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vectra a
Maintenance Manual
16 pgs531.79 Kb0

Opel vectra a Maintenance Manual

1
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
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
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
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
5
4
3
2
1
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
1
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
1
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
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