Haynes Vauxhall Cavalier 1981 to 1988 Owners Workshop Manual 1850103704, 9781850103707

Citation preview

VAUXHALL WAN

ES. (petrol)

1981 to 1988 1297 cc

1598 cco 1796 cco 1998 cc

(Terr Dave ©

ei

Digitized by the Internet Archive in 2022 with funding from Kahle/Austin Foundation

https://archive.org/details/vauxhallcavalierOO00coom

Vauxhall Cavalier Owners

Workshop Manual | M Coomber Models covered All Vauxhall Cavalier front-wheel-drive models, including special and limited editions Saloon, Hatchback and Estate 1297 cc, 1598 cc, 1796 cc & 1998 cc petrol engines Covers major mechanical features of Convertible Does not cover Diesel engine variants

A (812-7P1)

GPS A,

Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ

Aacoe

rons

es

KLMNO

Group

England

Haynes Publications, 861 Lawrence Drive Newbury Park California 91320 USA

Inc

Acknowledgements Thanks are due to Duckhams Oils who supplied lubrication data and the Champion Sparking Plug Company Limited who supplied the illustrations showing the spark plug conditions. Certain other illustrations are the copyright of Vauxhall Motors Ltd, and are used with their permission. Thanks are also due to Sykes-Pickavant who supplied some of the workshop tools, and all those people at Sparkford who assisted in the production of this Manual.

© Haynes Publishing Group 1988 A book in the Haynes Owners

Workshop

Manual

Printed by J. H. Haynes & Co. Ltd, Sparkford, Somerset BA22 7JJ, England

Series

Nr Yeovil,

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 85010 370 4 British Library Cataloguing Coomber, lan 7943-

in Publication

Data

Vauxhall Cavalier (fwd) owners workshop manual 1. Cars. Maintenance & repair. Amateurs’ manuals

|. Title 629.28'722 ISBN 1-85010-370-4 Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Contents Introductory

pages

About this manual

5

Introduction to the Vauxhall Cavalier General dimensions, weights and capacities Jacking, towing and wheel changing Buying spare parts and vehicle identification numbers

5 i] 8 10

General repair procedures

11

Tools and working facilities Safety first! Routine maintenance

14 15

Recommended lubricants and fluids Conversion factors Fault diagnosis

23 24 25

12

Chapter1

Engine

28

Chapter2 Cooling and heating systems

63

Chapter 3 Fuel and exhaust systems

75

Chapter4 Ignition system

108

Chapter 5

Clutch

125

Chapter 6 Manual and automatic transmissions

131

Chapter7 Driveshafts

170

Chapter 8 Steering

174

Chapter 9 Braking system

185

Chapter 10 Suspension

213

Chapter 11 Bodywork and fittings

231

Chapter 12 Electrical system

264

Index

33

N

\Ssrsrtonora BRinisaninieonnienininiiieiien

Vauxhall

Cavalier SRi 130

Vauxhall

Cavalier

L Estate

tin

About

this manual

/ts aim 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), 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. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work.

/ts arrangement The manual is divided into twelve Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided into Sections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on from the Section they are in, eg 5.1, 5.2, 5.3 etc. It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms

Introduction

of illustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the Chapter — eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related groups) as the Section or sub-section to which they relate. There is an alphabetical index at the back of the marual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver's seat facing forwards. Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise. Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity.

Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Project vehicles The appear Saloon, models

to the Vauxhall

The front-wheel-drive (fwd) Cavalier was introduced in August 1981 and replaced the earlier range of rear-wheel-drive Cavalier models. The bodywork was also revised to distinguish it from the earlier models and was initially available in a two or four-door Saloon version, or a five-door Hatchback. The five-door Estate variant was introduced in 1983.

The engine and transmission on all models is transversely mounted. Initially available with a 1.3, 1.6 or 1.8 litre engine, the 2.0 version was

vehicles in many an early — a 1.6L

used in the preparation of this manual, and which of the photographic sequences, were: an early 1.3 1.6 Estate, an early 1.8 SRi Hatchback, and two 1987 and an SRi.

Cavalier

added to the range in August of 1986. A 4 or 5-speed manual transmission, or a 3-speed automatic transmission will be fitted. The 2-door Convertible variant was introduced in October 1985. Various levels of trim and equipment are available depending upon the model selected from the range. These vehicles should present few problems for the home mechanic. They are of straightforward construction with good access to all service points.

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Ignition 134 L3/Terminal coil 15 12.92 Fig. Wiring diagram for Motronic fuel injection (2.0) system

331

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NUR FUER MOTOR 18SE ONLY FOR ENGINE 1.8 F|

Fig. 12.93 Wiring diagram for the EZ 61 microprocessor spark timing system 202 203 207

208

Throttle valve Throttle valve Fuel injection control unit K

switch S 44/Terminal switch S 44/Terminal system 15/Terminal 1

Fuel injection system control unit K 15/Terminal

See also main key

10

3 2

(1.8 from 1987)

Index A About this manual — 5 Air cleaner description and maintenance — 77 removal and refitting — 78 Alternator description — 267 fault diagnosis — 268 removal and refitting — 267 special precautions — 267 Alternator brushes inspection, removal and refitting Bosch — 270 Delco-Remy — 268 Ancillary components (engine) removal — 44 Antifreeze mixture — 64 Automatic transmission description — 163 fault diagnosis — 169 removal and refitting — 167 routine maintenance — 163 specifications — 131 torque wrench settings — 132

B Battery Capacity — 264 charging — 267 maintenance and inspection — 266 removal and refitting — 267 Bodywork and fittings — 231 et seq Bodywork and fittings damage repair (colour chart) — 238, 239 description — 232 specifications — 231 torque wrench settings — 231 Bonnet removal and refitting — 234 Bonnet release cable renewal — 235 Brake disc inspection, removal and refitting — 192 Brake disc shield removal and refitting — 193 Brake drum inspection and renovation — 198 Brakelines (flexible and rigid) inspection and renewal — 202 Brake light switch removal and refitting — 211 Brake master cylinder removal and refitting — 198 Brake pedal removal and refitting — 210 Brake pedal remote control assembly dismantling and reassembly — 207 Brake pedal remote control rod removal and refitting — 208 Braking system — 185 et seq Braking system description — 187

fault diagnosis — 211 routine maintenance — 187 specifications

— 185

torque wrench settings — 186

Bulbs renewal — 282 wattages — 265 Buying spare parts — 10

Cc Caliper (ATE type) removal, overhaul and refitting — 189 Caliper (GMF type) removal, overhaul and refitting — 191 Camshaft removal (engine in car) — 35 Camshaft front oil seal renewal (engine in car) — 35 Camshaft housing and camshaft dismantling and reassembly — 36 Camshaft toothed belt renewal — 34 Capacities (fluid) — 7 Carburettor (GM Varajet) description — 82 idle speed and mixture adjustment — 82 in-vehicle adjustments — 83 to 86 overhaul — 86 to 89 removal and refitting — 86 Carburettor (Pierburg 2E3) adjustments with carburettor removed — 94 description idle speed in-vehicle overhaul —

— 90 and mixture adjustments 94 removal and refitting — Central locking system description, component Centre console removal and refitting — Choke cabie removal and refitting — Cigar lighter removal and refitting — Clock removal and refitting — Clutch — 125 et seq Clutch adjustment — 125 description — 125 fault diagnosis — 130 specifications — 125 torque wrench settings Clutch cable removal and refitting — Clutch pedal removal and refitting — Clutch release bearing, removal and refitting —

adjustment — 93 — 93

94 removal and refitting — 291 252 104 279 279

— 125 126 127 lever, bushes and seal 129

Clutch unit removal, inspection and refitting engine or transmission, or both, removed — 129 leaving engine/transmission in car — 127 Coil — 116 Condenser removal, testing and refitting — 111 Control arm balljoint (front suspension) renewal — 220 Control arm bushes renewal — 220 Control arm support removal and refitting — 221

i

Conversion factors — 24 Coolant pump removal and refitting — 65 Coolant temperature sender

removal and refitting — 68 Cooling and heating systems - 62 et seq Cooling and heating systems antifreeze mixture — 64 Capacities — 62

description — 63 draining — 63 fault diagnosis — 74

filling — 64 flushing — 63 routine maintenance — 63 specifications — 62 torque wrench settings — 62 Cooling fan thermal switch removal and refitting — 67 Crankshaft front (pulley end) oil seal renewal — 38 Crankshaft rear (flywheel end) oil seal renewal — 39 Cylinder head dismantling, examination, renovation and decarbonising — 48 removal and refitting — 35

D Decarbonising — 48 Dimensions — 7 Disc pads inspection and renewal — 187

Distributor (breakerless type) dismantling, inspection and reassembly — 120 removal and refitting — 120, 122 Distributor (mechanical breaker type) dismantling, inspection and reassembly — 112 removal and refitting — 111 Distributor contact breaker points gap and dwell angle adjustment — 110 removal and refitting — 111 Door removal and refitting — 245 Door and lid hinges, locks and controls lubrication — 234 Door glass removal and refitting — 240 Door trim panel removal and refitting — 237 Drivebelt removal, refitting and tensioning — 66 Driveshafts — 170 et seq Driveshafts description and maintenance — 170 fault diagnosis — 173 removal and refitting — 170 specifications — 170 torque wrench settings — 170 Driveshaft joint bellows renewal — 172 renewal — 172

E Electrical accessories subsequent fitting — 293 to 298

Electrical system — 264 et seq Electrical system description — 265 fauit diagnosis — 303 routine maintenance — 266 specifications — 264 torque wrench settings — 265

wiring diagrams — 305 to 331

Index Engine — 28 et seq Engine description — 32 dismantling (complete) — 44 dismantling (general) — 44 examination and renovation — 49 fault diagnosis — 59 methods of removal — 39 operations possible without removing engine — 34 reassembly (general and complete) — 51 to 58 refitting — 58, 59 removal — 39, 40, 43 routine maintenance — 33 start-up after overhaul — 59 specifications — 28 torque wrench settings — 31 Engine components examination and renovation — 49 Engine/automatic transmission reconnection before refitting — 59 separation after removal — 43 Engine lubrication and crankcase ventilation systems description and maintenance — 44 Engine/manual transmission reconnection before refitting — 58 separation after removal — 43 Engine/transmission mountings renewal — 39 Exhaust system removal and refitting — 106 Exterior rear view mirror glass removal and refitting — 254 Exterior rear view mirror (manual) removal and refitting — 254 Exterior rear view mirror motor removal and refitting — 255 Exterior rear view mirror (powered) removal and refitting — 255

F

Facia panel removal and refitting — 252 Fault diagnosis (general) — 25 automatic transmission — 169

braking system — 211 cooling and heating systems — 74 clutch — 130 driveshafts — 173 electrical system — 303, 304 engine — 59 to 61 fuel system — 107 ignition systems — 117, 124 manual transmission — 163 steering — 184 suspension — 230 Flywheel removal and refitting — 38 Front anti-roll bar

removal and refitting — 222 Front bumper

removal and refitting — 235 Front door exterior handle removal and refitting — 243 Front door lock removal and refitting — 242 Front door lock cylinder removal, dismantling, reassembly and refitting — 243 Front foglights adjustment — 286 Front hub bearing renewal — 217 Front suspension control arm removal and refitting — 219

334

Index

a

Front suspension strut

overhaul — 217

Horn(s) and switch — 278

Hydraulic system (brakes)

removal and refitting — 216

bleeding — 203 flexible hose and rigid pipes — 202

Front wing removal and refitting — 237 Fuel and exhaust systems — 75 et seq

Fuel and exhaust systems

|

carburettor data — 75, 76 description — 77

Ignition switch

routine maintenance — 77 specifications — 75 torque wrench settings — 76

removal and refitting — 117 Ignition system — 108 et seq Ignition system (breakerless type)

unleaded

high octane petrol — 104

description — 118

Fuel injection system description — 95

distributor — 120 to 122 fault diagnosis — 124

idle speed and mixture adjustment — 98

precautions — 119

precautions — 98

routine maintenance — 120

Fuel injection system components

removal and refitting — 100 to 104

timing — 123

Ignition system (mechanical breaker type)

Fuel injection throttle valve adjustments — 99 Fuel injection throttle valve switch

description — 109 fault diagnosis — 117 routine maintenance — 109

adjustment — 100

specifications — 108

Fuel pump

timing — 113

description, maintenance, testing, removal and refitting — 79 Fuel system fault diagnosis — 107 Fuel tank

torque wrench settings — 108 Ignition timing adjustment — 113, 123 Input shaft (F10 series transmission)

removal and refitting — 80 Fuel tank sender unit

overhaul — 144 Instrument panel

removal and refitting — 79 Fuel tank vent chamber description, removal and refitting — 81 Fuses circuits and ratings — 264 general — 276

removal and refitting — 279 Instruments removal and refitting — 282

J

G

Jacking 9g — 8

Gear ratios

K

automatic — 132 manual — 131 Gearchange lever removal and refitting — 133 Gearchange lever reverse selector cable removal and refitting — 134 Gearchange linkage

adjustment — 135

Kickdown cable renewal and adjustment — 164

L

Level control system

removal and refitting — 134

Glove compartment

description — 223

Level control system components

removal and refitting — 252

removal and refitting (general) — 229 Level control system adjustment — 229

H

(manual)

Load area trim panels (Estate)

Handbrake adjustment — 208 Handbrake cables renewal — 209 Handbrake lever removal, overhaul and refitting — 210 Handbrake warning light switch

removal and refitting — 210 Head restraints removal and refitting — 253 Headlamp

beams

alignment — 286

Headlamp wash/wipe system — 289 Headlamps removal, refitting and modifications — 285 Heated rear window maintenance — 303 Heater — 68 Heater components removal and refitting — 68 to 73

removal and refitting Lubricants and fluids Luggage boot lid removal and refitting Luggage boot lid lock removal, dismantling

— 247 (recommended)

— 23

— 248 and cylinder and refitting — 248

M Mainshaft

(F10 series transmission)

overhaul — 145

Maintenance

(routine) — 15 to 22

bodywork and underframe — 232 upholstery and carpets Manifolds removal and refitting — Manual and automatic Manual and automatic

— 232 105 transmissions — 131 et seq transmissions

specifications — 131 torque wrench settings — 131, 132

Index Manual transmission description — 132 removal and refitting — 136 routine maintenance — 132 F10 series dismantling into major assemblies — 138 to 142 reassembly — 148 Type F10.5 description — 149 dismantling and reassembly — 150 Type F16 and F16.4 dismantling and overhaul — 152 Type F16.5 dismantling — 153 to 156 reassembly — 156 to 162 Master cylinder (ATE type) overhaul — 199 Master cylinder (GMF type) overhaul — 201 Minor body damage repair — 233

335

Rear brakes (pre 1984) adjustment — 193 Rear bumper removal and refitting — 236 Rear coil spring removal and refitting — 226 Rear door fixed quarter light removal and refitting — 242 Rear door exterior handle removal and refitting — 244 Rear door lock removal and refitting — 244 Rear hub bearings adjustment — 222 renewal — 223 Rear lights cluster unit removal and refitting — 286 Rear shock absorber removal, testing and refitting — 224 Rear suspension

stub axle

renewal — 47 Oil pressure regulator valve removal and refitting — 34 Oil pump overhaul — 47 removal and refitting — 37

removal and refitting — 226 Rear vent grille (Estate) removal and refitting — 263 Rear wheel alignment — 230 Rear window or tailgate glass removal and refitting — 249 Recommended lubricants and fluids — 23 Relays — 276 Repair procedures — 11 Reversing lights and rear foglights (Estate) unit removal — 286 Routine maintenance — 15 to 22

P

S

O Oil and filter (engine)

Pistons/connecting rods removal and refitting — 38 Power operated exterior mirror — 303 Power operated front windows — 303 Power steering system bleeding — 184 Power steering pump drivebelt tensioning — 184 Pressure regulating valves (braking system) — 202

R Radiator removal, inspection and refitting — 64 Radiator electric cooling fan removal and refitting — 67 Radiator grille removal and refitting — 235 Radio aerial (optional equipment) removal and refitting — 299 Radios and tape players fitting (general) — 299

suppression of interference (general) — 301 Rear air deflector (Estate) removal and refitting — 263 Rear anti-roll bar removal and refitting — 225 Rear axle removal and refitting — 226 Rear brake backplate removal and refitting — 198 Rear brake shoes (pre 1984)

inspection and renewal — 193 Rear brake wheel cylinder removal, overhaul and refitting — 197

Rear brakes (self-adjusting) description — 195 inspection and renewal — 196

Safety first! — 14 Seatbelts care and maintenance — 254

Seats removal and refitting — 251 Selector housing cover (F10 series transmission) overhaul — 143 Spanner jaw gap comparison table — 13 Spark plugs and HT heads — 114, 123 Spark plug conditions (colour chart) — 115 Speed selector control cable removal, refitting and adjustment — 166 Speedometer cable renewal — 282 Starter inhibitor switch (auto transmission) adjustment — 278 Starter motor description — 271 dismantling and reassembly — 274 removal and refitting — 271 renovation — 271 testing in car — 271 Starter motor brushes inspection and renewal — 272 Starter solenoid removal and refitting — 272 Steering — 174 et seq Steering description — 175 fault diagnosis — 184 routine maintenance — 176 specifications — 174

Steering angles and wheel alignment — 183 Steering column Overhaul — 182 removal and refitting — 181 Steering column lock removal and refitting — 183 Steering damper removal and refitting — 180

ww Index Steering gear overhaul — 179 removal and refitting — 177 Steering rack bellow s renewal — 178 Steering wheel removal and refitting — 181 Sump removal and refitting — 37 Sunroof (removable) Operation — 255 Sunroof (slide/tilt)

component renewal jn sity — 258 component renewal (unit removed) — 258 to 263 Operation and mainte nance — 257 removal and refitting (complete) — 258

Sunroof (sliding)

Operation, removal and refitting — 256 Suspension — 213 et seq Suspension description — 214 fault diagnosis — 230 routine maintenance — 216 Specifications — 213 torque wrench settings — 214 Switches removal and refitting — 276 Synchroniser units (manual transmission ) overhaul — 147

T Tailgate (Estate) removal and refitting — 246 Tailgate (Hatchback) removal and refitting — 245 Tailgate glass see Rea r window Tailgate lock (Estate) removal and refitting — 247 Tailgate lock barrel (Estate) removal and refitting — 247 Tailgate lock (Hatch back) removal and refitting — 246 Tailgate struts removal and refitting — 246 Tailgate washer sys tem — 288 Tailgate Wiper motor removal and refitting — 287 TDC sensor — 116 Thermostat removal, testing and refit ting — 64

Throttle control cabl e

adjustment and renewal — 104

Tie-rod end removal and refitting — 176 Tools — 12 Towing - 8 Trailing arm flexible bushes renewal — 227 Transmission case (F10 series)

overhaul — 144 Trip computer

description and compon ent renewal — 292 Turning circle — 174 Tyre sizes — 213 Tyre pressures — 214

U Unleaded

high octane petrol — 104

WV Vacuum servo unit (bra king system) removal and refitting — 204 renewal — 203 Vacuum servo booste r testing for faulty Operatio n — 204 Vehicle identification numbers — 10 Vents and grilles removal and refitting — 73

Ww Washer fluid — 290 Weights — 7 Wheel alignment — 174 Wheel changing - 8 Wheels and tyres data — 213 care and maintenance — 230 Window regulator removal and refitting — 240 Windows (side) removal and refitting — 250 Windscreen glass removal and refitting — 248 Windscreen washer system — 288 Windscreen wiper mot or and linkage removal and refitting — 287 Wiper blades and arm s removal and refitting — 286 Wiring diagrams — 305 to 331 Working facilities — Uz

|

|

| | | ||

Models covered by this manual All Vauxhall Cavalier front-wheel-drive models, including special and limited©

editions. Saloon, Hatchback and Estate

eck

1297 cc, 1598 cc, 1796 cc & 1998 cc petrol engines Covers major mechanical features of Convertible |

é

4 Bad \ ‘

Does not cover Diesel engine variants

his.

The clear, step-by-step illustrated instructions cover the dismantling, inspection, repair and refitting of the engine, cooling system, fuel and

emission control systems, exhaust, ignition system, clutch, manual gearbox, propeller shaft or drive shafts, braking system, electrical system, suspension, steering, bodywork“and fittings. Routine maintenance, complete specifications and detailed fault diagnosis procedures are also included. For rear axle differential units and automatic transmissions (where applicable) the removal, refitting and fault diagnosis procedures only are covered. ONLY HAYNES COMPLETELY STRIP AND REBUILD THE CAR FOR EACH MANUAL

‘These are really worthwhile manuals which

can save you a lot of money.’ Autocar

|

‘Haynes manuals are outstanding for giving the learner mechanic an easy to follow guide to doing most any type of repair on maintenance work on his or her car.’ Road & Track

|

‘These authentic manuals

Whether you just want to change your oil or replace your plugs, or change your clutch or rebuild your gearbox, the Haynes manual will show you how, and can help you save pounds on servicing and repair bills.

are actually written from

|

practical experience ...’ Car Mechanics

|

‘Excellent value for money,

beginners and experts should find it equally useful, overall a mine of information.’ Motor \

A Haynes manual can help you stretch your motoring budget that little bit further in other ways too. Regular maintenance and servicing will mean your Car is safer to drive whilst giving you more of those precious mpg. What's more, a car that is well looked after will hold its price better and last a lot longer!

‘It is thus opportune that a simply splendid Owners Workshop Manual has just come out. Every imaginable job is illustrated ...’ Autosport ‘For the home mechanic Haynes DIY workshop

manuals show clearly step-by-step service

pune

H 923573

ISBN

1 85010 370 4

|

Operations in pictures.’ Sunday Mirror

T