Opel Calibra G S 1990 1991-1998 Service Repair Manual
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🏷️ Basic Information Identification Make: Opel Model: Calibra Trim: GSi Codes Chassis Code: Calibra A (4300 series) 👋 Introduction Market Position Market Segment: Sporty coupe, competitor to Ford Sierra/Escort Cosworth, Audi Coupe, BMW E36 Coupe. Competitive Analysis Strengths: Aerodynamic design, available AWD, powerful engine options, good handling. Key Features Design Philosophy: Aerodynamically optimized 'tear drop' shape, low drag coefficient. 📋 Manual Details Coverage Areas Primary Coverage: 1990-1998 Opel Calibra GSi Page Count Estimated Pages: Extensive (precise count not provided, typical for comprehensive service manuals covering multiple years) Manual Type Type: Service and Repair Manual Language Language: English (assumed based on product description and target market) Format Format: Digital (Downloadable PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Disassembly, reassembly, overhaul, timing chain service, valve adjustment, cylinder head, block, crankshaft, pistons, connecting rods. Engine Electrical: Starting system, charging system, ignition system, electronic control modules (ECMs/ECUs), sensors, actuators, diagnostic procedures. Fuel System: Fuel pump, fuel lines, fuel injectors, fuel filter replacement, fuel tank service, fuel pressure testing, emission control system integration. Emission Control: Catalytic converter service, emissions-related sensors, diagnostics, regulatory compliance. Cooling System: Radiator service, thermostat replacement, cooling fan operation, water pump, coolant specifications, system flushing. Transmission Manual: Manual transaxle system: clutch service, gear selection mechanisms, internal component overhaul, fluid specifications. Transmission Automatic: Automatic transaxle system: fluid changes, troubleshooting, component replacement, torque converter service, shift control systems. Driveline Axle: Driveshafts, front and rear axles, U-joint service, Constant Velocity (CV) joint service, differential components. Suspension Front: Front suspension components: struts, shock absorbers, control arms, ball joints, tie rod ends, wheel bearings, alignment procedures. Suspension Rear: Rear suspension components: trailing arms, coil springs, shock absorbers, anti-roll bars, bushings, alignment procedures. Brakes: Brake system: disc brake inspection and service (pads, rotors), caliper service, brake line replacement, bleeding procedures, ABS system diagnostics. Parking Brake: Parking brake system: adjustment, cable replacement, component inspection and repair. Steering: Steering system: steering rack service, power steering pump and fluid service, steering column components, alignment checks. Restraint System Passive: Seat belts: inspection, replacement, tensioner service. Restraint System Active: Supplemental Restraint System (SRS): airbag system diagnostics, component replacement (airbags, control modules, impact sensors), warning light troubleshooting. Body Exterior: Exterior body panels: door panel removal and installation, window mechanisms, sunroof operation, hood and trunk lid adjustments, trim replacement. Body Interior: Interior components: dashboard disassembly, seat removal and installation, upholstery repair, interior trim panels, headliner service. Body Electrical: Body electrical systems: lighting (headlights, taillights, interior lights), power windows, power locks, mirrors, wiper systems, horn, wiring diagrams for all body circuits. HVAC: Heating, Ventilation, and Air Conditioning (HVAC): system operation, component replacement (compressor, condenser, evaporator, heater core), refrigerant handling, troubleshooting, blower motor, control panels. Procedures Included Maintenance: Regular scheduled maintenance, fluid checks and changes, filter replacements, belt inspections and replacement. Troubleshooting: Diagnostic charts, fault code interpretation, symptom-based troubleshooting for all major systems. Repair: Step-by-step repair procedures for virtually all components, from minor adjustments to complete overhauls. Installation: Procedures for replacing major components and accessories. Technical Depth Depth: Comprehensive factory-level technical information, suitable for advanced DIY repairs and professional mechanic use. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution, suitable for clear printing of text and diagrams. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format - Printable) ⚙️ Engine Specifications Primary Engine Engine Code: C20XE (for GSi models, common configuration) Engine Type: 2.0L Inline 4-cylinder, naturally aspirated Displacement: 1998 cc Performance Horsepower: 150 PS (110 kW; 148 hp) at 6000 rpm (for C20XE) Torque: 196 Nm (145 lb-ft) at 4800 rpm (for C20XE) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded gasoline (RON 95 or higher recommended) Engine Management Ignition System: Electronic ignition, distributorless ignition system (DIS) Engine Control: Opel-Bosch Motronic ECU (specific version varies) 🔧 Transmission Standard Transmission Type: 5-speed Manual (F20 gearbox typical for GSi) Optional Transmission Type: 4-speed Automatic (e.g., AW 03-71LE, less common on GSi) Features All Wheel Drive: Available (e.g., Calibra Turbo 4x4 with 6-speed manual, GSi usually FWD) 📐 Dimensions Exterior Length: Approx. 4492 mm (176.9 in) Width: Approx. 1780 mm (70.1 in) Height: Approx. 1310 mm (51.6 in) Wheelbase: Approx. 2600 mm (102.4 in) Weights Curb Weight: Approx. 1280-1350 kg (2822-2976 lb) for GSi 🛡️ Safety Features Ratings Euro Ncap Rating: N/A (Euro NCAP was established later in the Calibra's lifecycle, early models not tested) Passive Features Airbags: Driver's airbag standard from 1994 facelift; optional earlier. Passenger airbag optional. Seat Belts: Three-point inertia-reel seat belts, pre-tensioners available on later models. Active Features ABS: Anti-lock Braking System (ABS) typically standard on GSi models. 💡 Technology Features Infotainment Audio System: Factory fitted radio cassette/CD players with optional amplifier systems. Upgrades common. Driver Assistance Cruise Control: Optional on many models, particularly higher-spec variants. 🔧 Maintenance Service Intervals Oil Change: Every 10,000-15,000 km or 12 months,...
Supplemental Restraint System (SRS): airbag system diagnostics, component replacement (airbags, control modules, impact sensors), warning light troubleshooting.
Body Exterior:
Exterior body panels: door panel removal and installation, window mechanisms, sunroof operation, hood and trunk lid adjustments, trim replacement.
Body Interior:
Interior components: dashboard disassembly, seat removal and installation, upholstery repair, interior trim panels, headliner service.
Body Electrical:
Body electrical systems: lighting (headlights, taillights, interior lights), power windows, power locks, mirrors, wiper systems, horn, wiring diagrams for all body circuits.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC): system operation, component replacement (compressor, condenser, evaporator, heater core), refrigerant handling, troubleshooting, blower motor, control panels.
Procedures Included
Maintenance:
Regular scheduled maintenance, fluid checks and changes, filter replacements, belt inspections and replacement.
Troubleshooting:
Diagnostic charts, fault code interpretation, symptom-based troubleshooting for all major systems.
Repair:
Step-by-step repair procedures for virtually all components, from minor adjustments to complete overhauls.
Installation:
Procedures for replacing major components and accessories.
Technical Depth
Depth:
Comprehensive factory-level technical information, suitable for advanced DIY repairs and professional mechanic use.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution, suitable for clear printing of text and diagrams.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format - Printable)
⚙️ Engine Specifications
Primary Engine
Engine Code:
C20XE (for GSi models, common configuration)
Engine Type:
2.0L Inline 4-cylinder, naturally aspirated
Displacement:
1998 cc
Performance
Horsepower:
150 PS (110 kW; 148 hp) at 6000 rpm (for C20XE)
Torque:
196 Nm (145 lb-ft) at 4800 rpm (for C20XE)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (RON 95 or higher recommended)
Engine Management
Ignition System:
Electronic ignition, distributorless ignition system (DIS)
Engine Control:
Opel-Bosch Motronic ECU (specific version varies)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual (F20 gearbox typical for GSi)
Optional
Transmission Type:
4-speed Automatic (e.g., AW 03-71LE, less common on GSi)
Features
All Wheel Drive:
Available (e.g., Calibra Turbo 4x4 with 6-speed manual, GSi usually FWD)
📐 Dimensions
Exterior
Length:
Approx. 4492 mm (176.9 in)
Width:
Approx. 1780 mm (70.1 in)
Height:
Approx. 1310 mm (51.6 in)
Wheelbase:
Approx. 2600 mm (102.4 in)
Weights
Curb Weight:
Approx. 1280-1350 kg (2822-2976 lb) for GSi
🛡️ Safety Features
Ratings
Euro Ncap Rating:
N/A (Euro NCAP was established later in the Calibra's lifecycle, early models not tested)
Passive Features
Airbags:
Driver's airbag standard from 1994 facelift; optional earlier. Passenger airbag optional.
Seat Belts:
Three-point inertia-reel seat belts, pre-tensioners available on later models.
Active Features
ABS:
Anti-lock Braking System (ABS) typically standard on GSi models.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio cassette/CD players with optional amplifier systems. Upgrades common.
Driver Assistance
Cruise Control:
Optional on many models, particularly higher-spec variants.
🔧 Maintenance
Service Intervals
Oil Change:
Every 10,000-15,000 km or 12 months, whichever comes first (refer to specific manual for exact interval and oil type).
Timing Belt Chain:
C20XE uses a timing chain, generally considered maintenance-free for the life of the engine, but tensioners and guides should be checked during major overhauls.
Spark Plugs:
Typically replaced every 30,000-40,000 km.
Fluid Specifications
Engine Oil:
API SG/SH or ACEA A2-96, viscosity typically SAE 10W-40 or 15W-40 (check manual for exact specification).
Coolant:
Ethylene glycol based coolant, typically GM specification (e.g., Dex-Cool equivalent), mixed 50/50 with distilled water.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 synthetic gear oil recommended for F20 gearbox.
Issues with central locking, window regulators, alarm systems, and ABS sensor failures.
Engine C20Xe:
Eccentric shaft sensor failures (leading to no-start conditions), oil leaks from rocker cover and sump gaskets, potential for timing chain stretch over high mileage.
Suspension:
Worn front wishbone bushings, worn ball joints, and leaky dampers.
📚 Vehicle History
Brand Heritage
Opel Legacy:
Opel, a German automaker with a long history dating back to 1899, known for producing reliable and innovative vehicles across various segments.
Model Evolution
Calibra Introduction:
Launched in 1989 as a replacement for the Opel Monza, designed by Niels Van Roij.
Facelift:
Received a significant facelift in 1994 with updated front and rear styling, interior revisions, and improved safety features.
Production
Production Period:
1989-1997
Manufacturing Locations:
Germany (Rüsselsheim), United Kingdom (Vauxhall Calibra), Finland (Valmet Automotive).
🏆 Awards & Recognition
Recognitions
Design Awards:
Recognized for its groundbreaking aerodynamic design, often cited as one of the most aerodynamically efficient production cars of its era.