sensor OPEL VECTRA 1988 Service Repair Manual

4A
General
Fuel tank capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.0 litres
Fuel octane rating:
Leaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 RON (4-star)
Unleaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 RON (Premium)
Carburettor type (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pierburg 2E3
Air cleaner element
Application:
Round type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W103
Square type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U512
14 NV engine
Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925 ± 25 rpm
Idle mixture (CO content) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5%
Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2200 to 2600 rpm
Choke valve gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 3.5 mm
Choke pull-down gap:
“Small” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 to 2.1 mm
“Large” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 to 2.9 mm
Idle fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Idle air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Primary Secondary
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.0 mm 24.0 mm
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X95 X110
Chapter 4 Part A:
Fuel and exhaust systems - carburettor models
Accelerator pump - testing, removal and refitting . . . . . . . . . . . . . . .18
Air cleaner inlet air temperature control - description and testing . . . .4
Air cleaner - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Automatic choke unit - removal, refitting and adjustment . . . . . . . . .19
Automatic choke vacuum pull-down units - removal, refitting and
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Carburettor - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Carburettor - removal, overhaul and refitting . . . . . . . . . . . . . . . . . . .13
Carburettor filter - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .21
Fuel level sender unit - removal and refitting . . . . . . . . . . . . . . . . . . . .8
Fuel pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Fuel pump - testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Fuel system - precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Fuel tank - removal, examination and refitting . . . . . . . . . . . . . . . . . . .7
Fuel vapour separator (1.6 and 1.8 litre models) - removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Idle cut-off solenoid (1.8 litre models) - description and testing . . . .25
Idle speed and mixture - adjustment . . . . . . . . . . . . . . . . . . . . . . . . .14
Idle speed increase valve - testing . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Inlet manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .26
Needle valve and float - removal, inspection and refitting . . . . . . . . .15
Power valve diaphragm - removal and refitting . . . . . . . . . . . . . . . . .17
Secondary throttle valve vacuum diaphragm - testing, removal and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Throttle cable - removal, refitting and adjustment . . . . . . . . . . . . . . .11
Throttle pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .10
Throttle position sensor (automatic transmission models) - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Throttle valve dashpot (automatic transmission models) -
adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4A•1
Specifications Contents
Easy,suitable for
novice with little
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

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.

Refitting
6On refitting the filter, press it into the union
until it catches (see illustration). The
remainder of the reassembly procedure is the
reverse of removal.
22Throttle valve dashpot
(automatic models) -
adjustment
2
1Remove the air cleaner or air box, refer to
Section 3.
2Ensure that the lever (see illustration)is in
the idling position.
3Slacken the locknut and unscrew the
dashpot until a gap of 0.05 mm (0.002 in)
exists between the lever and the dashpot tip.
Then screw the dashpot downwards 2.5 full
turns and tighten the locknut.
4Refit all removed components.
23Throttle position sensor
(automatic transmission
models) - removal and refitting
2
Removal
1Disconnect the battery earth lead.
2Disconnect the wiring plug from the sensor.
3Either unscrew the two securing screws
and withdraw the sensor from its bracket, or
unbolt the bracket.
Refitting
4Refitting is the reverse of the removal
procedure, noting the following points.
a)Install the sensor when the throttle valve
is fully closed and ensure that the
adapter, “1” (see illustration),seats
correctly on the throttle valve spindle.
b)Tighten the screws carefully.
24Idle speed increase valve -
testing
2
1Certain models are fitted with an idle speed
increase valve that is attached to the side of
the carburettor.
2To test the operation of this valve first
remove the air filter and vacuum hose.
3With the valve’s plug connected, have
someone turn the ignition on (but do not start
the engine). A mechanical shifting noise
should be heard. If not replace the unit.
4After refitting replace the vacuum hose and
air filter.
25Idle cut-off solenoid (1.8 litre
models) - description and
testing
2
Note: Refer to Section 2 before proceeding
Description
1On 1.8 litre models, the carburettor is fitted
with an idle cut-off solenoid. This is an
electrically operated valve, which interrupts
the idle mixture circuit when the ignition isswitched off, thus preventing the engine from
running-on (see illustration).
2The idle cut-off solenoid is energised all the
time that the ignition is switched on. A
defective solenoid, or a break in its power
supply, will cause the engine to stall or idle
roughly, although it will run normally at speed.
Testing
3If the operation of the solenoid is suspect,
first check that battery voltage is present at
the solenoid terminal when the ignition is
switched on. Use a 12 volt test lamp or similar
test device.
4If no voltage is present, then the fault lies in
the wiring to the solenoid. If voltage is
present, the solenoid can be tested as
follows.
5With the solenoid unscrewed from the
carburettor, connect the body of the solenoid
to the negative terminal of a 12 volt battery.
When the battery positive terminal is
connected to the solenoid centre terminal,
there should be an audible click, and the
needle at the tip of the solenoid should
retract.
6A defective idle cut-off solenoid must be
renewed.
26Inlet manifold - removal and
refitting
3
Note: Refer to Section 2 before proceeding. A
new manifold gasket must be used on refitting
Removal
1Disconnect the battery negative lead.
2Drain the cooling system, as described in
Chapter 3.
3Proceed as described in Section 13,
paragraphs 2 to 7 inclusive, ignoring the
reference to coolant spillage in paragraph 5.
4A•12Fuel and exhaust systems - carburettor models
21.6 Refitting the carburettor fuel filter
23.4 Throttle position sensor - models with automatic
transmission
1 Adapter 2 Sensor22.2 Adjusting the throttle valve dashpot - models with
automatic transmission
1 Lever2 Locknut3 Dashpot

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

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•22Body electrical systems
Explanations of abbreviations used in wiring diagrams
ABSAnti-lock braking system
ACAir conditioning
AZVTrailer hitch
ATAutomatic transmission
ATCAutomatic temperature control
BRTrip (on-board) computer
CCCheck control system
CRCCruise control
DDiesel
DSTheft protection
DTTurbo Diesel
DWAAnti-theft warning system
DZMTachometer
EFCElectric folding roof (Convertible)
EKSPinch guard (electric windows)
EMPRadio
EUREuronorm (emission control standard)
engine
EZ + ElPlus ignition system (with self-
diagnosis)
EZVEcotronic
FHElectric windows
GBGreat Britain
HSHeated rear window
HWRear window wiper
HZGHeating
HRLLuggage compartment lampINSInstrument panel
IRLCourtesy lamps
KATCatalytic converter
KBSWiring harness
KVContact breaker distributor
L3.1Bosch Jetronic fuel injection system
LCDLiquid crystal display (LCD)
instruments
LHDLeft-hand drive
4WDFour-wheel-drive
LWRHeadlamp aim adjustment
M1.5Bosch Motronic M1.5 engine
management system
M2.5Bosch Motronic M2.5 engine
management system
MOTMotronic (general)
MTManual gearbox
MULMultec fuel injection system
NNorway
NSFront foglamps
NSLRear foglamps
OELOil level/pressure check system
OPTOptional equipment
PBSLPark and brake shift block
(automatic transmission, selector
lever in position ‘P’)P/NPark/neutral (automatic transmission)
POTPotentiometer
RCRear suspension level control
system
RFSReversing lamps
RHDRight-hand drive
SSweden
SDSunroof
SHHeated seats
SRAHeadlamp washers and wipers
TANKFuel level sender unit
TDTurbo Diesel
TEMPTemperature gauge
TFLDaytime driving lamps
TKSCourtesy lamp (door pillar) switches
TSZITransistorised ignition (inductive-
triggered) system
VGSCarburettor
WEGOdometer frequency/roadspeed
sensor
WHRRear suspension level control
system
WSWarning buzzer
ZVCentral locking
ZYLCylinder
Colour codes
BLBlue
HBLLight blue
BRBrown
GEYellow
GRGrey
GNGreenRTRed
WSWhite
SWBlack
LILilac
VIViolet
Wiring identification
Example: GEWS 1.5
GE -Wire basic colour
WS -Wire tracer colour
1.5 -Wire cross-section in mm
2
Note: Not all items shown are fitted to all models. Refer to Section 62 (Chapter 12) for details of diagram usage.

12•24Wiring diagrams
K84MSTS ignition control unit247 to 256
K85Automatic transmission control unit771 to 797
K86Check control unit370 to 392
K87Relay - auxiliary cooling fan833 to 834
K88Catalytic converter temperature control unit (not UK)760 to 762
K89Relay - rear fog lamps444 to 447
K90Relay - air conditioning compressor (not UK)820 to 821
K93Relay - air conditioning compressor (not UK)821 to 822
L1Ignition coil121 to 122, 133 to 134, 174 to 175,
225 to 226, 243 to 244, 261 to 262
M1Starter motor105 to 106
M2Windscreen wiper motor501 to 504
M4Cooling fan motor113
M6Headlamp wiper motor -left525 to 527
M7Headlamp wiper motor - right529 to 531
M8Rear window wiper motor513 to 515
M13Sunroof motor692 to 694
M18Central locking motor - driver’s door607 to 610
M19Central locking motor - left rear door622 to 624
M20Central locking motor - right rear door626 to 628
M21Fuel pump163, 196, 299
M26Electric aerial motor584 to 585
M30Door mirror motor and heater - driver’s door674 to 676
M31Door mirror motor and heater - passenger door680 to 682
M32Central locking motor - passengerdoor614to617
M33Idle speed adjuster146 to 149, 183 to 184, 277 to 278
M37Central locking motor - boot lid/tailgate618 to 621
M39Headlamp aim adjustment motor -left557 to 560
M40Headlamp aim adjustment motor - right561 to 564
M41Central locking motor - fuel filler flap623 to 625
M43Ride control actuator - front left (not UK)739 to 741
M44Ride control actuator - front right (not UK)743 to 745
M45Ride control actuator -rear left (not UK)747 to 749
M46Ride control actuator - rear right (not UK)751 to 753
M47Electric window motor - front left636 to 640
M48Electric window motor - front right654 to 658
M49Electric window motor - rear left642 to 646
M50Electric window motor - rear right660 to 664
M55Washer fluid pump518 to 519
P1Fuel gauge304
P2Coolant temperature gauge306
P3Clock551
P4Fuel level sender unit304
P5Coolant temperature sensor306
P7Tachometer308
P8Oil pressure gauge341
P9Voltmeter339
P10Oil pressure sensor341
P11Airflow meter (Motronic M4.1)185 to 189
P12Coolant temperature sensor178, 272
P13Trip computer outside air temperature sensor542 to 543
P14Distance sensor (not UK)336 to 337P17ABS wheel sensor - front left707
P18ABS wheel sensor -front right710
P19ABS wheel sensor -rear left712
P20ABS wheel sensor - rear right714
P21Speedometer frequency sensor (not UK)332
P23Pressure sensor 249 to 250
P24Oil temperature sensor251
P24Automatic transmission fluid temperature sensor795
P27Brake pad wear sensor - front left375
P28Brake pad wear sensor - front right375
P29Inlet manifold temperature sensor (not UK)207 to 208
P30Coolant temperature sensor209 to 210, 150
P31Throttle position sensor (not UK)209 to 211
P32Oxygen sensor - heated (not UK)193 to 194, 291 to 292
P33Oxygen sensor157
P34Throttle position sensor158 to 160, 780
P35Crankshaft speed/position sensor189 to 191, 223 to 225,
281 to 282
P39Trailer bulb failure sensor392 to 394
P43Electronic speedometer336
P44Air mass meter (Motronic M2.5)294 to 296
P45Automatic transmission input speed sensor787 to 788
P46Knock sensor284 to 285
P47Distributor ‘Hall-effect’ sensor (Motronic M2.5)287 to 288
P48Automatic transmission distance sensor785 to 786
P50Catalytic converter temperature sensor (not UK)761 to 762
R2Carburettor preheating116, 228
R3Cigarette lighter596 to 597
R5Glow plugs (Diesel models)858 to 859
R7Mixture preheating (not UK)232
R12Automatic choke117
R15Mixture adjustment potentiometer (not UK)155 to 157
R19Cooling fan motor resistor828, 848
S1Ignition switch102 to 106, 851 to 852
S2.1Lighting switch404 to 407
S2.2Courtesy lamp switch487
S2.3Instrument illumination lamp dimmer328
S3Heater blower switch837 to 844
S4Heated rear window switch570 to 571
S5.2Dipped beam switch438, 439
S5.3Direction indicator switch480 to 482
S5.4Sidelamp switch401 to 402
S7Reversing lamp switch497
S8Brake lamp switch462
S9.2Windscreen wiper switch501 to 504
S9.5Rear window wash/wiper switch516 to 518
S10Automatic transmission switch770 to 776
S11Brake fluid level warning sensor313
S13Handbrake-on warning switch315
S14Oil pressure switch310
S15Luggage compartment lamp switch485
S17Passenger door courtesy lamp switch490 Key to wiring diagrams for 1989 models (continued)
NoDescriptionTrackNoDescriptionTrack

Wiring diagrams 12•25
12
Key to wiring diagrams for 1989 models (continued)
S21Front foglamp switch450 to 452
S22Rear foglamp switch455 to 457
S27Air conditioning compressor low-pressure switch (not UK)821
S28Air conditioning compressor high-pressure switch (not UK)821
S29Cooling fan switch113
S30Seat heater switch - front left575 to 577
S31Rear door courtesy lamp switch - left491
S32Rear door courtesy lamp switch - right492
S35Sunroof travel microswitch692
S36Sunroof travel microswitch694
S37Electric windows switch assembly637 to 663
S37.1Electric window switch - front left637 to 639
S37.2Electric window switch - front right655 to 657
S37.3Electric window switch - rear left643 to 645
S37.4Electric window switch - rear right661 to 663
S37.5Electric windows safety cut-out switch641 to 642
S37.6Electric windows anti-jam switch659
S37.7Electric windows automatic control646 to 651
S39Electric windows switch - rear left door647 to 649
S40Electric windows switch - rear right door665 to 667
S41Central locking switch driver’sdoor601 to 603
S42Central locking switch passenger door605
S44Throttle position sensor173 to 174, 278 to 279
S47Driver’s door courtesy lamp switch493 to 494
S51Cooling fan switch (not UK models)825 to 827
S52Hazard warning flasher switch469 to 474
S55Seat heater switch - front right579 to 581
S57Sunroof switch690 to 696
S63.1Trip computer function reset switch543
S63.2Trip computer clock hours adjustment switch544
S63.3Trip computer function select switch545
S63.5Trip computer clock minutes adjustment switch546
S64Horn switch591 to 594
S68.1Door mirror adjustment switch672 to 677
S68.2Door mirror heater switch679 to 680
S68.3Door mirror left/right selector switch673 to 677
S76Air conditioning compressor switch -high-pressure,
cooling fan (not UK)832
S82Washer pump switch371
S91Oil pressure switch (not UK models)165 to 166
S93Coolant level sensor372
S95Oil level sensor373
S98Headlamp aim adjustment switch556 to 558
S99Electric windows switch - driver’s door634
S100Electric windows switch -passenger door652
S104Kickdown switch (automatics)792
S105Start-up assistance switch (automatics)796 to 798
S106Economy/power programme switch (automatics)791
S107Throttle position sensor 771 to 776
S108Cooling fan switch (Diesel models)847 to 848
S109Air conditioning compressor switch (not UK)817
S110Ride control switch (not UK)738 to 743S115Automatic transmission fluid temperature sensor793
S116Brake lamp switch464 to 465
S117Four-wheel-drive hydraulic pressure switch729
S118Air conditioning refrigerant temperature switch (not UK)829
U2Trip computer538 to 548
U4ABS hydraulic modulator assembly705 to 718
U4.1ABS hydraulic pump relay706 to 709
U4.2ABS solenoid valves relay715 to 718
U4.3ABS hydraulic pump705
U4.4ABS diode717
U4.5ABS solenoid valve - front left710
U4.6ABS solenoid valve - front right711
U4.7ABS solenoid valve - rear left712
U4.8ABS solenoid valve - rear right713
U5.1Check control tail lamp and dipped beam bulb failure
warning lamp362
U5.2Check control brake lamp bulb failure warning lamp 363
U5.3Check control coolant oil level warning lamp360
U5.5Check control brake pad wear warning lamp364
U5.6Check control washer fluid level warning lamp359
U5.7Check control coolant level warning lamp361
U7Air conditioning control unit (not UK)806 to 824
U7.6Air conditioning blower switch (not UK)806 to 811
U7.8Air conditioning switch (not UK)813 to 824
U12.1Temperature switch (Diesel models)865
U12.2Fuel filter heater (Diesel models)866
U13.1Automatic transmission solenoid valve -shift 1784
U13.2Automatic transmission solenoid valve - shift 2785
U13.3Automatic transmission solenoid valve - lock-up control786
U13.4Automatic transmission solenoid valve - pressure control787
V1Brake fluid level warning lamp test diode (not UK)312
V8 Air conditioning compressor diode (not UK)820
X1Trailer electrical socket453 ,458 to 460
X2Accessory electrical connectors587
X5 toWiring connectorsVarious
X62
Y1Air conditioning compressor clutch (not UK)821
Y4Headlamp washer solenoid valve523
Y5Fuel solenoid valve (Diesel models)860
Y7Fuel injectors186 to 193, 280 to 287
Y10Distributor (Hall-effect)249 to 253
Y23Distributor (Inductive discharge)123 to 127
Y24Distributor (Inductive discharge) (not UK)129 to 136
Y26Throttle valve positioner (not UK)201 to 207
Y27Pre-throttle valve (not UK)218 to 219
Y30Cold start valve (Diesel models)863
Y32Fuel injector (not UK)140
Y33Distributor170, 262
Y34Fuel tank ventilation valve (not UK)198, 292
Y43Air conditioning vacuum control (not UK)815 to 818
Y44Four-wheel-drive solenoid valve731 NoDescriptionTrackNoDescriptionTrack

Wiring diagrams 12•39
12
Key to wiring diagrams for 1991 models (continued)
NoDescriptionTrackNoDescriptionTrack
K20Ignition amplifier module122 to 124, 236 to 237, 975 to 976
K25Relay - glow plugs (Diesel models)889 to 892
K30Relay - intermittent rear window wipe513 to 515
K35Relay - door mirror heater550 to 552
K37Central locking control unit606 to 612
K47Relay - surge arrester (ABS)702 to 703, 735 to 736
K50ABS control unit707 to 721, 740 to 754
K51Relay - cooling fan829 to 830, 842 to 843, 837 to 838
K57Multec electronic control unit (ECU)139 to 161
K58Relay - fuel pump163 to 164, 996 to 997
K59Relay - daytime running lamps420 to 426
K62Dim-dip control unit427 to 431
K63Relay - horn594 to 595
K64Relay - air conditioning blower802 to 803
K67Relay - cooling fan825 to 826, 849 to 850
K68Relay - fuel injection system196 to 199
K69Motronic M2.5 module267 to 297
K73Relay - headlamp main beam relay (Calibra only)432 to 433
K76Glow plug control unit (Turbo diesel models)916 to 921
K77Relay - glow plugs (Turbo diesel models)923 to 924
K78Relay - preresistor (Turbo diesel models)926 to 927
K79Alternator charge warning lamp relay911 to 913
K80Relay - fuel filter heater (Diesel models)898 to 899, 931 to 932
K82Relay - engine revolution895 to 896
K83Four-wheel-drive control unit725 to 731
K84MSTS ignition module242 to 256
K85Automatic transmission control unit774 to 797
K86Check control unit347 to 368
K87Relay - auxiliary cooling fan832 to 833, 839 to 840, 940 to 941
K88Catalytic converter temp. control unit758 to 760, 966 to 968
K89Relay - rear foglamps444 to 447
K90Relay - air conditioning compressor820 to 821
K91Motronic M1.5 module170 to 194
K94Anti-theft alarm control unit633 to 647
K97Relay - headlamp washer pump time delay530 to 532
K101Relay - electric mirror parking position961 to 964
K102Parking brake control unit (automatic transmission)769 to 771
K103Relay - cooling fan845 to 847
K107Multec electronic control unit (ECU)978 to 996
L1Ignition coil121 to 122, 133 to 134, 173, 174,
237 to 238, 974 to 975
M1Starter motor105 to 106
M2Windscreen wiper motor501 to 504
M3Heater blower motor854 to 856
M4Radiator cooling fan motor113, 115, 829, 847, 935
M6Headlamp wiper motor - left522 to 524
M7Headlamp wiper motor - right526 to 528
M8Rear window wiper motor511 to 513
M10Air conditioning blower motor805 to 808
M11Cooling fan motor840, 941
M12Starter motor (Diesel models)887 to 888, 905 to 906
M13Sunroof motor assembly865 to 869
M13.1Sunroof motor866 to 868
M13.2Sunroof travel microswitch866
M13.3Sunroof travel microswitch868
M18Central locking motor - driver’s door607 to 610
M19Central locking motor - left rear door621 to 623
M20Central locking motor - right rear door625 to 627
M21Fuel pump164, 197, 229, 997
M24Headlamp washer pump532
M26Electric aerial motor588 to 589
M30Door mirror motor and heater - driver’s door538 to 541
M31Door mirror motor and heater - passenger door544 to 547
M32Central locking motor - passenger door613 to 616
M33Idle speed adjuster/idle air control stepper motor146 to 149,
185 to 186, 277 to 278, 985 to 988M39Headlamp aim adjuster motor - driver’s side759 to 762
M40Headlamp aim adjuster motor - passenger side763 to 766
M41Central locking motor - fuel filler623 to 624
M47Electric window motor - front left667 to 671
M48Electric window motor - front right685 to 689
M49Electric window motor - rear left673 to 677
M50Electric window motor - rear right691 to 695
M55Windscreen and rear window washer pump516
M60Central locking motor (Calibra models)627 to 628
M61Sunroof assembly (Calibra models)872 to 880
M61.1Sunroof motor (Calibra models)873 to 876
M61.2Relay 1 - sunroof motor (Calibra models)872 to 873
M61.3Relay 2 - sunroof motor (Calibra models)878 to 880
M62Door mirror motor - driver’s door947 to 953
M63Door mirror motor - passenger door956 to 962
P1Fuel gauge304
P2Coolant temperature gauge306
P3Clock662
P4Fuel level sender unit304
P5Coolant temperature gauge sender306
P7Tachometer308
P8Oil pressure gauge341
P9Voltmeter339
P10Oil pressure sensor341
P11Airflow meter (Motronic M1.5)185 to 189
P12Coolant temperature sensor182, 272
P13Trip computer outside air temperature sensor655 to 656
P14Distance sensor336 to 337, 915 to 916
P17ABS wheel sensor - front left707, 740
P18ABS wheel sensor - front right710, 742
P19ABS wheel sensor - rear left712, 744
P20ABS wheel sensor - rear right713, 746
P21Speedometer frequency sensor332
P23Pressure sensor152 to 154, 984 to 986
P24Automatic transmission fluid temperature sensor252, 795
P25Bulb failure sensor373 to 386
P27Brake pad wear sensor - front left351, 396
P28Brake pad wear sensor - front right351, 396
P30Coolant temperature sensor150, 982
P32Oxygen sensor - heated194 to 195, 291 to 292
P33Oxygen sensor157, 991
P34Throttle position sensor/potentiometer158 to 160, 180 to 181,
777 to 778, 987 to 989
P35Crankshaft speed/position sensor189 to 191,
281 to 282, 982 to 984
P39Trailer bulb failure sensor368 to 370, 387 to 389
P43Electronic speedometer336
P44Air mass meter (Motronic M2.5)294 to 298
P45Automatic transmission input speed sensor791 to 792
P46Knock sensor284 to 285
P47Distributor “Hall-effect” sensor (Motronic M2.5)287 to 288
P48Automatic transmission output speed sensor789 to 790
P50Catalytic converter temperature sensor759 to 760, 977 to 978
P53Anti-theft alarm sensor - driver’s side639 to 642
P54Anti-theft alarm sensor - passenger side644 to 647
P55Coolant temperature sensor (Turbo diesel models)919
R2Carburettor preheating121
R3Cigarette lighter597
R5Glow plugs (Diesel models)891 to 892, 922 to 924
R12Automatic choke118
R13Heated windscreen washer nozzle - left526
R14Heated windscreen washer nozzle - right528
R15Mixture adjustment potentiometer155 to 157
R19Cooling fan motor resistor115, 832, 935
R22Glow plugs resistor (Turbo diesel models)927
S1Ignition switch105 to 106, 885 to 886, 905 to 906