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Chapter 1
Routine maintenance and servicing
Contents
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
Degrees of difficulty
Easy, suitable for
Fairly easy, suitable
1
novice with little
for beginner with
experience
some experience
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
Fairly difficult,
2
3
suitable for competent
DIY mechanic
Difficult, suitable for
Very difficult,
4
experienced DIY
suitable for expert DIY
mechanic
or professional
1•1
1
5
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Summary of Contents for Opel vectra a
- Page 1 1•1 Chapter 1 Routine maintenance and servicing Contents Air cleaner element - renewal .......27 Headlamp alignment .
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Page 2: Servicing Specifications
Servicing Specifications 1•2 Lubricants and fluids Refer to “Weekly Checks” Capacities Engine oil Including filter: 1.4 litre ..........3.0 litres 1.6 litre . -
Page 3: Maintenance Schedule
Servicing Specifications 1•3 Idle mixture CO content: All carburettor models ........0.5 to 1.5% 20 NE and 20 SEH . - Page 4 Maintenance schedule 1•4 Every 250 miles (400 km) or weekly Refer to “Weekly checks” Basic service, every 9000 miles Full service, every 18 000 miles (15 000 km) or 12 months - (30 000 km) or 24 months - whichever comes sooner whichever comes sooner Along with the items in “Weekly checks”, carry out the following:...
- Page 5 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...
- Page 6 Maintenance - component location 1•6 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...
- Page 7 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...
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Page 8: Maintenance Procedures
Maintenance - component location 1•8 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... - Page 9 Every 9000 miles or 12 months 1•9 i) Check the idle speed and mixture test (refer to Chapter 2A) will provide valuable Primary operations information regarding the overall performance settings, as applicable (Section 9). a) Clean, inspect and test the battery (See 5 If the above operations do not prove fully of the main internal components.
- Page 10 Every 9000 miles or 12 months 1•10 2 Also check the security and condition of all 5 Steering and suspension the engine related pipes and hoses. Ensure check 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 Front suspension and steering...
- Page 11 Every 9000 miles or 12 months 1•11 significant amounts of fluid are being lost At the same time, check the general 9 Idle speed and mixture - condition of the CV joints themselves by first (carefully note the amounts being added, and adjustment holding the driveshaft and attempting to how often), check the transmission for leaks...
- Page 12 Every 9000 miles or 12 months 1•12 14 Brake fluid renewal 17 Power steering fluid check 1 With the engine off, remove the cap from the power steering reservoir. It is fitted with a Warning: Brake hydraulic fluid dipstick. can harm your eyes and 2 The fluid should be visible up to the ‘MAX’...
- Page 13 Every 18 000 miles or 24 months 1•13 5 Check that the steering feels positive, with 24 Door lock key battery - no excessive “sloppiness”, or roughness, and replacement check for any suspension noises when cornering, or when driving over bumps. Drivetrain 1 Carefully prise open the outer cover from the key.
- Page 14 Every 18 000 miles or 24 months 1•14 10 Before fitting new spark plugs check that 28 Air inlet temperature control their threaded connector sleeves are tight. check (carburettor models only) Refer to Chapter 4A for details. 29 Fuel filter renewal 30.3 Removing a spark plug Warning: Before carrying out the following operation, refer to...
- Page 15 Every 18 000 miles or 24 months 1•15 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.
- Page 16 Every 36 000 miles or 48 months 1•16 Major service, every 36 000 miles (60 000 km) or 48 months made available, to reduce the risk of plug 36 Timing belt renewal 37 Spark plug renewal (DOHC) damage (see illustration). 4 After refitting the spark plugs, remember to replace the plug cover.