Chevrolet Cavalier Vauxhall User Manual

Vauxhall Cavalier

Service and Repair Manual

Steve Rendle and Finn Deacon

Models covered

Vauxhall Cavalier front-wheel-drive models with four-cylinder petrol engines, including special/limited editions;
Saloon and Hatchback
1398 cc, 1598 cc, 1796 cc & 1998 cc (inc. DOHC)

Does not cover Diesel engine, V6 engine, air conditioning or four-wheel-drive models

1570 - 320 - 6AA10

© Haynes Publishing 1997

A book in the Haynes Service and Repair Manual Series

All rights reserved. No part of this book may be reproduced or transmitted
in any form or by any means, electronic or mechanical, including
photocopying, recording or by any information storage or retrieval system,
without permission in writing from the copyright holder.

ISBN 1 85960 088 3

British Library Cataloguing in Publication Data

A catalogue record for this book is available from the British Library.

Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil,

Somerset BA22 7JJ

Haynes Publishing

Sparkford, Nr Yeovil, Somerset BA22 7JJ, England

Haynes North America, Inc

861 Lawrence Drive, Newbury Park, California 91320, USA

Editions Haynes S.A.

147/149, rue Saint Honoré, 75001 PARIS, France

Haynes Publishing Nordiska AB

Fyrisborgsgatan 5, 754 50 Uppsala, Sverige

LIVING WITH YOUR VAUXHALL CAVALIER

Introduction to the Vauxhall Cavalier Page 0•4
Safety first! Page 0•5

Roadside Repairs

Introduction Page 0•6
If your car won’t start Page 0•6
Jump starting Page 0•7
Wheel changing Page 0•8
Identifying leaks Page 0•9
Towing Page 0•9

Weekly Checks

Introduction Page 0•10
Underbonnet check points Page 0•10
Engine oil level Page 0•12
Coolant level Page 0•12
Screen washer fluid level Page 0•13
Brake fluid level Page 0•13
Power steering fluid level Page 0•14
Electrical system Page 0•14
Battery Page 0•15
Wiper blade Page 0•15
Tyre condition and pressure Page 0•16

Lubricants, fluids and tyre pressures Page 0•17

MAINTENANCE

Routine Maintenance and Servicing

Maintenance schedule Page 1•4
Maintenance procedures Page 1•8

Contents

REPAIRS AND OVERHAUL

Engine and Associated Systems

SOHC engine procedures Page 2A•1
DOHC engine procedures Page 2B•1
Cooling, heating and ventilation systems Page 3•1
Fuel/exhaust systems - carburettor models Page 4A•1
Fuel/exhaust systems - fuel injection models Page 4B•1
Fuel/exhaust systems - exhaust and emissions Page 4C•1
Engine electrical systems Page 5•1

Transmission

Clutch Page 6•1
Manual transmission Page 7A•1
Automatic transmission Page 7B•1
Driveshafts Page 8•1

Brakes and Suspension

Braking system Page 9•1
Suspension and steering Page 10•1

Body equipment

Bodywork and fittings Page 11•1
Body electrical systems Page 12•1

Wiring Diagrams Page 12•22

REFERENCE

Dimensions and weights Page REF•1
Conversion factors Page REF•2
Buying spare parts and vehicle identification Page REF•3
General repair procedures Page REF•4
Jacking and vehicle support Page REF•5
Radio/cassette unit anti-theft system Page REF•5
Tools and working facilities Page REF•6
MOT test checks Page REF•8
Fault finding Page REF•12
Glossary of technical terms Page REF•20

Index Page REF•25

Contents

0•4

The Cavalier covered by this manual was first introduced to the UK
market in October 1988. Although there is a fundamental similarity to
its predecessor, the later version is much improved in all respects. This
manual covers models with petrol engines and front-wheel-drive, but
other models in the range are fitted with diesel engines, and four -wheel
drive is available on certain models.

Thirteen derivatives of 1.4, 1.6, 1.8 and 2.0 litre single overhead
camshaft (SOHC) versions and 2.0 litre double overhead camshaft
(DOHC) petrol engines have been fitted.

The latest ‘ECOTEC’ engines (X 16 SZ and X 20 XEV), have been
designed to meet strict EEC exhaust gas limits for 1996.

All the engines are of well-proven design and, provided regular
maintenance is carried out, are unlikely to give trouble.

Saloon and Hatchback body styles are available. In it’s later years
models started from a well-equipped ‘Envoy’ base model up to the
sporty SRi.

Selected models use the floorpan layout of
the four-wheel-drive models, to
accommodate fully independent rear
suspension. Other models in the range have
semi-independent torsion beam rear
suspension.

A five-speed manual transmission is fitted as
standard to all models, and four-speed
automatic transmission is available as an option.

A wide range of standard and optional
equipment is available within the Cavalier
range to suit most tastes, including an
anti-lock braking system.

Safety features such as front and rear, side
impact bars fitted to the inside of doors, were
fitted as standard from 1993. During the same
year , a full-size drivers airbag was intr oduced.
1994 saw the introduction of airbags for front
seat passengers.

For the home mechanic, the Cavalier is a
straightforward vehicle to maintain, and most
of the items requiring frequent attention are
easily accessible.

Your Vauxhall Cavalier Manual

The aim of this manual is to help you get the best value from your
vehicle. It can do so in several ways. It can help you decide what work
must be done (even should you choose to get it done by a garage). It
will also provide information on routine maintenance and servicing, and
give a logical course of action and diagnosis when random faults
occur. However, it is hoped that you will use the manual by tackling the
work yourself. On simpler jobs it may even be quicker than booking the
car into a garage and going there twice, to leave and collect it. Perhaps
most important, a lot of money can be saved by avoiding the costs a
garage must charge to cover its labour and overheads.

The manual has drawings and descriptions to show the function of
the various components so that their layout can be understood. Tasks
are described and photographed in a clear step-by-step sequence.

Cavalier SRi 16v

Hatchback

Cavalier 2.0 litre SRi Saloon

Introduction

We take great pride in the accuracy of information given in this
manual, but vehicle manufacturers make alterations and design
changes during the production run of a particular vehicle of which they
do not inform us. No liability can be accepted by the authors or
publishers for loss, damage or injury caused by errors in, or omissions
from, the information given.

Thanks are due to Champion Spark Plug who supplied the illustrations
showing spark plug conditions. Thanks are also due to Sykes­Pickavant Limited, who provided some of the workshop tools, and to
all those people at Sparkford who helped in the production of this
manual. Certain illustrations are the copyright of Vauxhall Motors Ltd,
and are used with their permission.

Acknowledgements

0•5

Safety First!

Working on your car can be dangerous.
This page shows just some of the potential
risks and hazards, with the aim of creating a
safety-conscious attitude.

General hazards

Scalding

• Don’t remove the radiator or expansion
tank cap while the engine is hot.

• Engine oil, automatic transmission fluid or
power steering fluid may also be dangerously
hot if the engine has recently been running.

Burning

• Beware of burns from the exhaust system
and from any part of the engine. Brake discs
and drums can also be extremely hot
immediately after use.

Crushing

• When working under or near
a raised vehicle,
always
supplement the
jack with axle
stands, or use
drive-on
ramps.

Never
venture
under a car which
is only supported by a jack.

• Take care if loosening or tightening high­torque nuts when the vehicle is on stands.
Initial loosening and final tightening should
be done with the wheels on the ground.

Fire

• Fuel is highly flammable; fuel vapour is
explosive.

• Don’t let fuel spill onto a hot engine.

• Do not smoke or allow naked lights
(including pilot lights) anywhere near a
vehicle being worked on. Also beware of
creating sparks
(electrically or by use of tools).

• Fuel vapour is heavier than air, so don’t
work on the fuel system with the vehicle over
an inspection pit.

• Another cause of fire is an electrical
overload or short-circuit. Take care when
repairing or modifying the vehicle wiring.

• Keep a fire extinguisher handy, of a type
suitable for use on fuel and electrical fires.

Electric shock

• Ignition HT
voltage can be
dangerous,
especially to
people with heart
problems or a
pacemaker. Don’t
work on or near the
ignition system with
the engine running or
the ignition switched on.

• Mains voltage is also dangerous. Make
sure that any mains-operated equipment is
correctly earthed. Mains power points should
be protected by a residual current device
(RCD) circuit breaker.

Fume or gas intoxication

• Exhaust fumes are
poisonous; they often
contain carbon
monoxide, which is
rapidly fatal if inhaled.
Never run the
engine in a
confined space
such as a garage
with the doors shut.

• Fuel vapour is also
poisonous, as are the vapours from some
cleaning solvents and paint thinners.

Poisonous or irritant substances

• Avoid skin contact with battery acid and
with any fuel, fluid or lubricant, especially
antifreeze, brake hydraulic fluid and Diesel
fuel. Don’t syphon them by mouth. If such a
substance is swallowed or gets into the eyes,
seek medical advice.

• Prolonged contact with used engine oil can
cause skin cancer. Wear gloves or use a
barrier cream if necessary. Change out of oil­soaked clothes and do not keep oily rags in
your pocket.

• Air conditioning refrigerant forms a
poisonous gas if exposed to a naked flame
(including a cigarette). It can also cause skin
burns on contact.

Asbestos

• Asbestos dust can cause cancer if inhaled
or swallowed. Asbestos may be found in
gaskets and in brake and clutch linings.
When dealing with such components it is
safest to assume that they contain asbestos.

Specia hazards

Hydrofluoric acid

• This extremely corrosive acid is formed
when certain types of synthetic rubber, found
in some O-rings, oil seals, fuel hoses etc, are
exposed to temperatures above 400

0

C. The
rubber changes into a charred or sticky
substance containing the acid. Once formed,

the acid remains dangerous for years. If it
gets onto the skin, it may be necessary to
amputate the limb concerned.

• When dealing with a vehicle which has
suffered a fire, or with components salvaged
from such a vehicle, wear protective gloves
and discard them after use.

The battery

• Batteries contain sulphuric acid, which
attacks clothing, eyes and skin. Take care
when topping-up or carrying the battery.

• The hydrogen gas given off by the battery
is highly explosive. Never cause a spark or
allow a naked light nearby. Be careful when
connecting and disconnecting battery
chargers or jump leads.

Air bags

• Air bags can cause injury if they go off
accidentally. Take care when removing the
steering wheel and/or facia. Special storage
instructions may apply.

Diesel injection equipment

• Diesel injection pumps supply fuel at very
high pressure. Take care when working on
the fuel injectors and fuel pipes.

Warning: Never expose the hands,
face or any other part of the body

to injector spray; the fuel can
penetrate the skin with potentially fatal
results.

Remember...

DO

• Do use eye protection when using power
tools, and when working under the vehicle.

• Do wear gloves or use barrier cream to
protect your hands when necessary.

• Do get someone to check periodically
that all is well when working alone on the
vehicle.

• Do keep loose clothing and long hair well
out of the way of moving mechanical parts.

• Do remove rings, wristwatch etc, before
working on the vehicle – especially the
electrical system.

• Do ensure that any lifting or jacking
equipment has a safe working load rating
adequate for the job.

A few tips

DON’T

• Don’t attempt to lift a heavy component
which may be beyond your capability – get
assistance.

• Don’t rush to finish a job, or take
unverified short cuts.

• Don’t use ill-fitting tools which may slip
and cause injury.

• Don’t leave tools or parts lying around
where someone can trip over them. Mop
up oil and fuel spills at once.

• Don’t allow children or pets to play in or
near a vehicle being worked on.

0•6

The following pages are intended to help in dealing with
common roadside emergencies and breakdowns. You will find
more detailed fault finding information at the back of the
manual, and repair information in the main Chapters.

Roadside repairs

If your car won’t start
and the starter motor
doesn’t turn

M If it’s a model with automatic transmission, make sure the

selector is in ‘P’ or ‘N’.

M Open the bonnet and make sure that the battery terminals

are clean and tight.

M Switch on the headlights and try to start the engine. If the

headlights go very dim when you’re trying to start, the
battery is probably flat. Get out of trouble by jump starting
(see next page) using a friend’s car.

If your car won’t start
even though the starter
motor turns as normal

M Is there fuel in the tank, or is the gauge faulty?
M Is there moisture on electrical components under the

bonnet? Switch off the ignition, then wipe off any obvious
dampness with a dry cloth. Spray a water-repellent
aerosol product (WD-40 or equivalent) on ignition and fuel
system electrical connectors like those shown in the
photos.
Pay special attention to the ignition coil wiring connector
and HT leads. (lights, heater, wipers, etc) is switched off.

Check that the spark plug HT leads are
securely connected by pushing them
home.

A

The fuel injection system wiring plug
may cause problems if not connected
securely.

B

Check the ECU multi-plug for security
(where fitted), with the ignition switched
off.

C

Check the security and condition of the
battery connections.

D

Check that the ignition coil wiring plug
is secure, and spray with water­dispersant if necessary.

E

Check that electrical connections are secure (with the ignition switched
off) and spray them with a water dispersant spray like WD40 if you
suspect a problem due to damp