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VAUXHALL OPEL CALIBRA Service Repair Manual 89-97

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🏷️ Basic Information Identification Make: Vauxhall Model: Calibra Alternative Make: Opel Codes Chassis Code: Manta F Platform Code: GMT K 👋 Introduction Market Position Segment: Sports Coupe / Grand Tourer...
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VAUXHALL OPEL CALIBRA Service Repair Manual 89-97
🏷️ Basic Information
Identification
Make:
Vauxhall
Model:
Calibra
Alternative Make:
Opel
Codes
Chassis Code:
Manta F
Platform Code:
GMT K
👋 Introduction
Market Position
Segment:
Sports Coupe / Grand Tourer
Competitors:
Ford Probe, Honda Prelude, Mitsubishi Eclipse, Toyota Camry Coupe, Alfa Romeo GTV, BMW 3 Series Coupe
Key Features
Design Philosophy:
Aerodynamic styling, distinctive wedge shape, low drag coefficient
Engineering Basis:
Based on the Vectra (Opel Vectra A) platform, shared components with other GM vehicles
Powertrain Options:
Front-wheel drive and all-wheel drive (4x4) options available
Target Audience:
Enthusiast drivers seeking stylish design and performance
📋 Manual Details
Coverage Areas
Years Covered:
1989-1997
Page Count
Approximate Pages:
Hundreds (Specific count not provided, but implied to be extensive)
Manual Type
Type:
Service Repair Manual
Language
Language:
English (Assumed based on product name and common market)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full overhaul, diagnosis, repair, timing belts, gaskets, seals, pistons, crankshaft, camshafts, cylinder heads, valves
Engine Electrical:
Ignition system, fuel injection system, sensors (ECT, MAP, TPS, O2), starter motor, alternator, ECU diagnosis, wiring diagrams
Fuel System:
Fuel pump, injectors, fuel lines, fuel filter replacement, fuel pressure testing, EVAP system
Cooling System:
Radiator, water pump, thermostat, coolant hoses, expansion tank, fan operation
Exhaust System:
Catalytic converter, mufflers, exhaust pipes, lambda sensors
Transmission Manual:
Clutch replacement, gearbox overhaul, shift linkage, transmission fluid changes
Transmission Automatic:
Transmission fluid changes, torque converter, valve body diagnosis, electronic control module (if applicable)
Drivetrain AWD:
Viscous coupling unit (VCU), front and rear driveshafts, differentials (if applicable to specific models)
Suspension:
Front struts, rear shock absorbers, coil springs, control arms, bushings, anti-roll bars, geometry adjustment
Steering:
Power steering pump, steering rack, tie rods, steering column, alignment procedures
Brakes:
Front and rear disc brakes, brake calipers, pads, rotors, brake lines, master cylinder, ABS system (diagnosis and components)
Electrical System:
Battery, charging system, lighting (headlights, taillights, interior), fuses, relays, wiring harnesses, diagnostic connectors
Body And Interior:
Door panels, dashboard removal, seat removal, trim pieces, body panel repair and alignment, rust prevention
HVAC:
Air conditioning system diagnosis, refrigerant handling, heater core, blower motor, climate control panel
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant flushes, brake fluid changes, timing belt replacement intervals
Troubleshooting:
Diagnostic fault codes (OBD-I/OBD-II depending on year and engine), symptom-based troubleshooting guides, electrical diagnostic flowcharts
Repair Procedures:
Step-by-step instructions for component replacement, engine rebuilding, transmission overhaul, suspension and brake component replacement
Rebuilding:
Detailed instructions for engine and transmission internal component rebuilding
Refurbishment:
Guidelines for restoring worn components and systems
Restoration:
Information relevant to bringing the vehicle back to its original specifications
Technical Specifications:
Torque specifications for all fasteners, engine timing data, electrical component resistance values, diagnostic data
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to complex engine and transmission overhauls, electrical system diagnostics, and bodywork
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text-based PDF, enabling quick information retrieval
Print Quality
Printability:
Printable pages for workshop use
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Quality:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code E G C20Xe:
C20XE (2.0L 16V Ecotec)
Engine Displacement 1:
1998 cc
Engine Configuration 1:
Inline 4-cylinder, DOHC
Horsepower 1:
150 PS (148 bhp, 110 kW) at 6000 rpm
Torque 1:
196 Nm (145 lb-ft) at 4800 rpm
Fuel System 1:
Multi-point fuel injection (MPI)
Engine Code E G X20Xev:
X20XEV (2.0L 16V Ecotec)
Engine Displacement 2:
1998 cc
Engine Configuration 2:
Inline 4-cylinder, DOHC
Horsepower 2:
136 PS (134 bhp, 100 kW) at 5600 rpm
Torque 2:
188 Nm (139 lb-ft) at 4000 rpm
Fuel System 2:
Multi-point fuel injection (MPI)
Engine Variant V6
Engine Code E G X30Xe:
X30XE (3.0L V6 24V Ecotec)
Engine Displacement V6:
2969 cc
Engine Configuration V6:
V6, DOHC, 24 valves
Horsepower V6:
204 PS (201 bhp, 150 kW) at 6000 rpm
Torque V6:
270 Nm (199 lb-ft) at 4200 rpm
Fuel System V6:
Multi-point fuel injection (MPI)
🔧 Transmission
Standard
Transmission Type Standard FWD:
5-speed Manual (F20/F25/F35 gearbox family)
Optional
Transmission Type Optional FWD:
4-speed Automatic (AF20/AF33 gearbox family)
Optional Awd
Transmission Type Optional AWD:
5-speed Manual with AWD (GM 4x4 gearbox)
Features
AWD System:
Ferguson viscous coupling system (for AWD models)
Specifications
Manual Gear Ratios:
Varies by engine/gearbox, detailed in manual
Automatic Gear Ratios:
Varies by engine/gearbox, detailed in manual
📐 Dimensions
Exterior
Length:
4475 mm (176.18 in)
Width:
1785 mm (70.28 in)
Height:
1320 mm (51.97 in)
Wheelbase:
2600 mm (102.36 in)
Drag Coefficient:
Cd 0.26 (one of the lowest production cars of its time)
Weights
Curb Weight:
Approx. 1280-1450 kg (depending on engine and drivetrain)
Cargo
Boot Capacity:
Approx. 420 liters (14.8 cu ft)
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Not applicable for this era of testing standards in a comparable format
Active Features
ABS:
Anti-lock Braking System (Standard on many models, optional on some early ones)
Passive Features
Airbags:
Driver airbag (standard on later models, optional on earlier models), passenger airbag (optional)
Seatbelts:
Front seatbelt pre-tensioners
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player or CD player. Upgrade options common. Speaker configurations vary by trim.
Display Technology:
Analog gauges, basic digital odometer display (on some models).
Driver Assistance
Cruise Control:
Optional on many models.
Traction Control:
Available on some higher-spec models, especially AWD variants.
Connectivity
Connectivity Features:
Limited by era. Primarily focused on basic audio and power accessories. Aftermarket upgrades are common for modern connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000-15,000 km (6,000-9,000 miles) or 12 months, whichever comes first. Consult manual for specific engine and oil type.
Timing Belt Replacement:
Crucial at intervals specified by engine variant (e.g., 60,000 km / 4 years for some engines). Failure can cause severe engine damage. Manual is essential for correct interval.
Spark Plug Replacement:
Varies by plug type (e.g., iridium, platinum). Typically 40,000-80,000 km. Manual provides specific recommendations.
Fluid Specifications
Engine Oil Type E G 5W30:
API SG/SH, ACEA A2/A3. Viscosity commonly 5W-30, 10W-40, or 15W-40 depending on ambient temperature and engine. Manual is critical for exact specs.
Coolant Type:
Ethylene glycol based, silicate-free coolant. GM specification (e.g., G11/G12 equivalent). Manual confirms specific type and mix ratio.
Brake Fluid Type:
DOT 4
Transmission Fluid Manual:
GL-4 gear oil (e.g., SAE 75W-90). Manual specifies exact type and capacity.
Transmission Fluid Automatic:
Dexron-III (or equivalent). Manual specifies exact type and capacity.
Known Issues
Rust Corrosion:
Common in wheel arches, sills, rear suspension mounts, and strut towers due to age and weather exposure.
Suspension Wear:
Bushings, ball joints, and shock absorbers are prone to wear, leading to knocking noises and poor handling.
Electrical Gremlins:
Faulty door lock actuators, window regulators, dashboard warning lights, and sensor issues can occur.
Viscous Coupling Unit Vcu:
On AWD models, the VCU can seize or degrade over time, affecting drivetrain performance and potentially causing damage to the transfer case.
Engine Idle Instability:
Common with 2.0 16V engines (C20XE/X20XEV) due to vacuum leaks, idle control valve issues, or dirty throttle bodies.
Exhaust Manifold Cracking:
The cast iron exhaust manifold on some models can develop cracks, leading to exhaust leaks and ticking noises.
📚 Vehicle History
Brand Heritage
Vauxhall Opel Legacy:
Part of General Motors' European operations, known for producing reliable and well-engineered vehicles
Model Evolution
Introduction Year:
1989
Facelift:
Minor facelift in 1994 (updated grille, mirrors, interior trim, engine management)
Production
Production Period:
1989-1997
Production Locations:
Germany (Rüsselsheim), Poland, South Korea (Daewoo)
Total Production Units:
Approx. 240,000
🏆 Awards & Recognition
Recognitions
Design Award:
Recognized for its groundbreaking aerodynamic design and styling, influencing coupe design of the 1990s.
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