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Opel Vauxhall Calibra 1990-1998 Service Repair Manual

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🏷️ Basic Information Identification Make: Opel / Vauxhall Model: Calibra Model Years Covered: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998 Codes Chassis Codes: Manta_B_based (shared elements with Vectra A platform) 👋 Introduction Market Position Segment: Sports Coupe / Grand Tourer Design Philosophy: Aerodynamically efficient, sleek coupe styling with a focus on driver engagement and performance. Competitive Analysis Key Competitors: Ford Probe, Toyota Celica, Honda Prelude, Mitsubishi Eclipse, Mazda MX-6. Key Features Aerodynamics: Cd value of 0.26, one of the lowest for a production car at its launch, contributing to high-speed stability and fuel efficiency. Styling: Distinctive wedge shape, pop-up headlights, frameless windows, integrated spoilers. 📋 Manual Details Coverage Areas Continents: Europe (primary markets for Opel and Vauxhall branding) Page Count Estimated Pages: Hundreds (exact number not specified, but indicative of comprehensive coverage) Manual Type Type: Workshop Service Repair Manual Intended Audience: DIY enthusiasts, home mechanics, professional automotive technicians. Language Language: English Format Delivery Format: PDF Download 📖 Manual Coverage Systems Covered Mechanical Systems: Engine mechanical, fuel system, exhaust system, cooling system, lubrication system, ignition system, emission control systems, chassis, suspension (front and rear), steering system, braking system (including ABS), driveline (front-wheel drive, optional all-wheel drive). Electrical Systems: Wiring diagrams, lighting systems, instrument cluster, power windows, central locking, audio systems, engine control module (ECM) diagnostics, body control modules (BCM). Interior Systems: Seat adjustment, dashboard removal, climate control system (HVAC) diagnosis and repair, airbag system (cautionary notes on handling). Procedures Included Maintenance: Routine maintenance (oil changes, fluid checks, filter replacements), scheduled maintenance, inspections. Repair And Overhaul: Complete disassembly and reassembly of major components, engine overhaul, transmission repair, brake component replacement, suspension repair, body panel repair, interior trim removal and installation. Diagnostics: Troubleshooting guides for common problems, diagnostic procedures for engine management and electrical systems, OBD-II (on-board diagnostics) information where applicable for later models. Bodywork And Trim: Body panel alignment, rust repair, interior trim removal and replacement, bumper repair, window seal replacement, door mechanism adjustments. Technical Depth Level Of Detail: Comprehensive, step-by-step instructions with detailed illustrations, photos, and diagrams, suitable for both DIY enthusiasts and professional mechanics. Covers complete disassembly and rebuilds. Diagnostic Tools: Information on using basic diagnostic tools and interpreting fault codes. For later models, reference to specific diagnostic equipment for engine management systems. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Printable without restrictions Binding Type Binding: Digital Download (printable pages) Paper Type Paper Type: N/A (digital) ⚙️ Engine Specifications Primary Engine Engine Family: Opel Ecotec (later models) and C20LET (turbocharged) Engine Displacement And Variants: 2.0L (C20NE, X20XEV), 2.5L V6 (C25XE, X25XE), 2.0L Turbo (C20LET). Engine Code Examples: C20NE, X20XEV, C20LET, C25XE, X25XE. Performance Horsepower Range: 115 hp (C20NE) to 204 hp (C20LET 4x4). Torque Range: 170 Nm (C20NE) to 280 Nm (C20LET). Fuel System Injection Type: Multi-point fuel injection (MPI). Turbocharging: Available on C20LET models (Garrett T25 turbocharger). 🔧 Transmission Standard Transmission Type Standard: 5-speed manual transmission. Optional Transmission Type Optional: 4-speed automatic transmission. Features Drivetrain: Front-wheel drive (FWD) standard, optional all-wheel drive (AWD) with Haldex coupling on turbo models. 📐 Dimensions Exterior Length: Approx. 4,507 mm (177.4 in). Width: Approx. 1,770 mm (69.7 in). Height: Approx. 1,330 mm (52.4 in). Weights Curb Weight Range: Approx. 1,350 kg (2,976 lbs) to 1,500 kg (3,307 lbs). 🛡️ Safety Features Ratings Euro Ncap Rating: Not directly applicable as Euro NCAP began its formalized testing procedures in 1997 and the Calibra predates widespread adoption of its scoring system. However, later models would likely have performed moderately. Active Features Braking: Anti-lock Braking System (ABS) available on most models, particularly higher-specification and turbocharged variants. Passive Features Airbags: Driver-side airbag standard on later models, passenger airbag optional or standard on top trims. Seatbelts: Pre-tensioned seatbelts. 💡 Technology Features Infotainment Audio Systems: Factory fitted radio/cassette players, optional CD players, upgraded speaker systems available. Limited digital integration by modern standards. Driver Assistance Cruise Control: Available as an option on many models, especially higher-spec variants. Traction Control: TC (Traction Control) was available on some later models, particularly the 4x4 Turbo variants. Connectivity Bluetooth Integration: Not available from the factory; requires aftermarket installation. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 10,000 km (6,000 miles) or 12 months, whichever comes first, depending on driving conditions and oil quality used. Major Service Intervals: Spark plug replacement, timing belt replacement (depending on engine type, e.g., 60,000 km for early non-interference engines, or as per specific engine recommendation for interference engines). Fluid Specifications Engine Oil Type: API SG/SH, ACEA A2-96/A3-96 rated oils. Viscosity grades typically 5W-30, 5W-40, 10W-40, or 10W-30 depending on climate and specific engine. Coolant Type: Ethylene glycol based coolant, typically a 50/50 mix with deionized water. Specific Opel/Vauxhall coolant may be recommended (e.g., G11 type). Brake Fluid Type: DOT 4 brake fluid. Transmission Fluid Manual: API GL-4 SAE 75W-90 or 80W-90 gear oil. Transmission Fluid...
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Opel Vauxhall Calibra 1990-1998 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Opel / Vauxhall
Model:
Calibra
Model Years Covered:
1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
Codes
Chassis Codes:
Manta_B_based (shared elements with Vectra A platform)
👋 Introduction
Market Position
Segment:
Sports Coupe / Grand Tourer
Design Philosophy:
Aerodynamically efficient, sleek coupe styling with a focus on driver engagement and performance.
Competitive Analysis
Key Competitors:
Ford Probe, Toyota Celica, Honda Prelude, Mitsubishi Eclipse, Mazda MX-6.
Key Features
Aerodynamics:
Cd value of 0.26, one of the lowest for a production car at its launch, contributing to high-speed stability and fuel efficiency.
Styling:
Distinctive wedge shape, pop-up headlights, frameless windows, integrated spoilers.
📋 Manual Details
Coverage Areas
Continents:
Europe (primary markets for Opel and Vauxhall branding)
Page Count
Estimated Pages:
Hundreds (exact number not specified, but indicative of comprehensive coverage)
Manual Type
Type:
Workshop Service Repair Manual
Intended Audience:
DIY enthusiasts, home mechanics, professional automotive technicians.
Language
Language:
English
Format
Delivery Format:
PDF Download
📖 Manual Coverage
Systems Covered
Mechanical Systems:
Engine mechanical, fuel system, exhaust system, cooling system, lubrication system, ignition system, emission control systems, chassis, suspension (front and rear), steering system, braking system (including ABS), driveline (front-wheel drive, optional all-wheel drive).
Electrical Systems:
Wiring diagrams, lighting systems, instrument cluster, power windows, central locking, audio systems, engine control module (ECM) diagnostics, body control modules (BCM).
Interior Systems:
Seat adjustment, dashboard removal, climate control system (HVAC) diagnosis and repair, airbag system (cautionary notes on handling).
Procedures Included
Maintenance:
Routine maintenance (oil changes, fluid checks, filter replacements), scheduled maintenance, inspections.
Repair And Overhaul:
Complete disassembly and reassembly of major components, engine overhaul, transmission repair, brake component replacement, suspension repair, body panel repair, interior trim removal and installation.
Diagnostics:
Troubleshooting guides for common problems, diagnostic procedures for engine management and electrical systems, OBD-II (on-board diagnostics) information where applicable for later models.
Bodywork And Trim:
Body panel alignment, rust repair, interior trim removal and replacement, bumper repair, window seal replacement, door mechanism adjustments.
Technical Depth
Level Of Detail:
Comprehensive, step-by-step instructions with detailed illustrations, photos, and diagrams, suitable for both DIY enthusiasts and professional mechanics. Covers complete disassembly and rebuilds.
Diagnostic Tools:
Information on using basic diagnostic tools and interpreting fault codes. For later models, reference to specific diagnostic equipment for engine management systems.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Printable without restrictions
Binding Type
Binding:
Digital Download (printable pages)
Paper Type
Paper Type:
N/A (digital)
⚙️ Engine Specifications
Primary Engine
Engine Family:
Opel Ecotec (later models) and C20LET (turbocharged)
Engine Displacement And Variants:
2.0L (C20NE, X20XEV), 2.5L V6 (C25XE, X25XE), 2.0L Turbo (C20LET).
Engine Code Examples:
C20NE, X20XEV, C20LET, C25XE, X25XE.
Performance
Horsepower Range:
115 hp (C20NE) to 204 hp (C20LET 4x4).
Torque Range:
170 Nm (C20NE) to 280 Nm (C20LET).
Fuel System
Injection Type:
Multi-point fuel injection (MPI).
Turbocharging:
Available on C20LET models (Garrett T25 turbocharger).
🔧 Transmission
Standard
Transmission Type Standard:
5-speed manual transmission.
Optional
Transmission Type Optional:
4-speed automatic transmission.
Features
Drivetrain:
Front-wheel drive (FWD) standard, optional all-wheel drive (AWD) with Haldex coupling on turbo models.
📐 Dimensions
Exterior
Length:
Approx. 4,507 mm (177.4 in).
Width:
Approx. 1,770 mm (69.7 in).
Height:
Approx. 1,330 mm (52.4 in).
Weights
Curb Weight Range:
Approx. 1,350 kg (2,976 lbs) to 1,500 kg (3,307 lbs).
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Not directly applicable as Euro NCAP began its formalized testing procedures in 1997 and the Calibra predates widespread adoption of its scoring system. However, later models would likely have performed moderately.
Active Features
Braking:
Anti-lock Braking System (ABS) available on most models, particularly higher-specification and turbocharged variants.
Passive Features
Airbags:
Driver-side airbag standard on later models, passenger airbag optional or standard on top trims.
Seatbelts:
Pre-tensioned seatbelts.
💡 Technology Features
Infotainment
Audio Systems:
Factory fitted radio/cassette players, optional CD players, upgraded speaker systems available. Limited digital integration by modern standards.
Driver Assistance
Cruise Control:
Available as an option on many models, especially higher-spec variants.
Traction Control:
TC (Traction Control) was available on some later models, particularly the 4x4 Turbo variants.
Connectivity
Bluetooth Integration:
Not available from the factory; requires aftermarket installation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000 km (6,000 miles) or 12 months, whichever comes first, depending on driving conditions and oil quality used.
Major Service Intervals:
Spark plug replacement, timing belt replacement (depending on engine type, e.g., 60,000 km for early non-interference engines, or as per specific engine recommendation for interference engines).
Fluid Specifications
Engine Oil Type:
API SG/SH, ACEA A2-96/A3-96 rated oils. Viscosity grades typically 5W-30, 5W-40, 10W-40, or 10W-30 depending on climate and specific engine.
Coolant Type:
Ethylene glycol based coolant, typically a 50/50 mix with deionized water. Specific Opel/Vauxhall coolant may be recommended (e.g., G11 type).
Brake Fluid Type:
DOT 4 brake fluid.
Transmission Fluid Manual:
API GL-4 SAE 75W-90 or 80W-90 gear oil.
Transmission Fluid Automatic:
Dexron III or equivalent automatic transmission fluid (ATF).
Known Issues
Common Problems:
Rusting (wheel arches, sills, rear window seal), head gasket leaks (especially on V6 engines), electrical gremlins (window regulators, central locking), suspension wear (bushings, ball joints), catalytic converter failure, fuel pump issues, turbocharger seal leaks (on turbo models).
Intermittent Faults:
Wiring loom chafing (particularly in the engine bay), sensor failures (crankshaft, camshaft position sensors), ABS sensor issues.
📚 Vehicle History
Brand Heritage
Opel Design Direction:
Opel has a long history of producing stylish and driver-focused cars, with the Calibra embodying their move towards more aerodynamic and sporty designs in the late 20th century.
Model Evolution
Generation Overview:
The Calibra was launched in 1989 as a successor to the sleek but aging Opel Monza. It was based on the chassis of the Vectra A and was designed to be a halo car for Opel, showcasing advanced engineering and striking design.
Production
Manufacturing Locations:
Born in Germany, assembly also took place in Finland (Valmet Automotive) for certain markets.
Production End Year:
2000 (although the manual covers up to 1998 models).
🏆 Awards & Recognition
Recognitions
Design Awards:
While specific awards are not detailed in the provided text, the Calibra's design was widely praised and it was considered a design icon of its era, influencing subsequent automotive styling.
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