Chevrolet Cavalier 1988 1995 User Manual

Chapter 1

Routine maintenance and servicing

Air cleaner element - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Air inlet temperature control check . . . . . . . . . . . . . . . . . . . . . . . . . .28

Alternator V-belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Automatic transmission check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . . .7

Automatic transmission fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . .38

Bodywork check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Brake pad check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Brake shoe check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Clutch cable check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Distributor and HT lead check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Door lock key battery - replacement . . . . . . . . . . . . . . . . . . . . . . . . .24

Driveshaft gaiter check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Engine oil and filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Handbrake linkage check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Headlamp alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Hose and fluid leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Idle speed and mixture - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .9

Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Intensive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Lock and hinge check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Manual transmission fluid check . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Power steering fluid check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Power steering pump drivebelt check . . . . . . . . . . . . . . . . . . . . . . . .18

Radiator inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Rear suspension level control system check . . . . . . . . . . . . . . . . . . .19

Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Spark plug renewal (SOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Spark plug renewal (DOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Steering and suspension check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Throttle linkage maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1•1

Contents

Easy, suitable for

novice with little experience

Fairly easy, suitable for beginner with some experience

Fairly difficult,

suitable for competent DIY mechanic

Difficult, suitable for experienced DIY mechanic

Very difficult,

suitable for expert DIY or professional

Degrees of difficulty

Lubricants and fluids

Refer to “Weekly Checks”

Capacities

Engine oil

Including filter:

1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 litres

1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 litres

1.8 and 2.0 litre SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 litres

20 XEJ and C 20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 litres

X 20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 litres

Quantity of oil required to raise level on dipstick from “MIN” to “MAX”:

1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 litre

All other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 litre

Cooling system (approx.)

1.4 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 litres

1.6 litre models (except C 16 NZ2) - manual transmission . . . . . . . . . . 5.8 litres

1.6 litre models (except C 16 NZ2) - automatic transmission . . . . . . . . 5.6 litres

C 16 NZ2, 1.8 and 2.0 litre SOHC models - manual transmission . . . . . 7.2 litres

C 16 NZ2, 1.8 and 2.0 litre SOHC models - automatic transmission . . . 7.1 litres

DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 litres

Transmission

Manual transmission codes:

F10 and F13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 litres

F16, F18 and F20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 litres

Automatic - at fluid change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 to 3.5 litres

Difference between dipstick MAX and MIN marks - approximate:

+ 20°C side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 litre

+ 80°C side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 litre

Power steering fluid

Approximately . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 litre

Fuel tank

All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.0 ± 2 litres

Washer fluid

Without headlamp washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 litres

With headlamp washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 litres

Engine

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion G102

Cooling system

Antifreeze mixture:

28% antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection down to -15°C (5°F)

50% antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection down to -30°C (-22°F)

Note:

Refer to antifreeze manufacturer for latest recommendations.

Fuel system

Note: Ignition timing adjustment is not possible on some models, shown for information only.

For further details refer to Chapters 4A or 4B, as applicable.

Idle speed:

14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925 ± 25 rpm

16 SV

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

Automatic transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . 825 ± 25 rpm

18 SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925 ± 25 rpm

C 16 NZ and X 16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 ± 80 rpm

C 16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 880 ± 80 rpm

C 18 NZ

Manual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 880 ± 80 rpm

Automatic transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . 830 ± 80 rpm

20 NE, C 20 NE and 20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ± 80 rpm

20 XEJ and C 20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 940 ± 80 rpm

X 20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 ± 160 rpm

1•2 Servicing Specifications

Idle mixture CO content:

All carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5%

20 NE and 20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 max.

20 XEJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 to 1.2%

All other injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 % (at 2800 to 3200 rpm)

Air filter element:

1.4 and 1.6 litre ‘round type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W103

1.6 and 1.8 litre ‘square type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U512

1.8 litre ‘round type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion type not available

2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U554

Fuel filter:

1.6, 1.8 and 2.0 litre ‘in-line’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L201

Ignition system:

Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Chapter 5

Spark plugs

SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RN9YCC or RN9YC

DOHC models:

except C20 XE and X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC9MCC *

C20 XE and X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vauxhall P/N 90444724 (FR8LDC)

Plug gap:

RN9YCC and RC9MCC * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm

RN9YC * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 mm

FR8LDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 to 0.8 mm

* Information on spark plug types and electrode gaps is as recommended by Champion Spark Plug. Where alternative types are used, refer to the manufacturer’s recommendations

Brakes

Minimum pad friction material thickness (including backing plate):

All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 mm

Minimum shoe friction material thickness:

All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm above rivet heads

Tyres

Tyre size:

51/2 J x 13 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 R13-82T

51/2 J x 14 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175/70 R14-82T, 195/60 R14-85H, or 195/60 R14-85V

6J x 15 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195/60 R15-87V or 205/55 R15-87V

Pressures See “Weekly checks”

Torque wrench settings Nm lbf ft

Automatic transmission drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33

Roadwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 81

Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18

Engine oil (sump) drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 41

Servicing Specifications 1•3

The maintenance intervals in this manual are provided with the assumption that you, not the dealer, will be carrying out the work. These are the minimum maintenance intervals recommended by the manufacturer for vehicles driven daily. If you wish to keep your vehicle in peak condition at all times, you may wish to perform some of these procedures more often. We encourage frequent maintenance, because it enhances the efficiency, performance and resale value of your vehicle.

If the vehicle is driven in dusty areas, used to tow a trailer, or driven frequently at slow speeds (idling in traffic) or on short journeys,

more frequent maintenance intervals are recommended. Vauxhall recommend that the service intervals are halved for vehicles that are used under these conditions.

When the vehicle is new, it should be serviced by a factory-authorised dealer service department, to preserve the factory warranty.

Maintenance is essential for ensuring safety and for getting the best in terms of performance and economy from your vehicle. Over the years, the need for periodic lubrication - oiling, greasing, and so on - has been drastically reduced, if not eliminated. This has unfortunately tended to lead some

owners to think that because no action is required, components either no longer exist, or will last for ever. This is certainly not the case; it is essential to carry out regular visual examination comprehensively to spot any possible defects at an early stage before they develop into major expensive repairs.

The following service schedules are a list of the maintenance requirements, and the intervals at which they should be carried out, as recommended by the manufacturers. Where applicable, these procedures are covered in greater detail near the beginning of each relevant Chapter.

Maintenance schedule

1•4 Maintenance schedule

Every 250 miles (400 km) or weekly

M Refer to “Weekly checks”

Basic service, every 9000 miles (15 000 km) or 12 months whichever comes sooner

Along with the items in “Weekly checks”, carry out the

following:

M Renew the engine oil and oil filter (Section 3). M Check all hoses and other components for fluid

leaks (Section 4).

M Check the steering and suspension components

(Section 5).

M Check the condition of the driveshaft rubber

gaiters (Section 6).

M Check the automatic transmission fluid level (if

applicable), (Section 7).

M Check the radiator for blockage (e.g. dead insects)

and clean as necessary (Section 8).

M Check and adjust the idle speed and mixture (if

applicable), (Section 9).

M Check the throttle linkage and lubricate if

necessary (Section 10).

M Check the exhaust system for corrosion, leaks and

security (Section 11).

M Check all wiring for condition and security

(Section 12).

M Check and adjust the ignition timing (if applicable),

(Section 13).

M Renew the brake fluid (Section 14). M Check the brake pad friction material for wear

(Section 15).

M Check the handbrake linkage (Section 16). M Check the power steering fluid level (if applicable),

(Section 17).

M Check the power steering pump drivebelt (if

applicable), (Section 18).

M Check the rear suspension level control system

height, if fitted (Section 19).

M Check the bodywork (Section 20). M Lubricate all locks and hinges (Section 21). M Check the alternator V-belt (Section 22). M Check the headlamp alignment (Section 23). M Replace battery in the door-lock key (if applicable),

(Section 24).

M Carry out a road test (Section 25).

Note: Vauxhall specify that an Exhaust Emissions Test should be carried out at least annually. However, this requires special equipment, and is performed as part of the MOT test (refer to the end of the manual).

Full service, every 18 000 miles (30 000 km) or 24 months whichever comes sooner

Along with the ‘basic service’, carry out the following:

M Renew the coolant (Section 26). M Renew the air cleaner element (Section 27). M Check the operation of the air cleaner air inlet

temperature control (carburettor models only), (Section 28).

M Renew the fuel filter (Section 29). M Renew the spark plugs (SOHC only), (Section 30) *. M Inspect and clean the distributor cap and HT leads

(Section 31).

M Check the clutch cable adjustment (Section 32). M Check the manual transmission oil level (Section 33). M Check the automatic transmission (Section 34). M Check the brake drum shoe for wear (Section 35).

Major service, every 36 000 miles (60 000 km) or 48 months whichever comes sooner

Along with the ‘full service’, carry out the following:

M Renew timing belt (Section 36). M Renew the spark plugs (DOHC models only),

(Section 37).

M Renew automatic transmission fluid (Section 38) *.

* Note: If a vehicle is used for heavy-duty work (e.g. taxi work, caravan/trailer towing, mostly short-distance, stop-start city driving) the fluid must be changed every 36 months or 27 000 miles (45 000 km), whichever occurs first.

Maintenance - component location 1•5

Underbonnet view of a 1989 1.6 L model (16 SV engine)

1 VIN plate 2 Air cleaner casing * 3 Suspension strut top 4 Coolant expansion tank 5 Brake fluid reservoir 6 Fuel pump 7 Steering rack 8 Octane rating plug 9 Washer fluid reservoir 10 Battery 11 Ignition coil 12 Distributor (Bosch type) 13 Cooling fan motor 14 Engine oil level dipstick 15 Oil filter 16 Oil filler cap

* Refer to Chapter 4A for

alternative type

Underbonnet view of a 1991 model Cavalier 1.6 L (C16 NZ engine)

1 Air cleaner casing 2 Suspension strut top 3 Coolant expansion tank 4 Brake fluid reservoir 5 Air box 6 Exhaust gas recirculation valve 7 Steering gear 8 Octane coding plug 9 Washer fluid reservoir 10 Battery 11 Ignition coil 12 Distributor 13 Cooling fan motor 14 Engine oil level dipstick 15 Engine oil filter 16 Oxygen sensor 17 Engine oil filler cap

1•6 Maintenance - component location

Underbonnet view of a 1989 2.0 SRi model (20 SEH engine)

1 VIN plate 2 Air cleaner casing 3 Airflow meter 4 Suspension strut top 5 Coolant expansion tank 6 Brake fluid reservoir 7 Throttle body 8 Relay box 9 Octane rating plug 10 Washer fluid reservoir 11 Battery 12 Power steering fluid reservoir 13 Power steering fluid hoses 14 Distributor cap 15 Engine oil level dipstick 16 Idle speed adjuster 17 Fuel pressure regulator 18 Oil filler cap 19 Thermostat housing

Underbonnet view of a 1990 GSi 2000 model (20 XEJ engine)

1 VIN plate 2 Air cleaner casing 3 Suspension strut top 4 Coolant expansion tank 5 Brake fluid reservoir 6 Air mass meter 7 Fuel pressure regulator 8 Relay box 9 Anti-theft alarm horn 10 ABS hydraulic modulator 11 Washer fluid reservoir 12 Power steering fluid reservoir 13 Battery 14 Distributor 15 Engine oil level dipstick 16 Oil filler cap

Maintenance - component location 1•7

Front underbody view of a 1989 1.6 L model (16 SV engine)

1 Brake caliper 2 Subframe 3 Oil filter 4 Clutch cover plate 5 Suspension lower arm 6 Differential cover plate 7 Engine oil drain plug 8 Driveshaft gaiter 9 Exhaust pipe 10 Anti-roll bar securing nut

Rear underbody view of a 1989 2.0 SRi model (semi-independent rear suspension)

1 Torsion beam 2 Trailing arm 3 Anti-roll bar 4 Shock absorber 5 Coil spring 6 Exhaust expansion box 7 Fuel flow damper 8 Fuel filter 9 Fuel tank securing strap 10 Handbrake cable

1 Introduction

This Chapter is designed to help the home mechanic maintain his/her vehicle for safety, economy, long life and peak performance.

The Chapter contains a master maintenance schedule, followed by Sections dealing specifically with each task in the schedule. Visual checks, adjustments, component renewal and other helpful items are included. Refer to the accompanying illustrations of the engine compartment and the underside of the vehicle for the locations of the various components.

Servicing your vehicle according to the mileage/time maintenance schedule and the following Sections will provide a planned maintenance programme, which should result in a long and reliable service life. This is a comprehensive

plan, so maintaining some items but not others at the specified service intervals, will not produce the same results.

As you service your vehicle, you will discover that many of the procedures can and should - be grouped together, because of the particular procedure being performed, or because of the proximity of two otherwiseunrelated components to one another. For example, if the vehicle is raised for any reason, the exhaust can be inspected at the same time as the suspension and steering components.

The first step in this maintenance programme is to prepare yourself before the actual work begins. Read through all the Sections relevant to the work to be carried out, then make a list and gather all the parts and tools required. If a problem is found, seek advice from a parts specialist, or a dealer service department.

2 Intensive maintenance

If, from the time the vehicle is new, routine maintenance schedule is followed closely, frequent checks made of fluid levels and highwear items, as recommended, the engine will be kept in relatively good running condition. The need for additional work will be minimised

It is possible that there will be times when the engine is running poorly due to the lack of regular maintenance. This is even more likely if a used vehicle, which has not received regular and frequent maintenance checks, is purchased. In such cases, additional work may need to be carried out, outside of the regular maintenance intervals.

If engine wear is suspected, a compression

1•8 Maintenance - component location

Rear underbody view of a 1990 GSi 2000 model (fully independent rear suspension)

1 Fuel tank securing strap 2 Shock absorber 3 ABS wheel sensor 4 Semi-trailing arm 5 Suspension crossmember mounting bracing bracket 6 Handbrake cable 7 Suspension crossmember 8 Exhaust expansion box 9 Fuel pump

Maintenance procedures

test (refer to Chapter 2A) will provide valuable information regarding the overall performance of the main internal components. Such a test can be used as a basis to decide on the extent of the work to be carried out. If, for example, a compression test indicates serious internal engine wear, conventional maintenance as described in this Chapter will not greatly improve the performance of the engine. It may also prove a waste of time and money, unless extensive overhaul work is carried out first.

The following series of operations are those most often required to improve the performance of a generally poor-running engine:

Primary operations

a) Clean, inspect and test the battery (See

“Weekly Checks”)

b) Check all the engine related fluids (See

“Weekly Checks”)

c) Check the condition and tension of the

auxiliary drivebelt (Sections 18 and 22, as appropriate).

d) Renew the spark plugs (Sections 30 and

37, as appropriate).

e) Inspect the distributor cap, rotor arm and

HT leads, as applicable (Section 31).

f) Check the condition of the air filter, and

renew if necessary (Section 27). g) Check the fuel filter (Section 29). h) Check the condition of all hoses, and

check for fluid leaks (Section 4).

i) Check the idle speed and mixture

settings, as applicable (Section 9).

5 If the above operations do not prove fully effective, carry out the following secondary operations:

Secondary operations

All items listed under “Primary operations”, plus the following:

a) Check the charging system (Chapter 5). b) Check the ignition system (Chapter 5). c) Check the fuel system (Chapters 4A and

4B).

d) Renew the distributor cap and rotor arm

(Section 31).

e) Renew the ignition HT leads (Section 31).

3 Engine oil and filter - renewal

1 Ideally, the oil should be drained with the engine hot, just after the vehicle has been driven. 2 On DOHC models, remove the engine undershield to expose the sump drain plug and the oil filter. 3 Place a container beneath the oil drain plug at the rear of the sump. 4 Remove the oil filler cap from the camshaft cover, then using a socket or spanner, unscrew the oil drain plug, and allow the oil to drain (see illustration). Take care to avoid scalding if the oil is hot.

5 Allow ten to fifteen minutes for the oil to drain completely, then move the container and position it under the oil filter.

6 On 1.8 and 2.0 litre models, improved access to the oil filter can be gained by jacking up the front of the vehicle and removing the right-hand roadwheel (see illustration). Ensure that the handbrake is applied, and that the vehicle is securely supported on axle stands (see “Jacking and Vehicle Support”). Note that further oil may drain from the sump as the vehicle is raised. 7 Using a strap wrench or a filter removal tool if necessary, slacken the filter and unscrew it from the mounting. Alternatively, if the filter is very tight, a screwdriver can be driven through the filter casing and used as a lever. Discard the filter. 8 Wipe the mating face on the filter mounting with a lint-free rag, then smear the sealing ring of the new filter with clean engine oil of the specified grade. 9 Screw the new filter into position and tighten it by hand only, do not use any tools. 10 Where applicable, refit the roadwheel and lower the vehicle to the ground. Fully tighten the roadwheel bolts with the vehicle resting on its wheels. 11 Examine the condition of the oil drain plug sealing ring and renew if necessary, then refit the drain plug and tighten it to the specified torque.

12 Refill the engine through the filler on the camshaft cover, using the specified grade and quantity of oil. Fill until the level reaches the “MAX” mark on the dipstick, allowing time for the oil to drain through the engine to the sump. 13 Refit the oil filler cap, then start the engine and check for leaks. Note that the oil pressure warning lamp may stay illuminated for a few seconds when the engine is started as the oil filter fills with oil. 14 Stop the engine and recheck the oil level, topping-up if necessary. 15 On DOHC models, refit the engine undershield. 16 Dispose of the old engine oil safely; do not pour it down a drain.

4 Hose and fluid leak check

1 Visually inspect the engine joint faces, gaskets and seals for any signs of water or oil leaks. Pay particular attention to the areas around the camshaft cover, cylinder head, oil filter and sump joint faces. Remember that, over a period of time, some very slight seepage from these areas is to be expected what you are really looking for is any indication of a serious leak. Should a leak be found, renew the offending gasket or oil seal by referring to the appropriate Chapters in this manual.

Every 9000 miles or 12 months 1•9

3.6 Oil filter viewed through right-hand wheel arch - SOHC model

3.4 Sump drain plug location -

2.0 litre DOHC model

(engine undershield removed)

Basic service, every 9000 miles (15 000 km) or 12 months

As the drain plug releases from the threads, move it away quickly so the stream

of oil, running out of the sump, goes into the container not up your sleeve (see illustration).

Note: It is antisocial and illegal to dump oil down the drain. To find the location of your local oil recycling bank, call this number free.

2 Also check the security and condition of all the engine related pipes and hoses. Ensure that all cable-ties or securing clips are in place, and in good condition. Clips that are broken or missing can lead to chafing of the hoses, pipes or wiring, which could cause more serious problems in the future. 3 Carefully check the radiator hoses and heater hoses along their entire length. Renew any hose that is cracked, swollen or deteriorated. Cracks will show up better if the hose is squeezed. Pay close attention to the hose clips that secure the hoses to the cooling system components. Hose clips can pinch and puncture hoses, resulting in cooling system leaks. It is always beneficial to renew hose clips whenever possible. 4 Inspect all the cooling system components (hoses, joint faces, etc.) for leaks.

5 Where any problems are found on system components, renew the component or gasket with reference to Chapter 3. 6 Where applicable, inspect the automatic transmission fluid cooler hoses for leaks or deterioration. 7 With the vehicle raised, inspect the petrol tank and filler neck for punctures, cracks and other damage. The connection between the filler neck and tank is especially critical. Sometimes a rubber filler neck or connecting hose will leak due to loose retaining clamps or deteriorated rubber. 8 Carefully check all rubber hoses and metal fuel lines leading away from the petrol tank. Check for loose connections, deteriorated hoses, crimped lines, and other damage. Pay particular attention to the vent pipes and hoses, which often loop up around the filler neck and can become blocked or crimped. Follow the lines to the front of the vehicle, carefully inspecting them all the way. Renew damaged sections as necessary. 9 From within the engine compartment, check the security of all fuel hose attachments and pipe unions, and inspect the fuel hoses and vacuum hoses for kinks, chafing and deterioration. 10 Where applicable, check the condition of the power steering fluid hoses and pipes.

5 Steering and suspension

check

Front suspension and steering check

1 Raise the front of the car, and support on axle stands (“Jacking and Vehicle Support”). 2 Visually inspect the balljoint dust covers and the steering rack-and-pinion gaiters for splits, chafing or deterioration. Any wear of these components will cause loss of lubricant, together with dirt and water entry, resulting in rapid wear of the balljoints or steering gear. 3 On vehicles with power steering, check the fluid hoses for chafing or deterioration, and the pipe and hose unions for fluid leaks. Also check for signs of fluid leakage under pressure from the steering gear rubber gaiters, which would indicate failed fluid seals within the steering gear. 4 Grasp the roadwheel at the 12 o’clock and 6 o’clock positions, and try to rock it (see illustration). Very slight free play may be felt, but if the movement is appreciable, further investigation is necessary to determine the source. Continue rocking the wheel while an assistant depresses the footbrake. If the movement is now eliminated or significantly reduced, it is likely that the hub bearings are at fault. If the free play is still evident with the footbrake depressed, then there is wear in the suspension joints or mountings. 5 Now grasp the wheel at the 9 o’clock and 3 o’clock positions, and try to rock it as before. Any movement felt now may again be caused by wear in the hub bearings or the steering track-rod balljoints. If the inner or outer balljoint is worn, the visual movement will be obvious. 6 Using a large screwdriver or flat bar, check for wear in the suspension mounting bushes by levering between the relevant suspension component and its attachment point. Some movement is to be expected as the mountings are made of rubber, but excessive wear should be obvious. Also check the condition of any visible rubber bushes, looking for splits, cracks or contamination of the rubber. 7 Inspect the front suspension lower arms for distortion or damage (Chapter 10, Section 5). 8 With the car standing on its wheels, have an assistant turn the steering wheel back and forth about an eighth of a turn each way. There should be very little, if any, lost movement between the steering wheel and roadwheels. If this is not the case, closely observe the joints and mountings previously described, but in addition, check the steering column universal joints for wear, and the rackand-pinion steering gear itself.

Suspension strut/shock absorber check

Note: Suspension struts/shock absorbers should always be renewed in pairs on the same axle.

9 Check for any signs of fluid leakage around the suspension strut/shock absorber body, or from the rubber gaiter around the piston rod. Should any fluid be noticed, the suspension strut/shock absorber is defective internally, and should be renewed. 10 The efficiency of the suspension strut/shock absorber may be checked by bouncing the vehicle at each corner. The body will return to its normal position and stop after being depressed. If it rises and returns on a rebound, the suspension strut/shock absorber is probably suspect. Examine also the suspension strut/shock absorber upper and lower mountings for any signs of wear.

6 Driveshaft gaiter check

With the vehicle raised and securely supported on stands, turn the steering onto full lock, then slowly rotate the roadwheel. Inspect the condition of the outer constant velocity (CV) joint rubber gaiters, squeezing the gaiters to open out the folds (see illustration). Check for signs of cracking, splits or deterioration of the rubber, which may allow the grease to escape, and lead to water and grit entry into the joint. Also check the security and condition of the retaining clips. Repeat these checks on the inner CV joints. If any damage or deterioration is found, the gaiters should be renewed as described in Chapter 8.

1•10 Every 9000 miles or 12 months

6.1 Check the condition of the driveshaft gaiters (A) and clips (B)

5.4 Check for wear in the hub bearings by grasping the wheel and trying to rock it

A leak in the cooling system will usually show up as white or rust coloured deposits on the area adjoining the leak

At the same time, check the general condition of the CV joints themselves by first holding the driveshaft and attempting to rotate the wheel. Repeat this check by holding the inner joint and attempting to rotate the driveshaft. Any appreciable movement indicates wear in the joints, wear in the driveshaft splines, or a loose driveshaft retaining nut.

7 Automatic transmission fluid

level check

Note: The transmission fluid level can be checked either when it is cold (only below 35ºC (100ºF) outside temperature) or when it is fully warmed up to normal operating temperature (after driving for a distance of approximately 12 miles/20 km). Since the fluid level must be checked with the engine running, ensure that the vehicle is parked on level ground with the handbrake firmly applied before leaving the driver’s seat. Be careful to keep loose clothing, long hair, etc., well clear of hot or moving components when working under the bonnet

Transmission cold

1 Park the vehicle on level ground and apply

the handbrake firmly. With the engine running at no more than idle speed and your foot firmly on the brake pedal, move the selector lever through all positions, ending in position “P”. Allow the engine to idle for one minute, then check the level within two minutes. 2 With the engine still idling and position “P” still selected, open the bonnet and withdraw the transmission dipstick from the filler tube located in the front of the transmission casing, at the left-hand end of the engine. 3 Note the fluid’s condition (see below), then wipe clean the dipstick using a clean, non-fluffy rag, insert it fully back into the tube and withdraw it again. 4 The level should be up to the “MAX” mark on the “+20°C” side of the dipstick (see

illustration). 5 If topping-up is required, switch off the

ignition and add only good quality fluid of the specified type through the filler tube. If

significant amounts of fluid are being lost (carefully note the amounts being added, and how often), check the transmission for leaks and either repair the fault or take the vehicle to a Vauxhall dealer for attention. 6 When the level is correct, ensure that the dipstick is pressed firmly into the filler tube.

Transmission fully warmed up

7 Work exactly as described above, but take

the level reading from the “+ 80°C” side of the dipstick. In this case, the level must be between the dipstick “MAX” and “MIN” marks.

Checking the fluid’s condition

8 Whenever the fluid level is checked,

examine the condition of the fluid and compare its colour, smell and texture with that of new fluid. 9 If the fluid is dark, almost black, and smells burnt, it is possible that the transmission friction material is worn or disintegrating. The vehicle should be taken to a Vauxhall dealer or automatic transmission specialist for immediate attention. 10 If the fluid is milky, this is due to the presence of emulsified droplets of water. This may be caused either by condensation after a prolonged period of short journeys or by the entry of water through the dipstick/filler tube or breather. If the fluid does not revert to its normal appearance after a long journey it must be renewed or advice should be sought from a Vauxhall dealer or automatic transmission specialist. 11 If the fluid is varnish-like (i.e. light to dark brown and tacky) it has oxidised due to overheating or to over or under filling. If renewal of the fluid does not cure the problem, the vehicle should be taken to a Vauxhall dealer or automatic transmission specialist for immediate attention. 12 If at any time on checking the fluid level or on draining the fluid, particles of dirt, metal chips or other foreign matter are found in the fluid, the vehicle must be taken to a Vauxhall dealer or automatic transmission specialist for immediate attention. It may be necessary to strip, clean and reassemble at least the valve body, if not the complete transmission, to rectify any fault.

8 Radiator inspection and

cleaning

1 Inspect radiator for leaks or corrosion, especially around the outlet or inlet connectors. 2 Clean the radiator with a soft brush or compressed air. Remove any debris, like dead insects or leaves. 3 If leaks are visible, replace radiator. Refer to Chapter 3, if necessary.

9 Idle speed and mixture -

adjustment

Note: On certain models, the idle and mixture are automatically adjusted by a control unit, therefore cannot be altered.

Refer to Chapters 4A or 4B as applicable.

10 Throttle linkage

maintenance

On models built before 1992, lubricate the throttle linkage, as described in Chapters 4A or 4B, as applicable.

11 Exhaust system check

1 With the engine off, check the security of the exhaust system. Pay particular attention to the rubber mountings that suspend the exhaust. 2 Start the engine and check underneath for leaks, which can be heard. This job is made easier if you have access to a ramp. 3 Listen for exhaust leaks from around the front pipe to exhaust manifold joint.

4 For further information, refer to Chapter 4C

12 Wiring check

1 Check all wiring in both the engine compartment and under the car.

2 Ensure that all wiring clips/clamps are secure. 3 Pay particular attention to wiring near

components that get hot, i.e. exhaust systems. 4 Make sure that electrical connections are secure and undamaged.

13 Ignition timing

Refer to Chapter 5 for details.

Every 9000 miles or 12 months 1•11

7.4 When checking the fluid level, ensure side of dipstick used corresponds with

fluid temperature

Warning: Voltages produced by an electronic ignition system are considerably higher than

those produced by conventional ignition systems. Extreme care must be taken when working on the system with the ignition switched on. Persons with surgically implanted cardiac pacemaker devices should keep away from the ignition circuits, components and test equipment.

14 Brake fluid renewal

Renew the brake and bleed the system.

Refer to Chapter 9 for full details.

15 Brake pad check

With the front or rear (as applicable) of the vehicle raised, remove the wheels and check brake pads for wear. Renew the pads if the lining is below that specified. See Chapter 9, for specifications and full details.

16 Handbrake linkage check

With the vehicle raised, check the operation of the handbrake and lubricate the linkages. Refer to Chapter 9, for further details.

17 Power steering fluid check

1 With the engine off, remove the cap from the power steering reservoir. It is fitted with a dipstick. 2 The fluid should be visible up to the ‘MAX’ mark (1), (see illustration). If not, top it up using specified fluid. 3 Start the engine and immediately top-up the fluid to the ‘MIN’ mark (2).

4 Do not allow the reservoir to run dry. 5 For details on how to bleed the system,

refer to Chapter 10.

18 Power steering pump

drivebelt check

Note: Vauxhall specify the use of a special gauge. Checking values for use with this gauge are given in the Specifications in Chapter 10, for reference.

Checking

1 The correct belt tension can be approximated by adjusting the length of the threaded rod. This should give a belt deflection of approximately 10.0 mm (0.4 in) under moderate thumb pressure at the midpoint of the belt run between the pulleys. If in doubt, err on the slack side, as an excessively tight belt may cause pump damage. 2 Check the condition of the belt and renew it if there are any signs of damage or excessive wear

Adjustment

3 Slacken the adjuster and mounting bolts. 4 Slacken the adjuster nuts, and adjust the

length of the threaded rod to remove or tension the belt as desired (see illustration). 5 Tighten the adjuster nuts, and tighten the adjuster and mounting bolts to the specified torque (see Chapter 10), on completion. 6 If a new drivebelt has been fitted, recheck the tension after a few hundred miles.

19 Rear suspension level

control system check

Refer to Chapter 10, for details.

20 Bodywork check

1 Clean the outside of the vehicle. If possible, clean underneath as well. If using a pressure cleaner take care not to damage any electrical components, especially in the engine compartment. 2 Check all around for signs of damage or corrosion and treat accordingly. Repair stone chips when you can to prevent rusting.

3 Read Chapter 11, for more details.

21 Lock and hinge check

1 Lubricate locks and hinges on all doors, tailgates (or boot lid) and bonnet. 2 Check for wear or damage and ensure correct operation of safety catches. 3 Check security of the bonnet stay and it’s securing clip.

4 Read Chapter 11, for further details.

22 Alternator V-belt check

Note: The new ribbed V-belt, fitted to later models, can not be adjusted.

1 Although special tools are available for measuring the belt tension, a good approximation can be achieved. Tension the belt so that there is approximately 13.0 mm (0.5 in) of free movement under firm thumb pressure at the mid-point of the longest run between pulleys. 2 With the mounting bolts just holding the unit, lever the alternator away from the engine using a wooden lever at the mounting bracket end until the correct tension is achieved. Then

1•12 Every 9000 miles or 12 months

17.2 Topping-up the power steering fluid level

18.4 Adjusting the length of the power steering pump threaded rod

Warning: Brake hydraulic fluid can harm your eyes and damage painted surfaces, so

use extreme caution when handling and pouring it. Do not use fluid that has been standing open for some time, as it absorbs moisture from the air. Excess moisture can cause a dangerous loss of braking effectiveness.

Old hydraulic fluid is usually darker in colour than new fluid.

For a quick check, the thickness of the friction material on each brake pad can be measured through the aperture in the caliper body.

tighten the mounting nuts and bolts. On no account lever at the free end of the alternator, as serious internal damage could be caused.

3 For details of replacement, see Chapter 5.

23 Headlamp alignment

Refer to Chapter 12 for details.

24 Door lock key battery -

replacement

1 Carefully prise open the outer cover from the key. Take care not to lose any of the internal components, as they are loose.

2 Remove the battery and discard it safely. 3 Place the new battery, “+” side up (see illustration). Check the operation of the key. If

the bulb does not light obtain a replacement.

4 Replace the outer cover.

25 Road test

Instruments and electrical equipment

1 Check the operation of all instruments and electrical equipment. 2 Make sure that all instruments read correctly, and switch on all electrical equipment in turn to check that it functions properly.

Steering and suspension

3 Check for any abnormalities in the steering, suspension, handling or road “feel”. 4 Drive the vehicle, and check that there are no unusual vibrations or noises.

5 Check that the steering feels positive, with no excessive “sloppiness”, or roughness, and check for any suspension noises when cornering, or when driving over bumps.

Drivetrain

6 Check the performance of the engine, clutch, transmission and driveshafts. 7 Turn the radio/cassette off and listen for any unusual noises from the engine, clutch and transmission. 8 Make sure that the engine runs smoothly when idling, and that there is no hesitation when accelerating. 9 Check that the clutch action is smooth and progressive, that the drive is taken up smoothly, and that the pedal travel is not excessive. Also listen for any noises when the clutch pedal is depressed. 10 Check that all gears can be engaged smoothly, without noise, and that the gear lever action is not abnormally vague or “notchy”. 11 Listen for a metallic clicking sound from the front of the vehicle, as the vehicle is driven slowly in a circle with the steering on full lock. Carry out this check in both directions. If a clicking noise is heard, this indicates wear in a driveshaft joint, in which case, the complete driveshaft must be renewed (see Chapter 8).

26 Coolant renewal

Refer to Chapter 3 for details.

27 Air cleaner element - renewal

Early round type

1 Release the spring clips from the perimeter of the air cleaner cover. 2 Unscrew and remove the small cross-head screw securing the cover extension to the main body near the inlet duct.

3 Unscrew and remove the three central cross-head cap nuts securing the air cleaner to the carburettor, taking care not to drop the washers and seals (see illustration). 4 Separate the cover from the main body, then lift out the element (see illustration). 5 Wipe clean the inside surfaces of the cover and main body. 6 Locate the new element in the air cleaner body, and refit the cover using a reversal of the removal procedure.

Square type with air box

7 If desired, to improve access, unclip the coolant expansion tank hose from the air cleaner cover. 8 Release the two clips from the left-hand side of the cover, and unscrew the two screws from the right-hand side, then lift the cover sufficiently to remove the element. 9 Wipe clean the inside surfaces of the cover and main body. 10 Refitting is a reversal of removal, noting that the element fits with the rubber locating flange uppermost.

Every 18 000 miles or 24 months 1•13

24.3 Replacing the battery in the door lock key

1 Battery (note, positive ‘+’ side up) 2 Bulb

27.4 Removing the air cleaner element note clip for crankcase ventilation hose

(arrowed)

27.3 Air cleaner-to-carburettor mounting cap nuts

Full service, every 18 000 miles (30 000 km) or 24 months

Warning: Wait until the engine is cold before starting the procedure. Do not allow

antifreeze to come in contact with your skin or with painted surfaces of the vehicle. Rinse off spills with plenty of water. Never leave antifreeze lying around in an open container. Always clean spilt fluids, as it can be harmful if swallowed.

28 Air inlet temperature control

check (carburettor models only)

Refer to Chapter 4A for details.

29 Fuel filter renewal

Fuel filters are fitted in various locations throughout the range. Some may be ‘in-line’ in the fuel tank itself, or fitted into the carburettor.

Refer to Chapters 4A or 4B, as appropriate.

30 Spark plug renewal (SOHC)

1 The correct functioning of the spark plugs is vital for the correct running and efficiency of the engine. It is essential that the plugs fitted are appropriate for the engine. Refer to the specifications in Chapter 5. If this type is used and the engine is in good condition, the spark plugs should not need attention between scheduled service replacement intervals. Spark plug cleaning is rarely necessary and should not be attempted unless specialised equipment is available, as damage can easily be caused to the firing ends. 2 Identify each HT lead for position so that the leads can be refitted to their correct cylinders. Then disconnect the leads from the plugs by pulling on the connectors, not the leads. 3 Clean the area around each spark plug using a small paintbrush, then using a plug

spanner (preferably with a rubber insert), unscrew and remove the plugs (see illustration). Cover the spark plug holes with a clean rag to prevent the ingress of any foreign matter. 4 The condition of the spark plugs will tell much about the overall condition of the engine. 5 If the insulator nose of the spark plug is clean and white, with no deposits, this is a sign of a weak mixture, or too hot a plug (a hot plug transfers heat away from the electrode slowly - a cold plug transfers heat away quickly). 6 If the tip and insulator nose is covered with hard black-looking deposits, then this is indicative that the mixture is too rich. Should the plug be black and oily, then it is likely that the engine is fairly worn, as well as the mixture being too rich. 7 If the insulator nose is covered with light tan to greyish brown deposits, then the mixture is correct, and it is likely that the engine is in good condition. 8 The spark plug gap is of considerable importance, because if it is either too large or too small, the size of the spark and its efficiency will be seriously impaired. The spark plug gap should be set to the figure given in the Specifications, in Chapter 5. 9 To set it, measure the gap with a feeler blade and then bend open, or close, the outer plug electrode until the correct gap is achieved. The centre electrode should never be bent, as this may crack the insulation and cause plug failure, if nothing worse (see

illustrations).

10 Before fitting new spark plugs check that

their threaded connector sleeves are tight.

11 Screw in the plugs by hand, then tighten them to the specified torque. Do not exceed the torque figure. 12 Push the HT leads firmly onto the spark plugs, ensuring that they are connected to their correct cylinders.

31 Distributor cap and HT lead

check

1 Remove the distributor cap and HT leads, and wipe them clean.

2 Also wipe clean the coil connections. Remove the rotor arm, then visually check the distributor cap, rotor arm and HT leads for hairline cracks, and signs of arcing.

1•14 Every 18 000 miles or 24 months

30.9A Tools required for spark plug

removal, gap adjustment and refitting

30.9C Measuring the spark plug gap with feeler blade

30.9B Measuring the spark plug gap with wire gauge

30.3 Removing a spark plug

Warning: Before carrying out the following operation, refer to the precautions given in “Safety

first!” at the beginning of this manual, and follow them implicitly. Petrol is a highly dangerous and volatile liquid, and the precautions necessary when handling it cannot be overstressed.

It is very often difficult to insert spark plugs into their holes without crossthreading them. To avoid this, fit a short length of 8 mm (internal diameter), rubber hose over the end of the spark plug. The flexible hose acts as a universal joint to help align the plug correctly. Should the plug begin to cross-thread, the hose will slip on the spark plug, preventing damage to the thread in the cylinder head.

Number the HT leads before removal to ensure correct refitting.

3 When refitting the distributor cap, check that the ends of the HT leads are fitted securely to the cap, plugs and coil. Also make sure that the spring-tensioned carbon brush in the centre of the distributor cap moves freely, and that the HT segments are not worn excessively. 4 Inspect the electrical and vacuum connections of the ignition/engine management systems, and make sure that they are clean and secure.

32 Clutch cable check

Check the clutch cable adjustment, as

described in Chapter 6.

Check also, the condition of the cable. Inspect the cable strands for fraying, and ensure that the cable is correctly routed, to avoid chafing against surrounding components. Renew the cable, as described in Chapter 6, if excessive wear or damage is evident.

33 Manual transmission fluid

check

Note: Models built after 1994 it is no longer necessary to check levels.

1 Ensure that the vehicle is on level ground. 2 Unscrew the transmission oil level plug,

which is located in the rear left of the differential housing on F10 and F13 transmissions, and in the rear right of the differential housing on F16 and F20 transmissions (see illustrations). The oil level should be up to the bottom of the level plug orifice. 3 If necessary, top-up the oil level through the breather/filler orifice in the gear selector cover. Unscrew the breather/filler plug, and top-up with the specified grade of oil, until oil just begins to run from the level plug orifice. Refit the level plug and the breather/filler plug on completion (see illustrations). 4 Renewal of the transmission oil is not specified by the manufacturers, and no drain plug is provided. If it is desired to renew the oil as a precaution, the oil may be drained by removing the differential cover plate. Use a new gasket when refitting the cover plate. Fill

the transmission through the breather/filler orifice, as described previously in this Section. 5 Periodically inspect the transmission for oil leaks, and check the gear selector linkage components for wear and smooth operation.

34 Automatic transmission

check

1 Carry out a thorough road test, ensuring that all gearchanges occur smoothly, without snatching and with no increase in engine speed between changes. 2 Check the operation of the kickdown. Check that all gear positions can be engaged at the appropriate movement of the selector lever and with the vehicle at rest, check that the operation of the parking pawl in position “P” prevents it from being moved. Ensure that the starter motor will work only with the selector lever in positions “P” or “N”, and that

the reversing lamps light only when position “R” is selected. 3 The manufacturer’s schedule calls for a regular check of the electrical control system using the special Vauxhall test equipment; owners will have to have this check carried out by a Vauxhall dealer. 4 Periodically inspect the transmission casing, checking all joint surfaces and seals for signs of fluid leaks. If any are found, the fault must be rectified immediately. 5 Check also that the transmission breather hose (under the battery mounting bracket) is clear and not blocked, kinked or twisted.

35 Brake shoe check

Note: On models fitted with rear brake pads, the handbrake operates brake shoes that are located inside the rear brake discs.

Refer to Chapter 9, for details.

Every 18 000 miles or 24 months 1•15

33.3A Transmission breather/filler plug (arrowed) - F16 type transmission

33.3B Topping-up the transmission oil level - F13 type transmission

33.2B Transmission oil level plug

(arrowed) - F16 type transmission (viewed

from below, with driveshaft removed)

33.2A Transmission oil level plug

(arrowed) - F13 type transmission (viewed

from above)

36 Timing belt renewal

1 To minimise risk of major damage to the engine the timing belt (or cambelt, as it is sometimes called), needs replacing at least, on every major service. 2 It is good practise however, not only to renew the belt whenever major engine work is carried out, but also if you buy a used car with unclear service history. 3 Some models are fitted with an inspection cover to view the condition of the belt. Whilst others involve a lot more work. 4 Full details on checking and replacement are shown in Chapters 2A or 2B, as appropriate.

37 Spark plug renewal (DOHC)

1 This procedure is basically the same shown in Section 30. However on these models, a spark plug cover needs to be removed from the camshaft cover before the plugs can be removed. 2 Take great care when removing and refitting spark plugs on these engines (see illustration). Hairline cracks in the ceramic of the plug can cause occasional or complete ignition failure. Damage to the catalytic converter may also occur. 3 Special tool (Vauxhall No. KM-194-B), with a 3 part conical sliding element have been

made available, to reduce the risk of plug damage (see illustration). 4 After refitting the spark plugs, remember to replace the plug cover.

38 Automatic transmission fluid

renewal

Renew the transmission fluid as detailed in

Chapter 7B.

1•16 Every 36 000 miles or 48 months

37.3 Removing spark plugs using special adapter (DOHC models)

A Torque wrench B Extension

C Joint D Special adapter (P/N KM-194-B)

37.2 Removing a spark plug DOHC model

Major service, every 36 000 miles (60 000 km) or 48 months

General

Type

All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in-line, water-cooled, transversely mounted at front of

vehicle. Single belt-driven overhead camshaft, acting on hydraulic valve lifters

Manufacturer’s engine codes:

14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 litre (1389 cc)

16 SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 litre (1598 cc)

X16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 litre (1598 cc) ‘Ecotec’ type engine

C16 NZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 litre (1598 cc) + catalyst

C16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 litre (1598 cc) + catalyst

18 SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 litre (1796 cc)

C18 NZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 litre (1796 cc) + catalyst

20 NE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 litre (1998 cc)

20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 litre (1998 cc) + early SRi

C20 NE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 litre (1998 cc) + catalyst

Pistons: Bore (mm) Stroke (mm)

14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.6 73.4

16 SV, C16 SV, C16 NZ and X16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . 79.0 81.5

C16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.0 79.5

18 SV and C18 NZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.8 79.5

20 NE, 20 SEH and C20 NE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.0 86.0

Chapter 2 Part A:

SOHC engine procedures

Camshaft front oil seal - removal and refitting . . . . . . . . . . . . . . . . . .15

Camshaft housing and camshaft - general . . . . . . . . . . . . . . . . . . . .17

Camshaft housing and camshaft - dismantling, inspection and

reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Camshaft rear oil seal - removal and refitting . . . . . . . . . . . . . . . . . . .16

Camshafts, “undersize” C16 NZ2, 1.8 and 2.0 litre engines -

general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Compression test - description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Crankcase ventilation system - description and maintenance . . . . . . .2

Crankshaft and bearings - examination . . . . . . . . . . . . . . . . . . . . . . .35

Crankshaft and bearings - removal and refitting . . . . . . . . . . . . . . . .34

Crankshaft front oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Crankshaft rear oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Cylinder block and bores - examination and renovation . . . . . . . . . .36

Cylinder head - dismantling and reassembly . . . . . . . . . . . . . . . . . . .22

Cylinder head - inspection and renovation . . . . . . . . . . . . . . . . . . . . .23

Cylinder head - removal and refitting (engine in vehicle) . . . . . . . . . .20

Cylinder head - removal and refitting (engine removed) . . . . . . . . . . .21

Engine - removal and refitting (leaving transmission in car) . . . . . . . . .7

Engine and transmission mountings - renewal . . . . . . . . . . . . . . . . . . .9

Engine and transmission - removal, separation, reconnection and

refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Engine oil and filter - renewal . . . . . . . . . . . . . . . . . . . . .See Chapter 1

Engine dismantling and reassembly - general . . . . . . . . . . . . . . . . . .10

Examination and renovation - general . . . . . . . . . . . . . . . . . . . . . . . .37

Flexplate (automatic transmission) - removal and refitting . . . . . . . . .26

Flywheel - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . .25

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

Hydraulic valve lifters - inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Initial start-up after major overhaul or repair . . . . . . . . . . . . . . . . . . .38

Major operations possible with the engine in the vehicle . . . . . . . . . . .4

Major operations requiring engine removal . . . . . . . . . . . . . . . . . . . . .5

Method of engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Oil pump - dismantling, inspection and reassembly . . . . . . . . . . . . .31

Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Pistons and connecting rods - examination and renovation . . . . . . .33

Pistons and connecting rods - removal and refitting . . . . . . . . . . . . .32

Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Timing belt and sprockets (without automatic tensioner) - removal,

refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Timing belt and tensioner 1.4 and 1.6 models (not C16 NZ2) - removal,

refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Timing belt and tensioner C16 NZ2, 1.8 and 2.0 litre - removal, refitting

and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Timing belt cover aperture, 1.4 and 1.6 models - general . . . . . . . . .13

2A•1

Specifications

Contents

Easy, suitable for

novice with little experience

Fairly easy, suitable for beginner with some experience

Fairly difficult,

suitable for competent DIY mechanic

Difficult, suitable for experienced DIY mechanic

Very difficult,

suitable for expert DIY or professional

Degrees of difficulty

Compression ratio

14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 : 1

16 SV, X16 SZ, 18 SV and 20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 : 1

C16 NZ, C16 NZ2, C18 NZ, 20 NE and C20 NE . . . . . . . . . . . . . . . . . 9.2 : 1

Maximum power:

14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 kW (75 bhp) at 5600 rpm

16 SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 kW (82 bhp) at 5400 rpm

X16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 kW (71 bhp) at 5000 rpm

C16 NZ and C16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 kW (75 bhp) at 5200 rpm

18 SV and C18 NZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 kW (90 bhp) at 5400 rpm

20 NE and C20 NE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 kW (116 bhp) at 5200 rpm

20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 kW (129 bhp) at 5600 rpm

Maximum torque:

14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Nm at 3000 rpm

X16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Nm at 2800 rpm

16 SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Nm at 2600 rpm

C16 NZ and C16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Nm at 2800 rpm

18 SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Nm at 2800 rpm

C18 NZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Nm at 3000 rpm

20 NE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Nm at 2600 rpm

20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm at 4600 rpm

C20 NE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Nm at 2600 rpm

Firing order:

All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2 (No 1 cylinder at timing belt end)

Cylinder block:

Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast iron

Maximum permissible bore out-of round . . . . . . . . . . . . . . . . . . . . . . 0.013 mm

Maximum permissible bore taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.013 mm

Maximum permissible rebore oversize . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm

Crankshaft and bearings

Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Main bearing journal diameter (mm):

14 NV, 16 SV, C16 NZ and X16 SZ

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.980 to 54.997

0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.730 to 54.747

0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.482 to 54.495

C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.974 to 57.995

0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.732 to 57.745

0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.482 to 57.495

Main bearing shell colour codes: Bearing cap shells Cylinder block shells

14 NV, 16 SV, C16 NZ and X16 SZ

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown Green

0.25 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/blue Green/blue

0.50 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/white Green/white

C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/green/white

0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/blue and Green/blue

0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown/white and Green/white

Centre (thrust) main bearing journal width (mm):

14 NV, 16 SV, C16 NZ and X 16 SZ

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.000 to 26.052

0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.200 to 26.252

0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.400 to 26.452

C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.950 to 26.002

0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.150 to 26.202

0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.350 to 26.402

Big-end bearing journal diameter (mm):

14 NV, 16 SV, C16 NZ and X16 SZ

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.971 to 42.987

0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.721 to 42.737

0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.471 to 42.487

C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.970 to 48.988

0.25mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.720 to 48.738

0.50mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.470 to 48.488

2A•2 SOHC engine procedures

Crankshaft and bearings (continued)

Big-end bearing shell colour codes (all models):

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None

0.25 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue

0.50 mm undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White

Main and big-end bearing journal out-of-round (all models) . . . . . . . . . 0.04 mm maximum

Main bearing permissible movement (mm):

14 NV, 16 SV, C16 NZ and X16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.017 to 0.047

C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . . . . 0.015 to 0.040

Big-end bearing permissible movement (mm):

14 NV, 16 SV, C16 NZ and X16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.019 to 0.071

C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . . . . 0.006 to 0.031

Crankshaft endfloat (mm):

14 NV, 16 SV, C16 NZ and X16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 to 0.2

C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . . . . 0.050 to 0.152

Connecting rod endfloat (mm) (all models) . . . . . . . . . . . . . . . . . . . . . . . 0.07 to 0.24

Piston and cylinder bores (Ø in mm) Bore diameter Piston dia ID mark

14 NV:

Production size 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.56 77.54 6

77.57 77.55 7

77.58 77.56 8

Production size 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.59 77.57 99

77.60 77.58 00

77.61 77.59 01

77.62 77.60 02

0.5 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.07 78.05 7 + 0.5

16 SV, C16 NZ and X16 SZ:

Production size 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.95 78.93 5

78.96 78.94 6

78.97 78.95 7

78.98 78.96 8

Production size 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.99 78.97 99

79.00 78.98 00

79.01 78.99 01

79.02 79.00 02

Production size 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.03 79.01 03

79.04 79.02 04

79.05 79.03 05

79.06 79.04 06

Production size 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.07 79.05 07

79.08 79.06 08

79.09 79.07 09

79.10 79.08 1

0.5 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.48 79.45 7 + 0.5

C16 NZ2:

Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.98 n/a 98

79.90 n/a 99

80.00 n/a 00

80.01 n/a 01

80.02 n/a 02

18 SV and C18 NZ:

Production size 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.78 mm 84.76 mm 8

Production size 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.79 mm 84.77 mm 99

84.80 mm 84.78 mm 00

84.81 mm 84.79 mm 01

84.82 mm 84.80 mm 02

0.5 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.27 mm 85.25 mm 7 + 0.5

20 NE, C20 NE and 20 SEH:

Production size 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.98 mm 85.96 mm 8

Production size 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.99 mm 85.97 mm 99

86.00 mm 85.98 mm 00

86.01 mm 85.99 mm 01

86.02 mm 86.00 mm 02

0.5 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.47 mm 86.45 mm 7 + 0.5

Piston clearance in bore (mm) (all models) . . . . . . . . . . . . . . . . . . . . . . . 0.02 to 0.04

SOHC engine procedures 2A•3

Piston rings

Number (per piston) (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 compression, 1 oil control

Ring end gap (mm):

Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 to 0.5

Oil control (top and bottom sections) . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 to 1.4

Ring gap offset (to gap of adjacent ring)* . . . . . . . . . . . . . . . . . . . . . . 180º

* See Section 32 for oil control ring sections

Cylinder head

Material (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light alloy

Maximum permissible distortion of sealing face (all models) . . . . . . . . . 0.025 mm

Height of cylinder head (sealing surface to sealing surface) (all models) . . 96.00 ± 0.25 mm Valve seat width (mm):

14 NV, 16 SV, C16 NZ, X 16 SZ and C16 NZ2

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 to 1.5

Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 to 1.8

18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.5

Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 to 2.2

Camshaft

Camshaft bearing journal diameter: Normal (mm) 0.1 mm undersize

14 NV, 16 SV, C16 NZ and X16 SZ:

No 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.435 to 39.455

No 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.685 to 39.705

No 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.935 to 39.955

No 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.185 to 40.205

No 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.435 to 40.455

C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH:

No 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.455 to 42.470 42.355 to 42.370

No 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.705 to 42.720 42.605 to 42.620

No 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.955 to 42.970 42.855 to 42.870

No 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.205 to 43.220 43.105 to 43.120

No 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.455 to 43.470 43.355 to 43.370

Camshaft bearing diameter in housing:

14 NV, 16 SV, C16 NZ and X16 SZ:

No 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.500 to 39.525

No 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.750 to 39.775

No 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.000 to 40.025

No 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.250 to 40.275

No 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.500 to 40.525

C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH:

No 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.500 to 42.525 42.400 to 42.425

No 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.750 to 42.775 42.650 to 42.675

No 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.000 to 43.025 42.900 to 42.925

No 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.250 to 43.275 43.150 to 43.175

No 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.500 to 43.525 43.400 to 43.425

Cam lift (mm):

14 NV (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12

16 SV and C16 NZ:

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.61

Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12

C16 NZ2, 18 SV and C18 NZ

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.01

Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.39

C20 NE and 20 NE (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . 6.67

20 SEH (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.70

Maximum permissible radial run-out (mm) (all models) . . . . . . . . . . . . . 0.04

Endfloat (mm) (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09 to 0.21

Timing belt (engines without automatic tension roller)

Tension, using Vauxhall gauge KM-51 0-A (see Section 11):

14NV, 16 SV and C16 NZ:

New belt, cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5

New belt, warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0

Used belt, cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0

Used belt, warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0

2A•4 SOHC engine procedures

18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH:

New belt, cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

New belt, warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

Used belt, cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

Used belt, warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0

Valves and guides Inlet Exhaust

Overall length - production (mm):

14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105.0 105.0

16 SV, X 16 SZ and C16 NZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.5 101.5

C16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.2 104.2

18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . . . . . . . . . . . . 104.2 104.0

Overall length - service (mm):

14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.6 104.6

16 SV, X 16 SZ and C16 NZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.1 101.1

C16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.8 103.8

18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . . . . . . . . . . . . 103.8 103.6

Head diameter (mm):

14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.0 29.0

16 SV, X 16 SZ, C16 NZ and C16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . 38.0 31.0

18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . . . . . . . . . . . . 41.8 36.5

Stem diameter (mm), (all engines):

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.998 to 7.012 6.978 to 6.992

0.075 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.073 to 7.087 7.053 to 7.067

0.150 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.148 to 7.162 7.128 to 7.142

0.250 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.248 to 7.262 7.228 to 7.242

Valve guide bore (mm), (all engines):

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.030 to 7.050

0.075 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.105 to 7.125

0.150 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.180 to 7.200

0.250 mm oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.280 to 7.300

Valve clearance in guide (mm), (all engines):

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.018 to 0.052

Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038 to 0.072

Valve seat angle:

All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44º

Valve clearances:

All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic adjustment by hydraulic lifters

Flywheel

Maximum permissible lateral run-out of starter ring gear (all models) . . 0.5 mm Refinishing limit - maximum depth of material that may be removed

from clutch friction surface (all models) . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm

Lubrication system

Lubricant type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Lubricants and fluids in “Weekly checks”

Lubricant capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Specifications

Oil pump clearances:

Inner-to-outer gear teeth clearance (backlash) (all models) . . . . . . . . 0.0 to 0.2 mm

Gear-to-housing clearance (endfloat):

14 NV, 16 SV, C16 NZ and X 16 SZ . . . . . . . . . . . . . . . . . . . . . . . . 0.08 to 0.15 mm

C16 NZ2, 18 SV, C18 NZ, 20 NE, C20 NE and 20 SEH . . . . . . . . . 0.03 to 0.10 mm

Oil pressure at idle (engine warm) (all models) . . . . . . . . . . . . . . . . . . . . 1.5 bar (21.8 lbf/in2)

Torque wrench settings Nm lbf ft

Note: Use new bolts where asterisked (*). The torque settings stated for the cylinder head are only applicable to latest specification bolts, available

from Vauxhall. Earlier type or alternative make, head bolts may require different torques. Consult your supplier.

Air inlet pre-heat to exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6

Alternator and inlet manifold to brackets:

1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15

C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13

Alternator to bracket (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22

Alternator to bracket (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30

Alternator to shackle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18

Big-end bearing cap: *

1.4 and 1.6 litre, (except C16 NZ2)

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 30º

SOHC engine procedures 2A•5

Torque wrench settings (continued) Nm lbf ft

Big-end bearing cap: *

C16 NZ2, 1.8 and 2.0 litre:

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 45º

Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 15º

Camshaft housing cover to housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6

Camshaft pulley to camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33

Camshaft thrust plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6

Coolant outlet to thermostat housing:

C 16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6

Coolant pump to cylinder block:

1.4 and 1.6 litre, (except C 16 NZ2) (M6) . . . . . . . . . . . . . . . . . . . . . . 8 6

C16 NZ2, 1.8 and 2.0 litre (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18

Crankshaft sensor wheel:

C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 10

Cylinder head to cylinder block: *

1.4 and 1.6 litre, (except C16 NZ2):

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 60º

Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 60º

Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 60º

C16 NZ2, 1.8 and 2.0 litre:

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 90º

Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 90º

Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 90º

Drivebelt (ribbed) pulley/timing belt drive to crankshaft: *

1.4 and 1.6 litre, (except C16 NZ2):

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 41

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 45º

Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 15º

Drivebelt pulley to timing belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15

Drivebelt (ribbed) tensioner to cylinder block . . . . . . . . . . . . . . . . . . . . . 20 15

Drivebelt (ribbed) tensioner to support:

1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15

C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13

Engine bracket to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 44

Engine bracket to transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 44

Engine mounting bracket to engine bracket . . . . . . . . . . . . . . . . . . . . . . 60 44

Engine mounting to engine mounting bracket . . . . . . . . . . . . . . . . . . . . 65 48

Engine mounting to front axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30

Engine mounting to power steering pump support . . . . . . . . . . . . . . . . 60 44

Engine mounting to side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 48

Exhaust manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16

Exhaust pipe to manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18

Flexplate to crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 44

Flywheel to crankshaft: *

1.4 and 1.6 litre, (except C16 NZ2):

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 30º

Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 15º

C16 NZ2, 1.8 and 2.0 litre:

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 48

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 30º

Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 15º

Front timing belt cover to rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3

Fuel pump to camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13

Guide sleeve, release bearing to transmission . . . . . . . . . . . . . . . . . . . . 22 16

Heat shield sleeves to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22

Inlet manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16

Knock sensor to cylinder block (X16 SZ) . . . . . . . . . . . . . . . . . . . . . . . . 13 10

Main bearing cap: *

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 45º

Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by 15º

Oil filter to oil pump/cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4

2A•6 SOHC engine procedures

Oil pick-up pipe bracket to cylinder block . . . . . . . . . . . . . . . . . . . . . . . 6 4

Oil pick-up pipe to oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6

Oil pipes to radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16

Oil pressure switch to oil pump:

1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22

C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 30

Oil pressure relief valve to oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22

Oil pump cover to oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4

Oil pump to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4

Oxygen sensor to exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22

Power steering pump bracket to support:

C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13

Power steering pump to support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18

Right engine mounting to subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 48

Shackle to alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18

Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18

Starter to cylinder block (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33

Starter to cylinder block (M12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 44

Sump:

1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6

C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11

Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 41

Support to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26

Temperature sender to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15

Thermostat housing:

1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7

C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11

Timing belt tensioner to oil pump:

1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 41

Timing belt cover to oil pump/camshaft housing:

1.4 and 1.6 litre, (except C16 NZ2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9

C16 NZ2, 1.8 and 2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4

Timing belt drive gear to crankshaft:

C16 NZ2, 1.8 and 2.0 litre:

Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 96

Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tighten by between 40º to 50º

Transmission to engine (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33

Transmission to engine (M12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 44

1 General description

General

The engine is of four-cylinder, in-line single or double overhead camshaft type (depending on model), mounted transversely at the front of the vehicle.

The crankshaft runs in five shell-type bearings, and the centre bearing incorporates a thrust bearing shell to control crankshaft endfloat.

The connecting rods are attached to the crankshaft by horizontally split shell-type big-end bearings. On single overhead camshaft (SOHC) models, the pistons are attached to the connecting rods by gudgeon pins, which are an interference fit in the connecting rod small-end bore. The aluminium alloy pistons are fitted with three piston rings: two compression rings and an oil control ring.

The camshaft on SOHC engines is driven from the crankshaft by a toothed composite rubber belt. Each cylinder has two valves (one

inlet and one exhaust), operated through rocker arms that are supported at their pivot ends by hydraulic self-adjusting valve lifters (tappets).

The inlet and exhaust valves are each closed by a single valve spring, and operate in guides pressed into the cylinder head.

A gear-type oil pump is located in a housing attached to the front of the cylinder block, and is driven directly from the crankshaft. A full-flow type oil filter is fitted.

The distributor is driven directly from the end of the camshaft. On carburettor models, the mechanical fuel pump is operated from the front end of the camshaft. The coolant pump is located at the front of the cylinder block, and is driven by the timing belt.

Chapter 2A describes the SOHC engine repair procedures. Many repairs and specifications to the DOHC engine are similar to the

2.0 litre SOHC. However where they differ, details can be found in Chapter 2B.

Engine identification codes general

Before ordering spare parts, or carrying out any repair or overhaul operations on the engine, it is essential to identify the exact

engine type being worked on. Later engines, although outwardly similar in appearance, often have significant differences in repair procedures, even though they may be of the same displacement and model year.

The following sub-Sections in this Chapter are mainly specific to engine type, as will be noted from the sub-Section headings. Check the engine identification code first, which is located on a horizontal surface on the exhaust manifold side of the cylinder block, at the distributor end. On later engines, the code is on the cylinder block-to-transmission flange, next to the engine oil dipstick.

2 Crankcase ventilation

system - description and

maintenance

Description

1 A crankcase ventilation system is fitted to all models, but the systems differ in detail depending on the model concerned. 2 Oil fumes and blow-by gases (combustion gases that have passed by the piston rings) are drawn from the crankcase into the area of

SOHC engine procedures 2A•7

the cylinder head above the camshaft(s) through a hose. From here the gases are drawn into the inlet manifold/throttle body (as applicable) and/or the air box on the carburettor (where applicable), where they are re-burnt with fresh air/fuel mixture, hence reducing harmful exhaust emissions.

Maintenance

3 Certain models have a mesh filter inside the camshaft cover, which should be cleaned in paraffin if clogging is evident (see

illustration). 4 On high mileage vehicles, particularly when

regularly used for short journeys, a jelly-like deposit may be evident inside the crankcase ventilation system hoses. If excessive deposits are present, the relevant hose(s) should be removed and cleaned. 5 Periodically inspect the system hoses for security and damage, and renew as necessary. Note that damaged or loose hoses can cause various engine running problems that can be difficult to trace. 6 The crankcase breather/dipstick tube can be unbolted from the cylinder block after disconnecting the hose. Use a new gasket when refitting.

3 Compression test -

description

Description

1 If engine performance is poor, or if misfiring occurs which cannot be attributed to the ignition or fuel system, a compression test can provide diagnostic clues. If the test is performed regularly, it can give warning of trouble on a high mileage engine before any other symptoms become apparent. 2 The engine must be at operating temperature, the battery must be fully charged, and the spark plugs must be removed. The help of an assistant will also be required. 3 Disable the ignition system by disconnecting the coil LT (“+15”) wire. Fit the compression tester to No 1 cylinder spark plug hole.

4 Have the assistant hold the throttle wide open and crank the engine on the starter. Record the highest reading obtained on the compression tester. 5 Repeat the test on the remaining cylinders, recording the pressure developed in each. 6 The difference in pressure between any two cylinders should be no more than 1.0 bar (14.5 lbf/in2). If the pressure in any cylinder is low, pour a teaspoonful of clean engine oil into the spark plug hole, and repeat the test. 7 If the addition of oil temporarily improves the compression pressure, this indicates that cylinder bore or piston ring wear was responsible for the pressure loss. No improvement suggests that leaking or burnt valves, or a blown head gasket may be to blame. 8 A low reading from two adjacent cylinders is almost certainly due to the head gasket leaking between them. 9 On completion of the test, refit the spark plugs and reconnect the coil LT wire.

4 Major operations possible

with the engine in the vehicle

1 The following operations may be carried out

without removing the engine from the vehicle:

a) Removal and refitting of oil pressure relief

valve (see Section 30)

b) Removal and refitting of timing belt and

sprockets

c) Removal and refitting of camshaft housing

(SOHC engines) d) Removal and refitting of camshaft(s) e) Removal and refitting of cylinder head f) Removal and refitting of sump g) Removal and refitting of oil pump h) Removal and refitting of

piston/connecting rod assemblies i) Removal and refitting of flywheel j) Renewal of crankshaft front oil seal k) Removal and refitting of

engine/transmission mountings

Note: It is possible to renew the crankshaft rear oil seal with the engine in the vehicle, but this requires the use of special tools, and is a difficult operation, due to the lack of working space. For this reason, this operation is described with the engine removed from the vehicle.

5 Major operations requiring

engine removal

The engine must be removed from the

vehicle to carry out the following operations:

a) Renewal of the crankshaft main bearings b) Removal and refitting of the crankshaft c) Renewal of crankshaft rear oil seal

6 Method of engine removal

The engine may be removed either on its own, or together with the transmission. Unless work is also necessary on the transmission, it is recommended that the engine is removed on its own. In either case, the engine or engine/transmission assembly must be lifted out through the top of the engine compartment, using a hoist and lifting tackle.

7 Engine - removal and refitting,

(leaving transmission in car)

Note: A hoist and lifting tackle will be required for this operation. If the torque converter is removed (even partially) from the transmission, a considerable amount of the fluid inside it will leak out. To prevent this, when prising the engine from the transmission and removing it, be careful to keep the torque converter pressed firmly into the transmission. If the transmission is to be removed for some time, retain the torque converter by bolting a strip of metal across the bellhousing mating surface.

Removal

1 Disconnect the battery negative lead. 2 Remove the bonnet (Chapter 11). 3 Apply the handbrake, then jack up the front

of the vehicle, and support securely on axle stands (see “Jacking and Vehicle Support”). 4 Drain the cooling system, remove the radiator and transmission fluid cooler hoses (automatic models), as described in Chapter 3. 5 Drain the engine oil as described in Chapter 1, remove the oil filter and discard, safely. 6 Remove the air cleaner (or air cleaner cover), the air cleaner trunking, and the air box from the carburettor or throttle body (as applicable), referring to Chapter 4A or 4B, if necessary. On carburettor models, disconnect the hot air hose from the exhaust manifold hot air shroud and the air cleaner, and remove the hose. On automatic models, disconnect additional wiring, hoses, etc., from the carburettor, as described in Chapter 4A. 7 Remove the alternator, as described in Chapter 5. 8 On models with power steering, remove the hydraulic pump, as described in Chapter 10. 9 Disconnect the brake servo vacuum hose from the inlet manifold. 10 Disconnect the throttle cable from the throttle lever and the bracket on the carburettor or inlet manifold, as applicable. 11 On carburettor models, disconnect the coolant hoses from the automatic choke housing, and disconnect the wiring from the automatic choke heater and the choke pull-down solenoid (see illustrations). Also disconnect the air box vacuum pipe from the carburettor.

2A•8 SOHC engine procedures

2.3 Crankcase ventilation filter removed from camshaft cover -

1.6 litre engine

12 Disconnect the pressure sensor vacuum pipe from the carburettor (see illustration). 13 Remove the coolant hose(s) from the inlet

manifold and/or throttle body, as applicable. 14 Disconnect the fuel hoses from the fuel pump and vapour separator on carburettor models or from the fuel pipes at the right-hand side of the engine compartment on other models. Be prepared for fuel spillage, and take adequate fire precautions. Plug the open ends of the pipes and hoses, to prevent dirt ingress and further fuel leakage (see

illustrations). 15 Disconnect all relevant wiring connections

and plugs, and remove the fuel injection wiring harness. Pull up on the wiring harness housing, and compress the wiring plug retaining clips to release the harness housing from the fuel injectors (see illustration).

16 Disconnect the heater coolant hoses from the coolant gallery at the rear of the cylinder block. 17 Disconnect the wiring from the following components (where applicable):

a) Starter motor b) Distributor (note HT lead positions) c) Oil pressure switch d) Oil temperature switch e) TDC sensor f) Oil level sensor g) Knock sensor h) Coolant temperature sensor i) Temperature gauge sender

18 Make a final check to ensure that all relevant hoses, pipes and wires have been disconnected, and that they are positioned clear of the engine. 19 Remove the front section of the exhaust system, as described in Chapter 4C. 20 Unbolt and remove the bellhousing cover plate (see illustration). 21 Remove the clutch (if applicable), as described in Chapter 6. On automatic models, use chalk or a felt-tip pen to mark the relationship of the torque converter to the flexplate before unbolting the torque converter. Refer to note at the beginning of this Section and to Chapter 7B for further information. 22 Remove the crankshaft pulley. Some pulleys are secured by four bolts, which must be unscrewed using an Allen key or hexagon bit. Unscrew each of the three bolts in turn and remove them. On other engines, the pulley is secured by a single bolt, which also

secures the crankshaft sprocket. On manual transmission models, if the engine is in the vehicle, the crankshaft can be prevented from turning by having an assistant engage first gear and depress the brake pedal. Alternatively, the flywheel (or flexplate, on automatics), ring gear teeth can be jammed, through the bellhousing cover aperture using a large screwdriver, or similar tool. Access to the crankshaft pulley is most easily obtained through the right-hand wheel arch, after removing the roadwheel. 23 Attach a hoist and lifting gear to the engine lifting brackets on the cylinder head, and support the weight of the engine. 24 Unscrew and remove two of the three upper engine-to-transmission bolts, accessible from the engine compartment, leaving one fastened for safety. 25 Unbolt the right-hand engine mounting from the body and from the cylinder block, and withdraw the mounting bracket. 26 Unscrew and remove the four lower engine-to-transmission bolts. 27 Support the transmission using a trolley jack and interposed block of wood. Remove the last upper transmission bolt. 28 Manipulate the engine as necessary to separate it from the transmission. Note that the transmission locates on dowels in the cylinder block. 29 Carefully raise the hoist, and lift the engine from the vehicle, taking care not to damage any of the surrounding components in the engine compartment.

SOHC engine procedures 2A•9

7.12 Disconnect the pressure sensor vacuum pipe from the carburettor -

1.6 litre model

7.20 Removing the transmission bellhousing cover plate

7.15 Removing the fuel injection wiring harness -

2.0 litre SOHC model

7.14B Fuel hose-to-pipe connections at

right-hand side of engine compartment -

2.0 litre SOHC model

7.14A Disconnecting a fuel hose from the fuel pump - 1.6 litre model

7.11B . . .and disconnect the choke

heater/pull-down solenoid wiring plug -

1.6 litre model

7.11A Disconnect the coolant hoses from the automatic choke housing . . .

30 With the engine removed, the transmission can be supported by placing a length of wood between the bellhousing and the front suspension subframe. Once the wooden support is in place, remove the trolley jack from under the transmission.

Refitting

Note: New left and right-hand engine/transmission mounting-to-body bolts must be used on refitting.

31 Use an M10 x 1.25 bottoming tap to clean the threads in the torque converters threaded bosses and ensure that new bolts are available for reassembly, where applicable.

32 Support the transmission with a trolley jack and remove the length of wood from between the bellhousing and the subframe. 33 Support the engine with the hoist and lifting tackle, and gently lower it into position in the engine compartment. 34 Mate the engine and transmission together, ensuring that the transmission locates on the dowels in the cylinder block, then refit the three upper engine-to-transmission bolts. 35 Tighten all nuts and bolts to their specified torque wrench settings. When tightening the torque converter-to-flexplate bolts to their specified torque wrench settings, a commercially available adapter will be required (see illustration). 36 If the clutch is still bolted to the flywheel, ensure that the weight of the transmission is not allowed to hang on the input shaft as it is engaged with the clutch friction disc. 37 Refit the four lower engine-to-transmission bolts, but again do not fully tighten them at this stage. 38 Fit the right-hand engine mounting bracket to the cylinder block, and tighten the securing bolts to the specified torque.

39 Manipulate the engine and transmission as necessary to enable the right-hand engine mounting-to-body bolts to be fitted, then fit new bolts and tighten them to the specified torque. 40 Tighten all the engine-to-transmission bolts to the specified torque, then disconnect the lifting tackle and hoist from the engine, and remove the trolley jack from beneath the transmission. 41 Refit the transmission bellhousing cover plate. 42 Refit the clutch, as described in Chapter

6. 43 Refit the front section of the exhaust system, as described in Chapter 4C. 44 Refit the crankshaft pulley using a reversal of the removal procedure described earlier in paragraph 22, and tighten the securing bolt(s) to the specified torque.

45 Lower the vehicle to the ground. 46 Refit all relevant wires, pipes and hoses,

etc., using a reversal of the removal procedure described earlier. 47 Where applicable, refit the power steering pump, tension the pump drivebelt, and bleed the hydraulic fluid circuit, as described in Chapter 10. 48 Refit the alternator and tension the drivebelt, as described in Chapter 5. 49 Refit the air cleaner components, referring to Chapter 4A or 4B, if necessary. On carburettor models reconnect the hot air hose to the exhaust manifold hot air shroud. 50 Fit a new oil filter (if not already replaced), and fill the engine with oil, as described in Chapter 1. 51 Refit the radiator and refill the cooling system, as described in Chapter 3. 52 Refit the bonnet as described in Chapter

11.

53 Reconnect the battery negative lead. 54 Refer to Section 37

8 Engine and transmission -

removal, separation, reconnection and refitting

Note: A hoist and lifting tackle will be required for this operation

Removal

1 Proceed as described in Section 7, paragraphs 1 to 18 inclusive. 2 Working in the engine compartment, remove the gear selector linkage, as described in Chapters 7A and 7B, as appropriate. 3 On manual transmission models, remove the retaining clip, then slide the clutch cable from the release lever, pushing the release lever back towards the bulkhead if necessary to allow the cable to be disconnected. On automatic models disconnect the selector cable from the actuating lever, then either unbolt the cable bracket or release the cable from the bracket. In either case, pull the cable

support from the bracket on the transmission casing, then move the cable and secure to one side out of the way, taking note of its routing. 4 Disconnect the wiring from the reversing lamp switch, which is located at the front of the manual transmission casing, above the left-hand mounting bracket. On automatic models, disconnect the transmission wiring by unplugging the five connector plugs from the various switches, solenoids and sensors. Release also the wiring from any clips or ties securing to the vehicle. 5 Where applicable, withdraw the automatic transmission breather hose from under the battery bracket. Disconnect the oxygen sensor wiring if fitted. 6 Unscrew the securing sleeve, and disconnect the speedometer cable from the transmission. 7 Unscrew the retaining nut, and disconnect the earth strap from the transmission endplate. 8 Make a final check to ensure that all relevant hoses, pipes, wires etc. have been disconnected, and that they are positioned clear of the engine and transmission. 9 Proceed as described in Section 7, paragraphs 19 and 22. 10 Disconnect the inboard ends of the driveshafts from the differential, referring to the relevant paragraphs of Chapter 8. Be prepared for oil spillage as the driveshafts are withdrawn, and plug the apertures in the differential, to prevent further loss of oil and dirt ingress. Support the driveshafts by suspending them with wire or string - do not allow them to hang down under their own weight. 11 Attach a hoist and lifting gear to the engine lifting brackets on the cylinder head, and support the weight of the engine. 12 Remove the left-hand transmission mounting completely by unscrewing the two bolts securing the rubber mounting to the vehicle, body, and the three bolts securing the mounting bracket to the transmission (see

illustration). 13 Unbolt the right-hand engine mounting

from the body and from the cylinder block, and withdraw the mounting bracket.

2A•10 SOHC engine procedures

8.12 Left-hand transmission mounting viewed from underside of vehicle

7.35 Commercially-available torque

wrench adapter being used to tighten

torque converter bolts

If a tap is not available, cut two slots into the threads of one of the old flywheel bolts

and use the bolt to remove the locking compound from the threads.

14 Working under the vehicle, unscrew and remove the two nuts securing the engine/transmission rear mounting to the front subframe, and the three bolts securing the mounting bracket to the transmission, then withdraw the mounting bracket (see

illustrations). 15 Carefully swing the engine/transmission

assembly across the engine compartment as necessary, to allow the assembly to be lifted vertically from the vehicle by raising the hoist. Take care not to damage any of the surrounding components in the engine compartment.

Separation

16 With the engine/transmission assembly removed, support the assembly on blocks of wood positioned on a workbench, or failing that, on a clean area of the workshop floor. 17 Clean away any external dirt using paraffin or a water-soluble solvent and a stiff brush. 18 Unbolt and remove the transmission bellhousing cover plate. 19 Ensure that both engine and transmission are adequately supported, then unscrew and remove the engine-to-transmission bolts. 20 Carefully withdraw the transmission from the engine, ensuring that the weight of the transmission is not allowed to hang on the input shaft while it is engaged with the clutch friction disc. Note that the transmission locates on dowels positioned in the cylinder block. 21 On automatic models unbolt the transmission bellhousing cover plate (three bolts), then use chalk or a felt-tip pen to mark the relationship of the torque converter to the flexplate before unbolting the torque converter. Note: If the torque converter is

removed (even partially) from the transmission, a considerable amount of the fluid inside it will leak out. To prevent this, when prising the transmission off its locating dowels and removing it, be careful to keep the torque converter pressed firmly into the transmission. If the transmission is to be removed for some time, retain the torque converter by bolting a strip of metal across the bellhousing mating surface. Applying a spanner to the crankshaft

pulley/sprocket bolt, rotate the crankshaft until the first bolt appears, then use a

screwdriver or similar to jam the flexplate ring gear teeth to prevent it from rotating as the bolt is unscrewed. Unscrew each of the three bolts in turn and remove them.

Reconnection

22 Before beginning the refitting operations, check that the two original bolts that secured the left-hand transmission rubber mounting to the vehicle body rotate freely in their threaded bores in the body. If necessary, re-cut the threaded bores using an M10 x 1.25 mm tap.

23 Where applicable, if the clutch assembly has been removed from the flywheel, it will prove easier to refit after the transmission has been refitted. 24 On automatics, if any fluid was spilled from the torque converter, be careful to refill it as much as possible. Wipe clean the converter’s spigot to prevent damage to the transmission’s input shaft oil seal as the converter is installed, and ensure that the converter engages correctly on the fluid pump shaft. 25 If the transmission has been renewed, be careful to flush clean the radiator fluid cooler passages. Vauxhall recommend the use of low-pressure compressed air, but this will require great care to avoid deforming the radiator. 26 Be very careful to ensure that all components are scrupulously clean, to avoid the risk of dirt getting into the system. 27 Use an M10 x 1.25 bottoming tap to clean the threads in the torque converters threaded bosses and ensure that new bolts are available for reassembly, where applicable. 28 Tighten all nuts and bolts to their specified torque wrench settings. 29 Refer also to Section 7, paragraphs 35 and 36. 30 Carefully offer the transmission to the engine until the bellhousing is located on the dowels in the cylinder block, then refit the engine-to-transmission bolts, and tighten them to the specified torque. 31 Refit the transmission bellhousing cover plate.

Refitting

32 Working under the vehicle, refit the rear engine/transmission mounting to the transmission, using new locking plates under the bolt heads, and tighten the bolts to the specified torque. 33 Fit the two bolts securing the engine/ transmission rear mounting to the front subframe, but do not fully tighten at this stage. 34 Fit the right-hand engine mounting bracket to the cylinder block, and tighten the securing bolts to the specified torque. 35 Fit new right-hand engine mounting-to-body bolts, but do not fully tighten them at this stage. 36 Fit the left-hand transmission mounting bracket to the transmission, and tighten the securing bolts to the specified torque. 37 Fit new left-hand transmission mounting-to-body bolts, and tighten them to the specified torque. 38 Tighten the right-hand engine mountingto-body bolts and the engine/transmission rear mounting-to-front subframe bolts to their specified torques, then remove the lifting tackle and hoist from the engine. 39 Where applicable, the clutch can now be fitted, and the transmission input shaft can be pressed into engagement with the splined hub of the clutch friction disc, (see Chapter 5). 40 Reconnect the inboard ends of the driveshafts to the differential, with reference to the relevant paragraphs of Chapter 8, and using new snap rings. 41 Refit the front section of the exhaust system, as described in Chapter 4C. 42 Refit the crankshaft pulley, using a reversal of the removal procedure described in Section 7, paragraph 22, and tighten the securing bolt(s) to the specified torque. 43 On automatic models, connect the wires to the various switches, solenoids and sensors. Replace the transmission breather hose and oxygen sensor (if fitted). 44 Reconnect the transmission earth strap, and tighten the securing nut.

45 Lower the vehicle to the ground. 46 Reconnect the speedometer cable to the

transmission, and tighten the securing sleeve.

47 Reconnect the reversing lamp wiring. 48 On manual transmission models, refit the

clutch cable to the bracket on the transmission casing, then reconnect the cable to the release lever, and adjust the cable as described in Chapter 6. Ensure that the cable is routed as noted during removal. 49 Refit the gear selector linkage, as described in Chapter 7A, if applicable. 50 Proceed as described in Section 7, paragraphs 41 to 52 inclusive. 51 Top-up the transmission oil level, as described in Chapters 7A and 7B. 52 Adjust the selector cable on completion, and refill the transmission with fluid (see above).

53 Reconnect the battery negative lead. 54 Refer to Section 37

SOHC engine procedures 2A•11

8.14B Rear engine/transmission mountingto-transmission bolts (arrowed)

8.14A Rear engine/transmission mounting-to-front subframe nuts

If a tap is not available, cut two slots into the threads of one of the old flywheel bolts and use the bolt to remove

the locking compound from the threads.

9 Engine and transmission

mountings - renewal

Note: New left and right-hand engine/transmission mounting-to-body bolts must be used on refitting

1 The engine/transmission assembly is suspended in the engine compartment on three mountings, two of which are attached to the transmission, and one to the engine.

Right-hand mounting

2 If not already done, apply the handbrake, then raise the front of the vehicle, and support securely on axle stands (see “Jacking and Vehicle Support”).. 3 Attach lifting tackle and a hoist to the engine lifting brackets on the cylinder head, and support the weight of the engine. 4 Working under the vehicle, unbolt the engine mounting bracket from the cylinder block, and unbolt the mounting block from the body, then withdraw the bracket/mounting assembly (see illustration). 5 Unbolt the mounting block from the bracket. 6 Fit the new mounting block to the bracket, and tighten the securing bolts to the specified torque. 7 Refit the mounting bracket to the cylinder block, and tighten the securing bolts to the specified torque. 8 Fit new mounting block-to-body bolts, and tighten them to the specified torque. 9 Disconnect the lifting tackle and hoist from the engine. 10 Lower the vehicle to the ground.

Left-hand mounting

11 Proceed as described in paragraphs 2 and 3. 12 Working under the vehicle, unbolt the mounting block from the mounting bracket and the body (see illustration).

13 Before fitting the new mounting block, check that the original engine bolts which secured the mounting block to the body rotate freely in their threaded bores in the body. If necessary, re-cut the threaded bores using an M10 x 1.25 mm tap.

14 Fit the new mounting block to the bracket, and tighten the securing bolts to the specified torque. 15 Fit new mounting block-to-body bolts, and tighten them to the specified torque. 16 Proceed as described in paragraphs 9 and 10.

Rear mounting

17 Proceed as described in paragraphs 2 and 3. 18 Working under the vehicle, unbolt the mounting block from the front subframe and the mounting bracket. 19 Fit the new mounting block to the subframe and mounting bracket, and tighten the securing bolts to the specified torque. 20 Proceed as described in paragraphs 9 and 10.

10 Engine dismantling and

reassembly - general

General

1 Ideally, the engine should be mounted on a dismantling stand, but if this is not available, stand the engine on a strong bench, at a comfortable working height. Failing this, the engine will have to be stripped down on the floor. 2 Cleanliness is most important, and if the

engine is dirty, it should be cleaned with paraffin in an upright position. 3 Avoid working with the engine directly on a concrete floor, as grit presents a real source of trouble. 4 If the engine oil appears extremely dirty or contaminated, avoid inverting the engine until the sump has been removed. This will prevent any contaminated “sludge” from entering the oilways. 5 As parts are removed, clean them in a paraffin bath. Do not immerse parts with internal oilways in paraffin, as it is difficult to remove, usually requiring a high pressure hose. Clean oilways with nylon pipe cleaners. 6 It is advisable to have containers available to hold small items, to prevent loss and confusion when refitting. 7 Always obtain complete sets of gaskets when the engine is being dismantled. Keep the old gaskets as they can be used as patterns to make replacements should new gaskets not be available. 8 Where possible, refit nuts, bolts and washers to their locations after removal of the relevant components, as this helps protect the threads, and will also prove helpful during reassembly. 9 Retain unserviceable components, to compare them with the new components supplied. 10 Many of the engine components are secured using socket-headed “Torx” or “Allen” bolts, and tools will be required to remove and refit such bolts. 11 Read through each relevant Section of this Chapter carefully before beginning work, to ensure that any special tools that may be required are available. Many components (gaskets, oil seals, and certain bolts) must be renewed on reassembly; where applicable, obtain the required new components before starting work. 12 Before beginning a complete strip of the engine, the following ancillary components can be removed once the engine has been removed from the vehicle:

2A•12 SOHC engine procedures

9.4 Right-hand engine mounting

1 Mounting block-to-body bolts

2 Mounting bracket-to-cylinder block bolts

9.12 Left-hand engine/transmission mounting

1 Mounting block-to-body bolts

2 Mounting block-to-mounting bracket bolts

If a tap is not available, cut two slots into the threads of one of the old flywheel bolts and use the bolt to remove

the locking compound from the threads.

a) Inlet and exhaust manifolds (where

applicable) b) Starter motor c) Rear coolant gallery and hoses d) Oil pressure switch e) Oil temperature switch (where applicable) f) Oil level sensor (where applicable) g) Knock sensor (where applicable) h) TDC sensor (where applicable) i) Distributor components j) Fuel pump (where applicable) k) Thermostat/housing (N 16 NZ2, 1.8 and

2.0 litre models)

l) Power steering pump and mounting

bracket (where applicable) m)Alternator mounting bracket n) Engine lifting brackets o) Dipstick/crankcase breather tube p) Inlet manifold mounting bracket (where

applicable)

13 To ensure maximum life, with minimum trouble, from a rebuilt engine, not only must everything be correctly assembled, but it must also be spotlessly clean. All oilways and coolant passages must be clear, and all washers must be fitted in their original positions. Oil all bearings and other moving surfaces thoroughly with clean engine oil during assembly. 14 Before assembly begins, renew any bolts or studs with damaged threads. 15 Obtain a torque wrench, an angle-torque gauge, sockets and bits, an oil can, clean lint-free rag, and a set of engine gaskets and oil seals, together with a new oil filter.

16 If they have been removed, new cylinder head bolts, flywheel bolts, big-end bearing cap bolts and main bearing cap bolts will also be required. 17 On completion of reassembly, refit the applicable ancillary components listed in paragraph 12.

18 Follow procedure shown in Section 37.

11 Timing belt and sprockets

(without automatic tensioner) -

removal, refitting and adjustment

Note: A two-legged puller may be required to remove the crankshaft sprocket on N 16 NZ2,

1.8 and 2.0 litre models. Some of the later 1.4 and 1.6 litre engines, identifiable by the squared-off top surfaces of the timing belt covers, are fitted with spring-loaded auto-

matic timing belt tensioners to ensure correct belt tensioning on assembly.

Removal

1 Disconnect the battery negative lead. 2 On models with power steering, remove the

pump drivebelt, see Chapters 1 and 10. 3 Remove the alternator drivebelt, as described in Chapter 5. 4 On C 16 NZ2, 1.8 and 2.0 litre models, disconnect the wiring from the temperature gauge sender. 5 Release the securing clips (or hexagonheaded screws, if fitted), and remove the main outer timing belt cover, then unclip the smaller outer timing belt cover from the coolant pump. Where applicable, three screws retain the lower (small) outer cover to the rear cover, the fourth secures the tensioner (see illustrations). 6 On 1.6 litre models with power steering, remove the power steering pump, as described in Chapter 10. 7 Turn the crankshaft using a socket or spanner on the crankshaft sprocket bolt, until the timing mark on the camshaft sprocket is aligned with the notch in the rear timing belt cover, and the notch in the crankshaft pulley is aligned with the pointer on the rear timing belt cover (see illustrations). Note that on 1.4 litre engine there are two notches in the crankshaft pulley, representing 5° and 10° BTDC, and the 10° BTDC notch should be aligned with the pointer (see illustration). 8 Loosen the three coolant pump securing bolts (see illustration), and turn the pump to relieve the tension in the timing belt, then slide the belt from the camshaft sprocket.

SOHC engine procedures 2A•13

11.5C Timing belt lower (small) outer

cover screws (A), tensioner screw (B),

ignition timing fixed reference mark (C)

11.8 Loosening a coolant pump securing bolt - 2.0 litre engine

11.7C Crankshaft pulley 10° BTDC notch aligned with pointer on rear timing belt

cover - 1.4 litre engine

11.7B . . .and notch in crankshaft pulley aligned with pointer on rear timing belt

cover - 2.0 litre engine

11.7A Camshaft sprocket TDC mark aligned with notch in rear timing belt

cover . . .

11.5B . . .and the smaller cover from the coolant pump - 2.0 litre engine

11.5A Remove the main outer timing belt cover . . .

9 The crankshaft pulley must now be removed. On 1.4 and 1.6 litre engines (except C 16 NZ2), the pulley is secured by a single bolt, which also secures the crankshaft sprocket. On C 16 NZ2, 1.8 and 2.0 litre engines, the pulley is secured by four bolts, which must be unscrewed using an Allen key or hexagon bit. On manual transmission models, if the engine is in the vehicle, the crankshaft can be prevented from turning by having an assistant engage first gear and depress the brake pedal. Alternatively, the flywheel ring gear teeth can be jammed using a large screwdriver or similar tool. 10 With the crankshaft pulley removed, the timing belt can be withdrawn. 11 If desired, the sprockets and the rear timing belt cover can be removed as follows, otherwise go on to paragraph 23. 12 To remove the camshaft sprocket, first

disconnect the breather hose(s) from the camshaft cover, then unscrew the securing bolts noting the locations of the HT lead brackets and any other wiring brackets, and remove the camshaft cover. 13 Recover the gasket. Prevent the camshaft from turning by holding it with a spanner on the flats provided between No’s 3 and 4 camshaft lobes, and unscrew the camshaft sprocket bolt. 14 Withdraw the sprocket from the end of the camshaft. 15 To remove the crankshaft sprocket on 1.4 and 1.6 litre engines (except C 16 NZ2), if necessary, remove the lower securing bolts from the main rear timing belt cover and use two large screwdrivers behind the cover to lever off the sprocket. Remove the Woodruff key if it is loose. 16 To remove the crankshaft sprocket on C 16 NZ2, 1.8 and 2.0 litre engines, it will be

necessary to prevent the crankshaft from turning, as described in paragraph 9. Take care when unscrewing the sprocket bolt, as it is very tight. If necessary, use a two-legged puller to remove the sprocket. Recover the Woodruff key and the thrustwasher from the end of the crankshaft. 17 To remove the main rear timing belt cover on C 16 NZ2, 1.8 and 2.0 litre models disconnect the TDC sensor wiring plug and unclip the wiring from the belt cover. Then unscrew the two upper securing bolts and the lower securing bolt(s) (one in the case of C 16 NZ2, 1.8 and 2.0 litre engines, two on other SOHC engines). Withdraw the cover, manipulating it from the smaller rear belt cover on the coolant pump (see illustrations). 18 If desired, the smaller rear belt cover can be removed from the coolant pump, after unscrewing the securing bolt (see illustration), by rotating it to disengage it from the retaining flange on the pump.

Refitting

19 Refit the rear timing belt cover(s) using a reversal of the removal procedure, and ensuring that the main cover engages correctly with the smaller cover on the coolant pump. 20 On C 16 NZ2, 1.8 and 2.0 litre engines, refit the thrustwasher and the Woodruff key to the end of the crankshaft. Then refit the crankshaft sprocket, and tighten the securing bolt to the specified torque in the two stages given in the Specifications. Ensure that the washer is in place under the bolt head, and prevent the crankshaft from turning as during removal (see illustrations).

2A•14 SOHC engine procedures

11.17A Loosening the main rear timing belt cover lower securing bolt -

2.0 litre engine

11.18 Unscrewing the coolant pump rear belt cover securing bolt - 2.0 litre engine

11.20E Tighten the bolt to the specified torque . . .

11.20D . . .and the washer and bolt11.20C . . .the crankshaft sprocket . . .

11.20B . . . the Woodruff key . . .11.20A Refit the thrustwasher . . .

11.17B Main rear timing belt cover lower securing bolts (arrowed) - 1.6 SV engine

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