the two securing bolts, and
withdraw the pump from the camshaft
housing (see illustration).
5Recover the plastic insulating block.
Refitting
6Refitting 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.
7Run 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.
7Fuel tank - removal,
examination and refitting
4
Note: Refer to Section 2 before proceeding
Removal
1Disconnect the battery negative lead.
2Siphon out any remaining fuel in the tank
through the filler pipe. Siphon the fuel into a
clean metal container that can be sealed.
3Chock 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.
4Disconnect the exhaust system front
flexible joint. Suspend the front section of the
exhaust system with wire or string from the
underbody.
5Disconnect 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.
6Unclip the handbrake cable from the
bracket on the left-hand fuel tank securing
strap.
7Disconnect the fuel hoses from the fuel
level sender unit located in the right-hand side
of the fuel tank. Make a note of the hosepositions 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.
8Disconnect the wiring plug from the fuel
level sender unit.
9Disconnect the filler and vent hoses from
the rear of the fuel tank.
10Support the weight of the fuel tank on a
jack with an interposed block of wood.
11Unscrew 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.
12With 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
13If 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.
14Any 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
15Refitting is a reversal of removal, ensuring
that all hoses are reconnected to their correct
locations as noted during removal.
16On 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.
8Fuel level sender unit -
removal and refitting
3
Note: Refer to Section 2 before proceeding
Removal
1Disconnect the battery negative lead.
2Siphon out any remaining fuel in the tank
through the filler pipe. Siphon the fuel into a
clear metal container that can be sealed.
3Chock 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.
4The sender unit is located in the right-hand
side at the fuel tank.
5Make alignment marks on the sender unit
and the fuel tank, so that the sender unit can
be refitted in its original position.6Disconnect 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.
7Disconnect the wiring plug from the fuel
level sender unit.
8To 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.
9Withdraw the unit carefully, to avoid
bending the float arm.
10Recover the sealing ring.
Refitting
11Refitting is a reversal of removal,
remembering the following points.
12Examine the condition of the sealing ring,
and renew if necessary.
13Ensure that the marks made on the
sender unit and fuel tank before removal are
aligned.
14Ensure that the hoses are reconnected to
their correct locations as noted during
removal.
15On 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.
9Fuel vapour separator (1.6
and 1.8 litre models) -
removal and refitting
3
Note: Refer to Section 2 before proceeding
Removal
1The fuel vapour separator is located on a
bracket attached to the side of the
carburettor.
2Note 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.
3Remove the two securing screws, and lift
the vapour separator from its bracket.
4Check the body of the separator for cracks
or leaks before refitting, and renew if
necessary.
Refitting
5Refitting is a reversal of removal, but ensure
that the three fuel hoses are connected to
their correct locations as noted during
removal.
6Run 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•4Fuel and exhaust systems - carburettor models
6.4 Withdrawing the fuel pump and plastic
insulating block - 1.6 litre model

2A separate idle system operates
independently from the main jet system,
supplying fuel by way of the mixture control
screw.
3The 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.
4To 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.
5A 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.
61.8 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”.13Carburettor - 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
1Disconnect the battery negative lead.
2Remove 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.
3On 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.
4Extract 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.
5Disconnect 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.
6Disconnect the vacuum pipes from the front
of the carburettor, noting their locations and
routing for use when refitting (see
illustration).
7Disconnect the choke heater wire and any
additional wiring.8Unscrew the three securing nuts, and
withdraw the carburettor from the inlet
manifold studs.
9Recover the gasket(s) and insulator block
that fit between the carburettor and the inlet
manifold.
Overhaul
10With 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).
11Blow 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.
12Remove 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•6Fuel 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.

13Clean 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.
14Renew 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.
15Further 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.
16Reassemble in the reverse order to
dismantling. Use new gaskets and seals
throughout; lubricate linkages with a smear of
molybdenum based grease.
Refitting
17Carry 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.
18Refitting is a reversal of removal, but
renew the gasket(s).
19After refitting, carry out the following
checks and adjustments.
20Check the throttle cable free play and
adjust if necessary, as described in Section 11.
21Check and if necessary top-up the
coolant level, as described in Chapter 3.
22Check and if necessary adjust the idle
speed and mixture, as described in Section 14.
14Idle 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
1To 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 cleanf)On automatic models, always select
position, “P”.
2Connect a tachometer and an exhaust gas
analyser to the vehicle, according to the
equipment manufacturer’s instructions.
3Start 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).
4When 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).
5On 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.
6With the idle mixture correct, readjust the
idle speed if necessary.
7If the cooling fan cuts in during the
adjustment procedure, stop the adjustments,
and continue when the cooling fan stops.
8When both idle speed and mixture are
correctly set, stop the engine and disconnect
the test equipment.
9Fit a new tamperproof plug to the idle
mixture adjustment screw, where this is
required by law.
15Needle 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
1Disconnect the battery negative lead.
2Remove 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.
3Thoroughly clean all external dirt from the
carburettor.
4Disconnect 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.
5Identify 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.
6Disconnect the choke heater wiring plug.
7Disconnect the lower vacuum hoses from
the choke pull-down unit.
8Remove the four carburettor top cover
securing screws, noting their locations, as two
lengths of screw are used (see illustration).
9Lift off the top cover and recover the
gasket.
Inspection
10Hold 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.
11Measure 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

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

Brake fluid level sensor
14The procedure is as described for the
coolant level sensor in paragraphs 7 to 10
inclusive.
Engine oil level sensor
Removal
15Apply 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.
16On DOHC models, remove the engine
undershield, as described in Chapter 11.
17Disconnect the sensor wiring plug.
18Unscrew 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.
19Examine the condition of the sealing ring,
and renew if necessary.
Refitting
20Refitting is a reversal of removal. On
completion, check, and if necessary top-up,
the engine oil level.
Bulb failure sensor
Removal
21The bulb failure sensor is mounted behind
the fuse/relay panel in the facia.
22Release the retaining clips from the lower
end of the fuse/relay panel, and tilt it forwards.23Reach up behind the fuse/relay panel, and
pull the sensor from its socket.
Refitting
24Refitting is a reversal of removal.
22Horn(s) - removal and refitting
2
1On 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
2Disconnect the battery negative lead.
3Remove the radiator grille panel, with
reference to Chapter 11.
4Disconnect the wiring from the rear of the
horn.
5Reach up behind the mounting bracket, and
unscrew the single nut securing the horn to the
bracket (see illustration). Withdraw the horn.
Refitting
6Refitting is a reversal of removal.
Twin horns
Removal
7Disconnect the battery negative lead.
8Apply 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.
9Remove the securing screws, and withdraw
the plastic cover (where fitted) from the
bumper/front wing to expose the horns.
10Remove the bolt securing the horn
mounting bracket to the bracket below the
washer fluid reservoir (see illustration).
11Withdraw the horns and disconnect the
wiring.
12If desired, the horns can be unbolted from
the bracket.
Refitting
13Refitting is a reversal of removal.
23Interior lamps - removal and
refitting
2
Removal
1Disconnect the battery negative lead.
2Using a thin-bladed screwdriver, prise the
lamp from its location and disconnect the
wiring (see illustration).
Refitting
3Refitting is a reversal of removal.
24Interior lamp bulbs - renewal
1
1Disconnect 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
2Using a thin-bladed screwdriver, prise the
lamp from its location and disconnect the
wiring.
3On 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•8Body electrical systems
21.18 Engine oil level sensor - DOHC model
22.10 Horn mounting bracket securing
bolt (arrowed) - twin horned model23.2 Withdrawing the courtesy lamp
22.5 Horn viewed from behind with radiator removed - single
horned model

41Washer fluid reservoir -
removal and refitting
2
1Disconnect the battery negative lead.
Models without headlamp wash
Removal
2Disconnect the wiring from the washer
pump.
3Disconnect the washer fluid hose from the
pump. Be prepared for fluid spillage.
4Remove the screw(s) securing the reservoir
to the body, and withdraw the reservoir.
Refitting
5Refitting is a reversal of removal.
Models with headlamp wash
Removal
6On 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.
7Disconnect the wiring from the headlamp
wash non-return valve in the top of the
reservoir.
8Disconnect the washer fluid hoses from the
non-return valve. Be prepared for fluid spillage.
9Remove the screw securing the upper
section of the reservoir to the wing panel.
10Loosen 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.
11To remove the lower section of the
reservoir, continue as follows.
12Apply 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.
13Remove the securing screws, and
withdraw the plastic cover from thebumper/front wing to expose the lower
section of the reservoir.
14Remove the horns, (Section 22).
15Remove the wheel arch liner, (Chapter 11).
16Disconnect the wiring and the fluid hoses
from the washer pump. Be prepared for fluid
spillage.
17Unscrew the bolts securing the
horn/reservoir support bracket and the
reservoir to the body, then withdraw the
bracket and the reservoir (see illustration).
Refitting
18Refitting is a reversal of removal.
42Washer pump -removal and
refitting
2
1Disconnect the battery negative lead.
Models without headlamp wash
Removal
2Disconnect the wiring and the fluid hose
from the pump. Be prepared for fluid spillage.
3Pull the pump from the reservoir, being
prepared for fluid spillage if the reservoir still
contains fluid.
4Examine 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
5Refitting is a reversal of removal.
Models with headlamp wash
6Apply the handbrake, then jack up the front
of the vehicle, and support on axle stands
positioned under the body side members.
7Remove the securing screws, and withdraw
the plastic cover from the bumper/front wing
to expose the lower section of the fluid
reservoir.
8Remove the wheel arch liner, (Chapter 11).
9Proceed as described in paragraphs 2 to 5
inclusive.
43Headlamp washer fluid
non-return valve -removal
and refitting
2
Removal
1The valve is located on a bracket attached
to the upper section of the washer fluid
reservoir (see illustration).
2Disconnect the battery negative lead.
3Disconnect the wiring and the fluid hoses
from the valve. Be prepared for fluid spillage.
4Remove the screw securing the valve
bracket to the reservoir, and withdraw the
valve.
Refitting
5Refitting is a reversal of removal.
44Electric 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.
1Disconnect the battery negative lead.
Rear door-mounted switches
Removal
2Prise the plastic surround from the door
interior handle.
3Carefully prise the switch from its location,
and disconnect the wiring plug.
Refitting
4Refitting 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

53Anti-theft alarm - general
1Certain models are fitted with an anti-theft
alarm as standard equipment.
2The alarm system is triggered by door,
bonnet and boot lid/tailgate mounted
switches, and by ultrasonic sensors mounted
inside the passenger compartment (see
illustration).
3The 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.
54Anti-theft alarm system
components -removal and
refitting
4
Control unit
Removal
1Disconnect the battery negative lead.
2Remove the driver’s side lower facia panel
as described in Chapter 11.
3If necessary, remove the footwell side trim
panel as described in Chapter 11.4Undo the control unit retaining bolt,
disconnect the wiring plug and remove the
unit from its location.
Refitting
5Refitting is a reversal of removal.
Ultrasonic sensor
6Disconnect the battery negative lead.
7Remove the centre body pillar trim panel as
described in Chapter 11.
8Carefully release the ultrasonic sensor trim
panel and withdraw it downwards.
9Release the ultrasonic sensor from its
location, disconnect the wiring plug and
remove the unit from the car.
Refitting
10Refitting is a reversal of removal.
Bonnet contact unit
Removal
11Disconnect the battery negative lead.
12Using a screwdriver, depress the catch at
the base of the contact unit and withdraw the
contact from its location.
13Disconnect the contact wiring and remove
the unit.
Refitting
14Refitting is a reversal of removal.
55Airbag - 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 notfit 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 probe4 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.

12•38Wiring diagrams
Key to wiring diagrams for 1991 models
NoDescriptionTrackNoDescriptionTrack Wiring diagrams for 1991 models
Location of applicable circuitsTrackLocation of applicable circuitsTrack
Air conditioning system800 to 850
Alternator111
Anti-lock braking system (ABS)701 to 722
Anti-theft alarm system633 to 647
Automatic transmission control system773 to 799
Battery100
Brake lamps461 to 462
Carburettor118 to 121
Central locking system600 to 627
Check control system347 to 371
Cigarette lighter597 to 598
Clock661 to 663
Courtesy lamps - front487 to 494
Courtesy lamps - rear569 to 573
Direction indicator and hazard warning lamps467 to 482
Door mirrors536 to 548
Electric windows665 to 699
Engine compartment lamp415
Foglamps - front444 to 452
Foglamps - rear444 to 457
Fuel injection and ignition (Multec) - C16NZ engine129 to 164
Fuel injection and ignition (Multec) - C18NZ engine972 to 997
Fuel injection/ignition (Motronic M1.5) - 2.0litre sohc 168 to 199
Fuel injection/ignition (Motronic M2.5) - 2.0litre dohc 261 to 299
Glovebox lamp599Headlamp aim adjustment system758 to 766
Headlamp dim-dip427 to 431
Headlamp washers519 to 532
Headlamps437 to 442
Headlamps “ON” warning buzzer493 to 495
Heated front seats560 to 566
Heated rear window549 to 556
Heater blower motor853 to 862
Horn(s)592 to 596
Ignition (HEI) - 14NV engine121 to 128
Ignition (MSTS/EZ+) - 16SV, 18 SV engines236 to 256
Instruments301 to 344
Luggage compartment lamp485
Radiator cooling fan113, 115
Radio/cassette player586 to 591
Rear number plate lamp413
Reversing lamps496 to 498
Side and tail lamps401 to 410
Starter motor102 to 110
Sunroof863 to 870
Tailgate wiper510 to 516
Trip computer650 to 662
Windscreen and tailgate washers511 to 529
Windscreen wipers501 to 506
E1Side lamp - left406
E2Tail lamp - left356, 374, 407
E3Number plate lamp413
E4Side lamp - right409
E5Tail lamp - right358, 376, 410
E6Engine compartment lamp415
E7Headlamp main beam - left437
E8Headlamp main beam - right438
E9Headlamp dipped beam - left360, 378, 439
E10Headlamp dipped beam - right362, 380, 440
E11Instrument illumination lamps328 to 329
E12Selector lever illumination lamp (automatic transmission)799
E13Luggage compartment lamp485
E14Courtesy lamp487
E15Glovebox lamp599
E16Cigarette lighter illumination lamp596
E17Reversing lamp - left497
E18Reversing lamp - right498
E19Heated rear window552
E20Front foglamp - left448
E21Front foglamp - right447
E24Rear foglamp - left454
E25Driver’s seat heater580
E27Courtesy lamp - rear left569 to 570
E28Courtesy lamp - rear right572 to 573
E30Passenger front seat heater564
E32Clock illumination lamp663
E38Trip computer illumination lamp654
E39Rear foglamp - right455
E41Courtesy lamp (with delay)488 to 490
E50Kerb lamp - driver’s door666
E51Kerb lamp - passenger door684
F1 onFusesVarious
G1Battery101
G2Alternator111
G3Battery - (Diesel models)882, 901
G6Alternator - (Diesel models)884 to 886, 909 to 911H1Radio/cassette player589 to 590, 634
H2Horn592
H3Direction indicator warning lamp315 to 320
H4Oil pressure warning lamp310
H5Brake fluid level warning lamp313
H6Hazard warning flasher lamp470
H7Alternator charge warning lamp310
H8Headlamp main beam warning lamp322
H9Brake lamp - left364, 382, 461
H10Brake lamp - right366, 384, 462
H11Direction indicator lamp - front left472
H12Direction indicator lamp - rear left473
H13Direction indicator lamp - front right461
H14Direction indicator lamp - rear right482
H15Fuel level warning lamp305
H16Glow plug warning lamp (Diesel models)323
H17Trailer direction indicator warning lamp321
H18Horn593
H19Headlamps-on warning buzzer494 to 495
H21Handbrake-on warning lamp315
H25Door mirror warning lamp542, 952
H26ABS warning lamp319
H30Engine fault warning lamp324
H33Direction indicator side repeater lamp - left476
H34Direction indicator side repeater lamp - right478
H42Automatic transmission warning lamp325
H45Four-wheel-drive warning lamp327
H46Catalytic converter temperature warning lamp329
H47Anti-theft alarm horn638
H48Horn594
K3Relay - starter motor (anti-theft alarm)109 to 110
K5Relay - front foglamps448 to 450
K6Relay - air conditioning801 to 802
K7Relay - air conditioning blower804 to 805
K8Relay - intermittent windscreen wipe503 to 506
K9Relay - headlamp wash519 to 520
K10Relay - direction indicator/hazard warning flashers467 to 469

5If the engine turns over at normal speed but
will not start, check the HT circuit by
connecting a timing light and turning the
engine over on the starter motor. If the light
flashes, voltage is reaching the spark plugs,
so these should be checked first. If the light
does not flash, check the HT leads
themselves followed by the distributor cap,
carbon brush and rotor arm.
6If there is a spark, check the fuel system for
faults as far as possible (Chapters 4A or 4B).
7If there is still no spark, check the voltage at
the ignition coil “+” or “15” terminal; it should
be the same as the battery voltage (i.e., at
least 11.7 volts). If the voltage at the coil is
more than 1 volt less than that at the battery,
check the connections back through the
ignition switch to the battery and its earth until
the fault is found. Note, however, that the
ECU controls the coil’s feed; do not attempt
to “test” the ECU with anything other than the
correct test equipment, which will be available
only to a Vauxhall dealer. If any of the wires
are to be checked which lead to the ECU,
always first unplug the relevant connector
from the ECU so that there is no risk of the
ECU being damaged by the application of
incorrect voltages from test equipment.
8If the feed to the ignition coil is sound,
check the coil’s primary and secondary
windings (refer to Section 16). Renew the coil
if faulty, but check the condition of the LT
connections themselves before doing so, to
ensure that the fault is not due to dirty or
poorly fastened connectors.
9If the ignition coil is in good condition, the
fault may be within the amplifier module or the
distributor on the C16 NZ and C16 NZ2
engines, or the amplifier or the crankshaft
speed/position sensor on the C18 NZ engine.
A quick check of these components can be
made by connecting a low-wattage bulb
across the ignition coil’s (disconnected) LT
terminals. If the bulb flickers or flashes when
the engine is turned over, the amplifier and
distributor (C16 NZ and C16 NZ2 engines), or
amplifier and crankshaft speed/position
sensor (C18 NZ engine), are sound.
10If this is the case, the entire LT circuit is in
good condition; the fault, if it lies in the
ignition system, must be in the HT circuit
components. These should be checked
carefully, as outlined above.
11If the indicator or bulb does not flash, the
fault is in either the amplifier or the distributor
(C16 NZ and C16 NZ2 engines), or the
amplifier or crankshaft speed/position sensor
(C18 NZ engine). Owners should note,
however, that by far the commonest cause of
“failure” of either of these is a poor
connection, either between the components
themselves or in the LT circuit wiring
connections. If such a fault is suspected, the
vehicle must be taken to a suitably equipped
Vauxhall dealer for testing; no information is
available to eliminate these components by
other means.12An irregular misfire suggests either a
loose connection or intermittent fault on the
primary circuit, or a HT fault on the coil side of
the rotor arm.
13With the ignition switched off, check
carefully through the system ensuring that all
connections are clean and securely fastened.
If the equipment is available, check the LT
circuit as described in paragraphs 7 to 11
above.
14Check that the HT coil, the distributor cap
and the HT leads are clean and dry. Check the
leads and the spark plugs (by substitution, if
necessary), then check the distributor cap,
carbon brush and rotor arm.
15Regular misfiring is almost certainly due to
a fault in the distributor cap, HT leads or spark
plugs. Use a timing light (paragraph 5, above)
to check whether HT voltage is present at all
leads.
16If HT voltage is not present on any
particular lead, the fault will be in that lead or
in the distributor cap. If HT is present on all
leads, the fault will be in the spark plugs;
check and renew them if there is any doubt
about their condition.
17If no HT voltage is present, check the
ignition coil; its secondary windings may be
breaking down under load.
18If all components have been checked for
signs of obvious faults but the system is still
thought to be faulty, take the vehicle to a
Vauxhall dealer for testing on special
equipment.
5Battery - testing and charging
2
Note: Refer to Section 3 before proceeding.
Testing
1Topping-up and testing of the electrolyte in
each cell is not possible. The condition of the
battery can therefore only be tested by
observing the battery condition indicator.
2The battery condition indicator is fitted in
the top of the battery casing, and indicates
the condition of the battery from its colour. If
the indicator shows green, then the battery is
in a good state of charge. If the indicator turns
darker, eventually to black, then the battery
requires charging, as described later in this
Section. If the indicator shows clear/yellow,
then the electrolyte level in the battery is too
low to allow further use, and the battery
should be renewed.
Charging
3Do not attempt to charge, load or jump start
a battery when the indicator shows
clear/yellow. If the battery is to be charged,
remove it from the vehicle and charge it as
follows.
4The maintenance-free type battery takes
considerably longer to fully recharge than the
standard type, the time taken being
dependent on the extent of discharge.5A constant-voltage type charger is required,
to be set, when connected, to 13.9 to 14.9
volts with a charger current below 25 amps.
6If the battery is to be charged from a fully
discharged state (less than 12.2 volts output),
have it recharged by a Vauxhall dealer or
battery specialist, as the charge rate will be
high and constant supervision during charging
is necessary.
6Battery - removal and refitting
2
Note: Refer to Section 3 before proceeding.
Removal
1The battery is located at the left-hand front
corner of the engine compartment.
2Disconnect the lead(s) at the negative
(earth) terminal by unscrewing the retaining
nut and removing the terminal clamp.
3Disconnect the positive terminal lead(s) in
the same way.
4Unscrew the clamp bolt sufficiently to
enable the battery to be lifted from its
location. Keep the battery in an upright
position, to avoid spilling electrolyte on the
bodywork.
Refitting
5Refitting is a reversal of removal, but smear
petroleum jelly on the terminals when
reconnecting the leads, and always connect
the positive lead first and the negative lead
last.
7Alternator - description
1A Delco-Remy or Bosch alternator may be
fitted, depending on model and engine
capacity. The maximum output of the
alternator varies accordingly.
2The alternator is belt-driven from the
crankshaft pulley. Cooling is provided by a
fan, mounted outside the casing on the end of
the rotor shaft. An integral voltage regulator is
incorporated, to control the output voltage.
3The alternator provides a charge to the
battery even at very low engine speed, and
consists of a coil-wound stator in which a
rotor rotates. The rotor shaft is supported in
ball-bearings, and slip rings are used to
conduct current to and from the field coils
through the carbon brushes.
4The alternator generates ac (alternating
current), which is rectified by an internal diode
circuit to dc (direct current) for supply to the
battery.
5Later models are fitted with a Delco-Remy,
‘compact’ series alternators (see illustration).
They use a ribbed V-belt type drivebelt with
automatic tensioner. They are rigidly mounted
to the engine.
Engine electrical systems 5•5
5