Primary Focus:
Mechanical and electrical repair, maintenance, and troubleshooting.
Engine Coverage:
OHV, OHC, and DOHC (16-valve) engines.
Transmission Coverage:
Manual and Automatic transmissions.
Chassis Coverage:
Braking system, Suspension and steering, Exhaust system.
Electrical Coverage:
Electrical system, Body electrical system, Ignition systems (Contact breaker and Electronic).
Bodywork Coverage:
Bodywork and fittings, Hinges and locks.
Estimated Page Count:
Estimated 300-600 pages (typical for comprehensive manuals of this era).
Type:
Service and Repair Manual
Primary Type:
Factory Service Manual
Secondary Type:
Workshop Manual
Format:
Likely printed book or PDF.
Engine:
Detailed coverage of OHV, OHC, and DOHC (16-valve) engines, including removal, overhaul, component replacement, and diagnostics.
Cooling Heating Ventilation:
Comprehensive coverage of cooling, heating, and ventilation systems, including fluid renewal and component checks.
Fuel Exhaust:
Detailed procedures for both carburettor and fuel-injected models, covering fuel filters, pumps, lines, and exhaust systems.
Ignition:
In-depth coverage of contact breaker and electronic (breakerless) ignition systems, including component testing and adjustment.
Transmission:
Procedures for manual transmission oil checks and automatic transmission fluid checks and renewal.
Brakes:
Detailed information on brake fluid renewal, pad, caliper, disc checks, handbrake adjustment, and rear brake shoe/drum checks.
Suspension Steering:
Coverage of suspension and steering system checks and potential adjustments.
Electrical:
Comprehensive electrical system checks, body electrical system diagnostics, and headlamp aim checks.
Routine Maintenance:
Routine maintenance tasks such as fluid level checks, filter renewals, belt checks, spark plug replacement, and tyre checks.
Engine Overhaul:
Complete engine dismantling, reassembly, overhaul procedures, including cylinder head, pistons, crankshaft, and camshafts.
Component Replacement:
Step-by-step instructions for removal and refitting of ancillary components, engine mounts, flywheels, and oil pumps.
Diagnostics Troubleshooting:
Includes compression tests, interpretation of results, and general engine checks to aid in diagnosing issues.
Adjustments:
Procedures for clutch adjustment, handbrake adjustment, idle speed and mixture adjustments, and valve clearance adjustments.
Lubrication:
Guidance on hinge and lock lubrication, engine oil and filter renewal, and engine lubrication system descriptions.
Road Testing:
A 'Road test' section is included, suggesting guidance on post-repair verification.
Bodywork Fittings:
Coverage of bodywork and fittings, including hinge and lock lubrication, suggests attention to cosmetic and functional body components.
Depth:
Comprehensive, suitable for professional mechanics and skilled DIY enthusiasts.
Diagnostic Capabilities:
Covers engine compression testing, ignition system checks, and general system diagnostics.
Rebuild Instructions:
Detailed instructions for engine dismantling, reassembly, and overhaul of major internal components.
Special Tools:
May list specific special tools required for certain procedures, common in factory manuals.
OHV Variants:
Includes engines like the 1.3L and 1.4L OHV petrol engines, often found in earlier models.
Ohc Variants:
Includes OHC engines such as the 1.6L and 1.8L petrol, known for improved performance over OHV.
DOHc Variants:
16-valve DOHC engines, likely including 1.8L and 2.0L variants (e.g., C20XE found in GSi models), offering higher power outputs.
Horsepower Range:
Varies significantly by engine: from approx. 60 HP (OHV) to over 150 HP (performance DOHC variants).
Torque Range:
Corresponding torque figures vary, with higher performance engines offering more robust torque curves.
Carburettor Models:
Features carburettor fuel inlet filter cleaning and associated maintenance.
Fuel Injection Models:
Includes fuel filter renewal for fuel-injected models, indicating support for multi-point fuel injection (MPI) and potentially single-point injection (SPI).
Oil Change Interval:
Typically every 12,000-15,000 km or 12 months for petrol engines, depending on driving conditions and oil type.
Timing Belt Replacement:
Crucial for OHC and DOHC engines, typically around 60,000-90,000 km or 4-5 years. Manual will specify precise interval and part numbers.
Engine Oil Spec:
Likely API SF/SG or ACEA A2/A3, with viscosity grades like 10W-40 or 15W-40. Manual will detail exact specifications and capacities.
Coolant Spec:
Ethylene glycol based coolant, typically silicate-free or low-silicate, with a 50/50 mix with water. Manual will specify Opel/GM type.
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid is common for this era. Manual will specify the exact type.
Common Problems:
Potential issues include cooling system leaks (radiator, hoses), alternator failure, starter motor issues, wear on suspension components (bushings, ball joints), and rust in certain body areas.
Engine Specific Issues:
OHC/DOHC engine timing belt failure if not replaced on schedule can cause catastrophic engine damage. Carburettor models may require more frequent tuning.
