Opel Calibra 1990-1998 Workshop Repair Service Manual
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๐ท๏ธ Basic Information Identification Make: Opel Model: Calibra Generation: First Generation Body Style: 2-door Coupe Codes Chassis Code: Type 52 ๐ Introduction Market Position Positioning: The Opel Calibra was a sporty, stylish coupe that competed in the premium sports coupe segment, offering a blend of performance and unique design. Competitive Analysis Competitors: Primary competitors included the Ford Probe, Honda Prelude, Toyota Celica, and Mitsubishi Eclipse. Key Features Aerodynamics: Known for its exceptionally low drag coefficient (Cd=0.26 for early models), making it one of the most aerodynamic production cars of its era. Design: Distinctive wedge-shaped profile, large glass area, and sleek, futuristic styling, penned by GM Europe designer Henry Lack. Target Audience Audience: Appealed to buyers seeking a stylish, performance-oriented coupe with a distinctive European flair. ๐ Manual Details Coverage Areas Model Years Covered: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998 Page Count Estimated Page Count: Likely extensive, typical for comprehensive workshop manuals (estimated 1000+ pages depending on engine variants) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF ๐ Manual Coverage Systems Covered Engine: Comprehensive engine repair, overhaul, tuning, lubrication system, cooling system, fuel system, ignition system, emissions control. Transmission: Manual and automatic transmission repair, overhaul, removal, installation, clutch system, drive shafts. Brakes: Brake system diagnostics, repair, ABS system (if applicable), brake fluid, calipers, rotors, lines. Electrical: Complete electrical system troubleshooting, wiring diagrams, lighting, charging system, starting system, ECUs, sensors, power windows, central locking. Suspension Steering: Front and rear suspension repair, steering system diagnostics, power steering, alignment specifications. Body Chassis: Body repair, panel replacement, interior trim, door mechanisms, window regulators, structural components, corrosion protection. Exhaust: Exhaust system components, catalytic converter, muffler, exhaust manifold repair and replacement. Heating Ventilation Air Conditioning: HVAC system operation, refrigerant, blower motor, A/C compressor, climate control system. Procedures Included Maintenance: Routine maintenance, oil changes, filter replacements, fluid checks, spark plug replacement, belt inspection and replacement. Troubleshooting: Diagnostic procedures for common faults, symptom-based troubleshooting guides. Repair: Step-by-step repair procedures for all major components and systems. Disassembly Assembly: Detailed instructions for dismantling and reassembling various assemblies. Tune Ups: Engine tuning procedures to optimize performance and efficiency. Special Tools: Identification and usage of special tools required for specific repairs. Technical Depth Depth: Comprehensive coverage from basic maintenance to complete engine and transmission overhauls, suitable for professional technicians and advanced DIYers. ๐ Manual Specifications File Format Format: PDF Print Quality Printability: Printable Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Delivery Delivery Method: Electronic via Email โ๏ธ Engine Specifications Primary Engine 20Seh: 2.0L 8-valve Inline-4, 115 PS (85 kW), C20NE variant. C20Xe: 2.0L 16-valve Inline-4 (C20XE 'Red Top'), 150 PS (110 kW), DOHC, MFI. X20Xev: 2.0L 16-valve Inline-4 (Ecotec), 136 PS (100 kW), DOHC, MPI. C25Xe: 2.5L V6 24-valve, 170 PS (125 kW), DOHC, MFI (Calibra V6). C30Se: 3.0L V6 24-valve, 210 PS (154 kW), DOHC, MFI (limited production for C30SEJ). Performance Top Speed 20Xe: Approx. 225 km/h (140 mph) Acceleration 0 100 Kmh 20Xe: Approx. 8.5 seconds Fuel System Type: Multi-Point Fuel Injection (MPI) / Motronic electronic fuel injection. Fuel Requirement Octane Rating: Premium unleaded gasoline (95 RON or higher recommended for performance engines). ๐ง Transmission Standard Type Early Models: 5-speed manual transmission. Optional Type Automatic: 4-speed automatic transmission (available on most engine variants). Features Drivetrain: Front-wheel drive (FWD) standard. Optional All-Wheel Drive (AWD) available on some models (e.g., 2.0i 16V 4x4). AWD System: Viscous coupling centre differential on AWD models. ๐ Dimensions Exterior Length: Approx. 4492 mm (176.9 in) Width: Approx. 1784 mm (70.2 in) Height: Approx. 1320 mm (52.0 in) Wheelbase: Approx. 2530 mm (99.6 in) Weights Curb Weight 20Seh: Approx. 1265 kg (2789 lbs) Curb Weight 20Xe: Approx. 1280 kg (2822 lbs) Curb Weight V6: Approx. 1380 kg (3042 lbs) Cargo Trunk Volume: Approx. 420 liters (14.8 cu ft) with rear seats up. ๐ก๏ธ Safety Features Ratings Euro Ncap Rating: Limited data available for this era, but generally considered to have a robust structure for its time. Active Features ABS: Anti-lock Braking System (ABS) was an option on many models and standard on performance variants. Passive Features Airbags: Driver's airbag became standard during the production run, passenger airbags were optional or introduced later. Seatbelts: Pre-tensioned seatbelts. ๐ก Technology Features Infotainment Audio System: Factory-fitted radio/cassette players, with optional CD players. Basic sound systems. Driver Assistance Cruise Control: Optional cruise control system available on some models. Connectivity Original Connectivity: Limited to standard automotive systems of the era; no advanced connectivity features like Bluetooth or USB. ๐ง Maintenance Service Intervals Oil Change: Typically every 10,000-15,000 km or annually, whichever comes first. Check manual for specific engine. Timing Belt: Crucial replacement interval, typically 60,000-90,000 km or 4-6 years for 16V and V6 engines. Failure can cause catastrophic engine damage. Fluid Specifications Engine Oil: API SG/SH or ACEA A2/A3. Viscosity...
Brake system diagnostics, repair, ABS system (if applicable), brake fluid, calipers, rotors, lines.
Electrical:
Complete electrical system troubleshooting, wiring diagrams, lighting, charging system, starting system, ECUs, sensors, power windows, central locking.
Suspension Steering:
Front and rear suspension repair, steering system diagnostics, power steering, alignment specifications.
Body Chassis:
Body repair, panel replacement, interior trim, door mechanisms, window regulators, structural components, corrosion protection.
Exhaust:
Exhaust system components, catalytic converter, muffler, exhaust manifold repair and replacement.
Heating Ventilation Air Conditioning:
HVAC system operation, refrigerant, blower motor, A/C compressor, climate control system.
Procedures Included
Maintenance:
Routine maintenance, oil changes, filter replacements, fluid checks, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic procedures for common faults, symptom-based troubleshooting guides.
Repair:
Step-by-step repair procedures for all major components and systems.
Disassembly Assembly:
Detailed instructions for dismantling and reassembling various assemblies.
Tune Ups:
Engine tuning procedures to optimize performance and efficiency.
Special Tools:
Identification and usage of special tools required for specific repairs.
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to complete engine and transmission overhauls, suitable for professional technicians and advanced DIYers.
Premium unleaded gasoline (95 RON or higher recommended for performance engines).
๐ง Transmission
Standard
Type Early Models:
5-speed manual transmission.
Optional
Type Automatic:
4-speed automatic transmission (available on most engine variants).
Features
Drivetrain:
Front-wheel drive (FWD) standard. Optional All-Wheel Drive (AWD) available on some models (e.g., 2.0i 16V 4x4).
AWD System:
Viscous coupling centre differential on AWD models.
๐ Dimensions
Exterior
Length:
Approx. 4492 mm (176.9 in)
Width:
Approx. 1784 mm (70.2 in)
Height:
Approx. 1320 mm (52.0 in)
Wheelbase:
Approx. 2530 mm (99.6 in)
Weights
Curb Weight 20Seh:
Approx. 1265 kg (2789 lbs)
Curb Weight 20Xe:
Approx. 1280 kg (2822 lbs)
Curb Weight V6:
Approx. 1380 kg (3042 lbs)
Cargo
Trunk Volume:
Approx. 420 liters (14.8 cu ft) with rear seats up.
๐ก๏ธ Safety Features
Ratings
Euro Ncap Rating:
Limited data available for this era, but generally considered to have a robust structure for its time.
Active Features
ABS:
Anti-lock Braking System (ABS) was an option on many models and standard on performance variants.
Passive Features
Airbags:
Driver's airbag became standard during the production run, passenger airbags were optional or introduced later.
Seatbelts:
Pre-tensioned seatbelts.
๐ก Technology Features
Infotainment
Audio System:
Factory-fitted radio/cassette players, with optional CD players. Basic sound systems.
Driver Assistance
Cruise Control:
Optional cruise control system available on some models.
Connectivity
Original Connectivity:
Limited to standard automotive systems of the era; no advanced connectivity features like Bluetooth or USB.
๐ง Maintenance
Service Intervals
Oil Change:
Typically every 10,000-15,000 km or annually, whichever comes first. Check manual for specific engine.
Timing Belt:
Crucial replacement interval, typically 60,000-90,000 km or 4-6 years for 16V and V6 engines. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil:
API SG/SH or ACEA A2/A3. Viscosity grades like 5W-30, 5W-40, or 10W-40 depending on climate. (Refer to manual for exact specification).
Coolant:
Propylene glycol-based or ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with deionized water. (e.g., G11 specification).
Brake Fluid:
DOT 3 or DOT 4, depending on original specification. Must be replaced every 2-3 years.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 80W-90.
Transmission Fluid Automatic:
Dexron III (or equivalent) automatic transmission fluid.
Known Issues
Rust:
Susceptible to rust, especially around wheel arches, sills, and tailgate. Regular inspection and rust proofing are advised.
Suspension Wear:
Worn suspension components like ball joints, bushings, and shock absorbers are common due to age and mileage.
Electrical Gremlins:
Older wiring can degrade, leading to intermittent electrical issues. Check connections and grounds.
Engine Oil Leaks:
Valve cover gaskets, oil pan gaskets, and crankshaft seals can develop leaks over time.
Cooling System:
Radiator leaks, thermostat issues, and water pump failure can lead to overheating.
Gearbox Synchros:
Manual gearbox synchromesh wear can cause difficult shifting, particularly into second and third gears.
๐ Vehicle History
Brand Heritage
Opel Legacy:
Opel, a German automobile manufacturer with a long history dating back to 1898, known for engineering and performance, particularly in European markets.
Model Evolution
Introduction Year:
1989
Facelift:
A minor facelift occurred in 1994, with updated bumpers, grille, and interior trim.
Production
Production Period:
1989-1997
Manufacturing Locations:
Primarily manufactured in Rรผsselsheim, Germany. Also assembled in other GM facilities globally.
Sales Performance
Global Sales:
Sold over 260,000 units worldwide during its production run.
๐ Awards & Recognition
Recognitions
Design Awards:
The Calibra was widely praised for its futuristic and aerodynamic design, winning several design awards. It was frequently cited in automotive press for its styling.
Ratings
Performance Reviews:
Praised for its handling and road-holding, especially the 4x4 and V6 models. The 2.0 16V ('Red Top') was a popular performance choice.