Opel Corsa / Vauxhall. Manual - part 11
11•6 Bodywork and fittings
12.2 Window winder handle spring clip
12.3 Removing the surround from the
12.4 Unscrewing the lock button
(arrowed)
remote control handle
5 The two halves of the wind deflector can be
are two Torx screws at the fore end (see
separated if wished by pulling them apart.
illustrations). Some armrests also have an
13 Door - removal and refitting
Each half may also be removed individually,
ordinary self-tapping screw at the rear end.
leaving the other in place.
7 With some trim levels there is a self-tapping
screw securing the trim to the door shut face.
Refitting
Remove this if present (see illustration).
Removal
6 Refit in the reverse order to removal.
8 Uncap the retaining clips with a
1 The door hinges are welded onto the door
broad-bladed screwdriver or a palette knife
and onto the hinge pillar. The only remedy for
and remove the panel. The degree of force
12 Door inner trim panel -
worn hinges, unless oversize pins can be
needed to release the clips is not far off that
removal and refitting
procured, is to renew the door and/or pillar.
which will break them: obtain new clips for
2 To remove a door, open it fully and support
refitting if necessary.
its lower edge with well-padded blocks.
Removal
9 Free the plastic sheets from the door or trim
Disconnect any door component wiring
panel as appropriate.
1 Procedure is described for a front door; rear
harness (mirrors, windows, central locking
doors are similar, except where noted.
Refitting
etc).
2 Except on models with electric windows,
3 Disconnect the check strap and have an
10 Refit in the reverse order to removal. make
the window winder handle must first be
assistant support the door whilst the hinge
sure that the plastic sheet is intact and securely
removed. In the absence of special tool
glued round the bottom and sides on the door:
pins are extracted. The pins should be
KM-31 7-A, release the handle securing clip
if it is broken or detached, rainwater may leak
extracted upwards, using a slide hammer,
by introducing a strip of rag between the
into the vehicle or damage the door trim.
after removing their caps.
handle and the door trim panel and working it
back and forth to pick up the ends of the clip.
Remove the handle, clip and trim plate (see
illustration).
3 Prise the surround from the remote control
handle (see illustration).
4 Unscrew the interior lock button
(see
illustration).
5 When a door pocket is fitted, prise out the
screw cover and remove the securing screw
(see illustrations). Remove the two screws at
the bottom of the pocket, if fitted, then
remove the pocket. On rear doors, unclip the
ashtray housing.
6 Remove the armrest. Precise details of
12.5a Door pocket screw cover
12.5b Removing a door pocket screw
fixing will vary with trim level, but usually there
12.6a Removing the armrest screw cover
12.6b Removing an armrest screw
12.7 Trim securing screw on the door shut
face - rear door shown
Bodywork and fittings 11•7
3 Disconnect the control rods and remove the
Refitting
lock. (In the case of the front door, do not
4 Reassemble in the reverse order, noting the
disconnect the interior lock button rod, but
position of the spring legs and their
withdraw the lock and rod complete.)
relationship to the arm.
5 Refit in the reverse order to removal. Check
Refitting
for correct operation before refitting the trim
4 Refit in the reverse order to removal. When
panel.
refitting the front door lock, make sure that
the tongue on the lock engages with the slot
18 Window lifting mechanism -
in the cylinder arm (see illustration).
5 Check for correct operation before refitting
removal and refitting
the door trim panel.
13.4 Adjusting a door lock striker
Removal
15 Door exterior handle -
1 Remove the door trim panel, as described
removal and refitting
in Section 12.
Refitting
2 Various types of mechanism may be fitted:
4 Refit the door in the reverse order to
scissors or cable, manual or electric. In all
Removal
removal, using new hinge pins. Gross
cases the principles of removal are similar.
adjustment of the door position is possible by
1 Remove the door trim panel, as described
The electric motors cannot be repaired,
bending the hinges or hinge eyes. Fine
in Section 12.
though sometimes they can be renewed
adjustment to obtain satisfactory shutting is
2 Wind up the window fully.
separately from the lifting mechanism. Note:
made by turning the socket-headed lock
3 Unclip the handle-to-lock rod from the lock.
On Convertible models with electric windows,
striker (see illustration).
4 Unbolt the handle from inside the door and
prior to removal position the window lifting
remove it. Some manipulation will be needed
mechanism and secure it in position with
to get the goose-neck and the operating rod
some stout wire as shown (see illustration).
14 Door lock - removal and
through the hole.
This will prevent the mechanism being
refitting
suddenly released as it is disconnected.
Refitting
3 Lower the window to the halfway position
Removal
5 Refit in the reverse order to removal. Check
and wedge it securely.
for correct operation before refitting the trim
4 Disconnect the wiring harness from the
1 Remove the door trim panel (Section 12).
panel.
electrically-operated mechanism.
2 Remove the three screws which secure the
5 Drill the heads off the rivets and remove the
lock to the door shut face (see illustration).
mechanism from the door. The cable
16 Door remote control handle -
removal and refitting
Removal
1 Remove the door trim panel, as described
in Section 12.
2 Slide the handle rearwards to free it (see
illustration). Unhook the link rod and remove
it from the door.
Refitting
3 Refit in the reverse order to removal. Check
for correct operation before refitting the trim
14.2 Door lock securing screws (arrowed)
16.2 Removing a remote control handle
panel.
17 Front door lock cylinder -
removal and refitting
Removal
1 Remove the door trim panel, as described
in Section 12.
2 Release the lock cylinder retaining clip by
prising it forwards. Withdraw the cylinder and
associated components from the outside of
11
the door.
3 The cylinder may be separated from the
17.3 Exploded view of lock cylinder
14.4 Door lock attachments inside the door
other items by inserting the key in the slot,
then using a screwdriver to prise off the end
1 Key
5 Seal
A Remote control
C Exterior handle rod
piece and arm. Withdraw the cylinder from the
2 Cylinder
6 Spring
handle rod
D Lock cylinder arm
housing and recover the circlip
(see
3 Circlip
7 Arm
B Lock button rod
illustration).
4 Housing
8 End piece
11•8 Bodywork and fittings
18.2 Convertible electric window lifter arm
18.5a Two window lifting mechanism
18.5b Window lifting channel bolts
secured (1) prior to removal of the
securing rivets (arrowed)
(arrowed)
regulator unit
5 Carefully lift the window out through its
opening in the door. It will have to be tilted at
21 Tailgate hinge - removal and
a considerable angle.
refitting
Refitting
6 Refit in the reverse order to removal. Adjust
Removal
the angle of the rear door window guide rail by
1 Open the tailgate and have an assistant
means of the adjustment screw and locknuts
support it.
until smooth operation is achieved
(see
2 Disconnect the strut on the side being
illustration). Note that there are two locknuts,
worked on see Section 22.
one on each side of the panel.
3 Extract the circlip and press or drive out the
hinge pin.
4 Unclip the roof trim panels and loosen the
18.6 Scissors lifting mechanism slider
20 Tailgate - removal and refitting
headlining to gain access to the hinge screws.
5 Undo the two screws with an offset
screwdriver and remove the hinge, seal and
mechanism lifter must also be unbolted from
screw plate.
Removal
the window channel (see illustrations).
1 Open the tailgate and have an assistant
Refitting
Refitting
support it.
6 Refit in the reverse order to removal.
6 Refit in the reverse order to removal, using
2 Disconnect the rear screen washer tube
Tighten the hinge screws to the specified
new blind rivets. Lubricate the sliders and
and any wiring that enters the tailgate - this
torque. Lubricate the hinge pin before fitting;
channel of the scissors type mechanism with
will vary according to model and equipment.
fit the pin with its circlip end facing outwards.
silicone grease (see illustration). Tension the
Remove the tailgate trim panel if necessary to
cable on the electric mechanism by turning
carry out the disconnections.
22 Tailgate strut - removal and
the adjusters through 90°.
3 Disconnect the struts from the tailgate - see
refitting
7 Check for correct operation before refitting
Section 22.
the door trim. On Convertible models the
4 Extract the hinge pin circlips and press or
operation of the window can be adjusted by
drive out the hinge pins (see illustration). Lift
Removal
slackening the mounting bolts and
away the tailgate.
1 Open the tailgate and have an assistant
repositioning the window guide. Find the
support it.
place where the window operates the
Refitting
2 Release the strut from its mounting
smoothest the securely tighten the bolts.
5 Refit in the reverse order to removal. Note
balljoints by prising the spring clips a little way
that the circlip ends of the hinge pins face
out and pulling the strut off the balljoints (see
outwards. Lubricate the pins before fitting.
19 Door window - removal and
illustration). If the strut is to be re-used, do
refitting
Removal
1 Remove the door trim panel as described in
Section 12.
2 Remove the window weatherstrip from the
top of the opening in the door.
3 In the case of the rear door, unbolt and
remove the rear guide rail, then remove the
fixed part of the window complete with seal.
4 If a scissors type lifter is fitted to the front
door remove the rear guide rail. If a cable type
lifter is fitted, unbolt the lifter from the glass
channel.
19.6 Adjusting the rear window guide rail
20.4 Tailgate hinge showing circlip
There is another locknut behind the panel
(arrowed)
Bodywork and fittings 11•9
22.2 Releasing a tailgate strut spring clip
23.2 Tailgate lock retaining screws
23.3 Lock operating rod connection to arm
(arrowed) - Hatchback
(arrowed)
not remove the spring clips completely, nor
3 Unhook the operating rod from the lock
prise them out further than 6 mm (0.24 in).
cylinder arm (see illustration). It may be
25 Boot lid and torsion rods -
3 Dispose of used struts carefully, since they
necessary to unbolt the lock cylinder in order
removal and refitting
contain gas under pressure.
to disengage the rod. Remove the lock and
rod together.
Refitting
4 If a new lock is being fitted, transfer the
Removal
4 Refit in the reverse order to removal.
spring and rod to it.
1 Open the boot.
2 Draw alignment marks between the boot lid
Refitting
23 Tailgate lock - removal and
and the hinge brackets on both sides of the
5 Refit in the reverse order to removal. Check
refitting
vehicle.
for correct operation before refitting the trim
3 On models with central locking, disconnect
panel.
the lock motor connector. The connector is
Removal
located in the left-hand corner of the boot.
1 Remove the tailgate trim panel by releasing
24 Tailgate lock cylinder -
4 With the aid of an assistant, support the
its retaining clips.
removal and refitting
boot lid and undo the hinge bolts
(see
2 Remove the retaining screws from the lock
illustration). Remove the boot lid.
(see illustration). There are three retaining
5 The torsion rods are held in place by their
Removal
screws on the Hatchback, four on the Estate
own spring tension. They can be removed by
and Van.
1 Remove the tailgate trim panel by releasing
carefully unhooking them first from the central
its retaining clips.
housing bracket, then from the hinge brackets
2 Remove the two retaining nuts, disengage
(see illustrations).
the lock operating rod and remove the lock
cylinder, complete with housing.
Refitting
3 Remove the lock cylinder from the housing
6 Refitting is the reverse of the removal
by driving out the roll pin, moving aside the
procedure. Observe the alignment marks if
catch and extracting the circlip
(see
refitting the original lid. If fitting a new lid, just
illustration). Remove the cylinder with the key
nip up the hinge bolts at first until satisfied
inserted.
4 Fit the new cylinder and secure with the
with the fit, then carry out final tightening.
circlip and roll pin.
Note: On early models it may be found that
despite correct alignment the boot lid
Refitting
contacts the rear screen at the centre of its
5 Refitting is a reversal of the removal
front edge. This can be remedied by fitting
24.3 Tailgate lock cylinder removal - roll
procedure. Check for correct operation before
rubber bump stops to limit the height of travel
pin and circlip arrowed
refitting the trim panel.
of the lid (see illustration 25.5b).
A Key number
11
25.4 Boot lid hinge bolts
25.5a Torsion rod central housing bracket
25.5b Hinge bracket assembly
1 Torsion rod
2 Bump stop
11•10 Bodywork and fittings
Refitting
5 Refit in the reverse order to removal.
29 Rear quarterlight (opening
type) - weatherstrip renewal
1 Remove the quarterlight, as described in
the previous Section.
2 Cut the old weatherstrip and rubber mount
from the body flange. Clean up the flange, but
do not remove the old adhesive completely.
3 Clean the mating face of the new
26.2 Boot lid lock securing screws
26.6 Boot lock catch retaining bolt (1),
weatherstrip with petrol or other suitable
spigots (2) and catch (3)
solvent, taking appropriate precautions.
10 Refitting is the reverse of the removal
4 Apply a 6 mm bead of polyurethane-based
26 Boot lid lock components -
procedure.
glass adhesive on top of the remains of the
old adhesive.
removal and refitting
5 Fit the new weatherstrip, refit the
27 Windscreen and other fixed
quarterlight and keep it closed for at least four
glass - removal and refitting
Boot lid lock assembly - removal
hours (or as advised by the makers of the
and refitting
adhesive) to allow the adhesive to set.
1 With the exception of the small fixed
1 Mark a line around the outer edge of the
windows in the rear passenger door, whose
lock assembly on the boot lid.
30 Exterior rear view mirror
removal is covered in Section 19, the fixed
2 Remove the securing screws
(see
glass is glued in position with adhesive.
components - removal and
illustration) and lift away the lock.
2 Special tools, equipment and expertise are
refitting
3 Refitting is the reverse of the removal
required for successful removal and refitting
procedure. Use the line marked before
of glass fixed by this method. The work must
removal as a guide to positioning the lock.
therefore be left to a GM dealer, a windscreen
Mirror glass
4 Check the operation of the lock by opening
specialist or other competent professional.
1 On all types, the mirror glass may be
and closing the boot lid several times. If
3 The same remarks apply if sealing of the
renewed separately.
necessary adjust the position of the lock or
windscreen or other glass surround is
2 Prise out the old glass (if intact) with a
catch.
necessary.
wooden wedge, and when applicable
Boot lock catch - removal,
disconnect the electrical cables. Engage the
refitting and adjustment
28 Rear quarterlight (opening
new glass with the linkage, connect the wires
5 Remove the protective trim panel from the
type) - removal and refitting
if applicable and snap the glass home (see
boot lip.
illustrations). Be careful when pressing the
6 Remove the retaining bolt. Disengage the
glass home: the sudden movement as the ball
Removal
catch spigots and remove it (see illustration).
enters its socket may cause the glass to
7 Refitting is the reverse of the removal
1 Unclip the interior trim panels from around
break.
procedure.
the quarterlight.
8 The height of the catch may be adjusted by
2 Remove the three screws which secure the
Mirror motor - electric mirror
slackening the retaining bolt and moving the
catch to the body.
3 To renew an electric mirror motor, prise out
catch up or down to provide satisfactory
3 Unscrew the two special nuts which hold
the glass as just described, undo the motor
closing and a snug fit with the edge seal.
the hinges to the front of the quarterlight.
securing screws and disconnect its
Remove the quarterlight and recover the
multi-plug. Fit the new motor in the reverse
Boot lid handle - removal and
hinge securing components.
order to removal.
refitting
4 Transfer the catch to the new quarterlight, if
Complete mirror - manual mirror
9 Open the boot and remove the two nuts,
applicable, by drilling out the connecting pin
accessible from inside, which secure the
and unscrewing the glass fitting. Use a new
4 To remove a manually adjusted mirror, pull
handle (see illustration).
connecting pin on reassembly.
off the adjuster handle and unclip the corner
26.9 Boot lid handle retaining nut
30.2a Remove the glass by levering with a
30.2b Engage the linkage and press the
wooden wedge
ball into the socket (arrowed)
Bodywork and fittings 11•11
30.4 Mirror retaining screws (arrowed)
31.1 Seat rail trim removal
31.2a Seat rail front retaining bolt
(one of two)
trim. Undo the three retaining screws and
Refitting
remove the mirror (see illustration).
4 Refit in the reverse order to removal, but
5 Refitting is the reverse of removal.
observe the following tightening sequence for
Complete mirror - electric mirror
the rail bolts:
6 Removal of the electrically adjusted mirror
a) Nip up the rear bolts.
is similar, but instead of pulling off the handle,
b) Tighten the front bolts to the specified
the wiring harness must be disconnected. The
torque.
harness connector is inside the door cavity.
c) Tighten the outboard rear bolt to the
7 Refitting is a reversal of the removal
specified torque.
procedure.
d) Tighten the inboard rear bolt to the
specified torque and refit the seat rail trim.
31 Front seat - removal and
31.2b Seat rail rear retaining bolt
refitting
32 Head restraints - removal and
(one of two)
refitting
Removal
33 Rear seat - removal and
Removal
1 Remove the trim which covers the seat
refitting
outboard rail. This trim is secured by a single
1 Both front and rear head restraints are
self-tapping screw at the front
(see
removed in the same way.
illustration).
2 Pull the head restraint up as far as it will go.
Removal
2 Remove the four bolts which secure the seat
3 Release the catch spring by pushing it
1 Uncover the hinges at the front of the seat.
rails to the floor (see illustrations). Remove the
rearwards and remove the head restraint. The
Free them by extracting the circlips and
seat, complete with rails; disconnecting the
catch springs are located on the left-hand
removing the hinge pins (see illustration).
seat heating wires (when fitted).
side on front seats and on the right-hand side
The bench section(s) of the seat can now be
3 The seat can be separated from the rails if
on rear seats.
removed if wished.
wished, for example if attention to the
4 The guide sleeves can be removed if
2 Unclip the carpet from the backrest (see
adjustment mechanisms is necessary.
necessary by releasing the retaining lugs with
illustration).
a screwdriver and pulling them upwards (see
3 Free the backrest from its catches, unscrew
illustration).
the side hinges and remove the backrest. If a
split seat is fitted, also separate the centre
Refitting
bearing. On Saloon models the rear seat
5 Refit in the reverse order to removal.
backrest catch is retained by a nut, accessible
from inside the boot (see illustrations).
11
32.4 Removing a head restraint guide
sleeve - push down with screwdriver to
33.1 Rear seat front hinge - circlip arrowed
33.2 Removing a carpet securing plug
release retaining lugs (arrowed)
11•12 Bodywork and fittings
33.3a Unscrewing the side hinge plate
33.3b Seat pivot lifts out of hinge
33.3c Unscrewing the centre hinge cover
33.3d Centre hinge top half bearing
33.3e Rear seat backrest catch retaining
33.5a Seat backrest catch striker -
nut - Saloon
Hatchback
34 Luggage area trim panel
35 Centre console - removal and
removal - general information
refitting
The ‘soft’ trim panels and carpets are
Removal
mostly retained by plastic plugs. These can be
levered out, but sometimes break. Where
1 The centre console is in two parts: the rear
more frequent removal is envisaged, eg for
half, surrounding the handbrake lever, and the
access to the spare wheel and tools, the
front half, which sits below the heater
plugs are of a different design and incorporate
controls.
pulling straps.
2 Commence removal with the rear half. Prise
The side covers may be removed by
out the screw cover and remove the securing
unbolting them and
(when applicable)
screw (see illustrations).
disconnecting the loudspeaker wires (see
3 Slide the console rearwards to free it.
illustration). They carry the rear parcel shelf
Removal of the front half may proceed without
catches on some models; the catches can be
further disturbing the rear; to remove the rear
removed simply by pulling them towards the
half completely, disconnect or remove any
centre of the vehicle.
switches from it and lift it over the handbrake
33.5b Rear seat backrest catch - Estate
Other ‘hard’ trim Panels are either clipped
lever.
1 Striker
or screwed into position.
4 Unclip the cover from around the base of
2 Distance to other striker = 1162 ± 2.5 mm
3 Backrest
4 Rear quarter panel
Refitting
4 Refit in the reverse order to removal. When
securing the split type backrest start at the
centre and work outwards.
5 If adjustment of the catch striker is
necessary, slacken the nut at the back of the
striker pin, engage the seat backrest and then
tighten the nut. This applies to Hatchback
models. No procedure is laid down for Estate
models; details of the catch construction are
as shown (see illustrations).
34.2 Removing a luggage area side panel
35.2a Centre console rear half screw cover
Bodywork and fittings 11•13
35.2b Removing the centre console rear
35.4a Centre console screw (arrowed) to
35.4b Centre console screw (arrowed) in
half screw
rear of gear lever
front of gear lever
5 Release the two retaining clips and remove
1 Inertia reel front seat belts are fitted to all
the oddments box from below the heater
models. According to trim level, these may
control panel.
have adjustable upper mountings. Rear seat
6 Remove the two screws which secure the
belts are available as an optional extra at time
console to the heater control panel
(see
of purchase, or as a kit for aftermarket fitting.
illustration). Withdraw the console.
2 Keep the belts untwisted so that they
retract into their reels when not in use.
Refitting
Occasionally check the function of the inertia
7 Refit in the reverse order to removal.
reel units by braking sharply from 5 mph
(traffic permitting): the belts should lock. A
36 Glovebox - removal and
defective unit must be renewed.
refitting
3 Only use soap and water to clean the belts.
Strong detergents, bleaches or dyes may
35.6 Centre console screw (arrowed)
weaken the webbing. After cleaning, keep the
below heater control panel
Removal
belts extended until they are dry.
the gear lever. There is no need to remove the
1 Open the glovebox and prise out the two
4 Belts which have been subject to impact
gear lever boot itself. Undo the two screws to
loads must be renewed.
check strap plugs (see illustration).
front and rear of the gear lever
(see
2 Support the glovebox and remove the two
5 When renewing a belt, note carefully the
illustrations). On automatic transmission
hinge bolts (see illustration). The glovebox
fitted sequence of mounting washers and
versions, remove the selector lever cover.
can now be removed.
spacers. Use new mounting components
when these are supplied, and tighten the
Refitting
mountings to the specified torque
(see
3 Refit in the reverse order to removal. Note
illustration).
that the hinge bolt holes are slotted to allow
6 Access to the adjustable top mounting is
for fine adjustment when fitting.
not immediately obvious. It is necessary to
remove the floor level trim strip, then free the
door seal from the pillar. The pillar trim can
37 Seat belts - general
then be pulled inwards to free its top and
centre mountings, then slid downwards to
Warning: If the vehicle has been
release the bottom lip. Notice how the belt
involved in an accident in which
feeds through the pillar trim
(see
structural damage was
illustrations).
sustained all the seat belt
7 Access to the rear inertia reel is gained by
36.1 Glovebox check strap disconnected
components must be renewed.
removing most of the rear quarter trim panels;
11
36.2 Glovebox hinge bolt
37.5 Front seat belt inertia reel and lower
37.6a Front seat belt adjustable top
mounting bolts (arrowed)
mounting
11•14 Bodywork and fittings
37.6b Belt feeds through guide in pillar trim
37.7a Rear seat belt inertia reel
37.7b Rear seat belt upper mounting
on 5-door models the door seal will have to be
the handle clockwise when the roof is closed
disturbed to remove the panels. Access to the
causes its rear end to tilt up for ventilation.
floor mountings is gained by folding the seat
2 A louvered panel, known as a sunshade,
forwards (see illustrations).
can be drawn out under the glass. This should
only be done when the glass is closed or in
the ‘tilt’ position.
38 Sunroof - operation and
3 Maintenance is confined to checking
maintenance
periodically that the drain hoses are not
blocked at their lower ends.
1 A slide-and-tilt glass panel sunroof is
4 No lubrication or other maintenance is
available as an optional extra on most models.
specified.
It is operated by a crank handle. After
depressing the release button, turning the
handle anti-clockwise open the roof. Turning
37.7c Rear seat belt floorpan mounting
12•1
Chapter 12
Body electrical system
Contents
Battery - removal and refitting
See Chapter 5A
Heated seats - general information
17
Battery check and maintenance
See Chapter 1
Horn(s) - removal and refitting
5
Bulbs - renewal
11
Instrument panel - removal and refitting
8
Central locking system - general information and component
Instrument panel - dismantling and reassembly
9
renewal
16
Loudspeakers - removal and refitting
26
Check control system - general information
24
Radio aerial - removal and refitting
27
Cigarette lighter - removal and refitting
7
Radio/cassette unit - removal and refitting
25
Clock - removal and refitting
6
Speedometer cable - removal and refitting
10
Electrical fault finding - general information
2
Switches - removal and refitting
4
Headlamp/direction indicator lens assembly - removal and refitting .12
Tailgate contact pins and plate - removal and refitting
18
Fuses and relays - general information
3
Rear window wiper motor- removal and refitting
21
General information
1
Trip computer - general information and component renewal
15
Headlamp beam adjustment - general information
13
Windscreen/rear window washer system - general information
22
Headlamp dim-dip system (UK models only) - general information . .14
Windscreen wiper motor and linkage - removal and refitting
20
Headlamp washer system - general information
23
Wiper blades and arms - removal and refitting
19
Degrees of difficulty
Easy, suitable for
Fairly easy, suitable
Fairly difficult,
Difficult, suitable for
Very difficult,
novice with little
for beginner with
suitable for competent
experienced DIY
suitable for expert
experience
some experience
DIY mechanic
mechanic
DIY or professional
Specifications
General
System type
12 volt, negative earth
Fuses - early models
Fuse Rating (amps)
Circuit(s) protected
1
10
LH side and tail lamps
2
10
RH side and tail lamps, instrument and engine compartment
illumination
3
10
LH main beam
4
10
RH main beam
5
10
LH dipped beam
6
10
RH dipped beam
7
10
Not used
8
10
Direction indicators, stop lamps and foglamp relay
9
30
Wipers and washers
10
10
Rear foglamp
11
30
Horn and radiator fan
12
20
Heater blower
13
20
Reversing lamps, cigarette lighter, carburettor pre-heating, electric
mirrors and glovebox lamp
14
20
Interior lights, hazard warning flasher, clock and radio
15
20
Trailer feed (terminal 30)
12
16
20
Fuel injection control unit
17
20
Front foglamps
18
20
Heated rear window
Note: Not all items fitted to all models
12•2 Body electrical system
Fuses - early models
Fuse Rating (amps)
Circuit(s) protected
1
10
LH side and tail lamps, instrument and engine compartment
illumination, “lights-on” warning buzzer
2
10
RH side and tail lamps, number plate lamps
3
10
LH main beam
4
10
RH main beam
5
10
LH dipped beam
6
10
RH dipped beam
7
10
Not used
8
15
Direction indicators, stop lamps and foglamp relay, ABS relay
9
30
Wipers and washers
10
10
Rear foglamp
11
30
Horn and radiator fan
12
20
Heater blower
13
20
Reversing lamps, cigarette lighter, carburettor pre-heating, electric
mirrors and glovebox lamp
14
20
Trailer feed (terminal 30)
15
15
Interior lights, hazard warning flasher, clock and radio
16
20
Fuel injection control unit
17
20
Front foglamps
18
20
Heated rear window
19
20
Central locking
20
30
Electric windows
Note: Not all items fitted to all models. Fuses 19 and 20 are located on the underside of the fusebox. On Convertible models (where applicable),
the fuse for the power hood system is located on the left-hand suspension strut in the engine compartment.
Bulbs
Lamp
Wattage
Headlamp
60/55
Front parking lamp
4
Front foglamp
55
Direction indicator lamp
21
Stop/tail lamp
21/5
Rear number plate lamp
10
Reversing lamp
21
Engine compartment lamp
10
Luggage compartment lamp
10
Glovebox:
Early models
5
Later models
10
Instrument warning lamps
1.2
Cigar lighter illumination
1.2
Switch illumination
1.2
Rear foglamps
21
Ashtray lamp
1.2
Clock illumination
1.2
Selector lever index (automatic transmission)
1.2
Direction indicator side repeater lamp
5
Vehicle interior lamp
10
Information on the battery, alternator and
particularly where an electronic control
starter motor can be found in Chapter 5A.
module is used.
1 General information
It should be noted that prior to working on
General
any component in the electrical system, the
Warning: Before carrying out
battery negative terminal should first be
1 A typical electrical circuit consists of an
any work on the electrical
disconnected to prevent the possibility of
electrical component, any switches, relays,
system, read through the
motors, fuses, fusible links or circuit breakers
electrical short circuits and/or fires.
precautions given in Safety
related to that component, and the wiring and
First! at the beginning of this
connectors which link the component to both
manual and Chapter 5
2 Electrical fault finding - general
the battery and the chassis. To help to
The electrical system is of the
12 volt
information
pinpoint a problem in an electrical circuit,
negative earth type. Power for the lights and
wiring diagrams are included at the end of this
all electrical accessories is supplied by a
Note: Refer to the precautions given in `Safety
Manual.
lead/acid type battery which is charged by the
first!’ and in Section 1 of this Chapter before
2 Before attempting to diagnose an electrical
alternator.
starting work. The following tests relate to
fault, first study the appropriate wiring
This Chapter covers repair and service
testing of the main electrical circuits, and
diagram to obtain a complete understanding
procedures for the various electrical
should not be used to test delicate electronic
of the components included in the particular
components not associated with engine.
circuits (such as anti-lock braking systems),
circuit concerned. The possible sources of a
Body electrical system 12•3
fault can be narrowed down by noting if other
11 Switch on the circuit, bearing in mind that
faulty, dismantle the connection and clean
components related to the circuit are
some circuits are live only when the ignition
back to bare metal both the bodyshell and the
operating properly. If several components or
switch is moved to a particular position.
wire terminal or the component earth
circuits fail at one time, the problem is likely to
12 If voltage is present (indicated either by
connection mating surface. Be careful to
be related to a shared fuse or earth
the tester bulb lighting or a voltmeter reading,
remove all traces of dirt and corrosion, then
connection.
as applicable), this means that the section of
use a knife to trim away any paint, so that a
3 Electrical problems usually stem from
the circuit between the relevant connector
clean metal-to-metal joint is made. On
simple causes, such as loose or corroded
and the battery is problem-free.
reassembly, tighten the joint fasteners
connections, a faulty earth connection, a
13 Continue to check the remainder of the
securely; if a wire terminal is being refitted,
blown fuse, a melted fusible link, or a faulty
circuit in the same fashion.
use serrated washers between the terminal
relay (refer to Section 3 for details of testing
14 When a point is reached at which no
and the bodyshell to ensure a clean and
relays). Visually inspect the condition of all
voltage is present, the problem must lie
secure connection. When the connection is
fuses, wires and connections in a problem
between that point and the previous test point
remade, prevent the onset of corrosion in the
circuit before testing the components. Use
with voltage. Most problems can be traced to
future by applying a coat of petroleum jelly or
the wiring diagrams to determine which
a broken, corroded or loose connection.
silicone-based grease or by spraying on (at
terminal connections will need to be checked
regular intervals) a proprietary ignition sealer.
in order to pinpoint the trouble spot.
Finding a short circuit
4 The basic tools required for electrical fault-
15 To check for a short circuit, first
3 Fuses and relays - general
finding include a circuit tester or voltmeter (a
disconnect the load(s) from the circuit (loads
12-volt bulb with a set of test leads can also
information
are the components which draw current from
be used for certain tests); a self-powered test
a circuit, such as bulbs, motors, heating
light (sometimes known as a continuity tester);
1 All the car’s electrical circuits are protected
elements, etc).
an ohmmeter (to measure resistance); a
by fuses; most of the fuses are found in a
16 Remove the relevant fuse from the circuit,
battery and set of test leads; and a jumper
fuse/relay box located under a cover to the
and connect a circuit tester or voltmeter to the
wire, preferably with a circuit breaker or fuse
right of and below the steering column (see
fuse connections.
incorporated, which can be used to bypass
illustration).
17 Switch on the circuit, bearing in mind that
suspect wires or electrical components.
2 Typical fuse applications are given in the
some circuits are live only when the ignition
Before attempting to locate a problem with
Specifications; model specific information will
switch is moved to a particular position.
test instruments, use the wiring diagram to
be found printed on the fuse/relay box lid.
18 If voltage is present (indicated either by
determine where to make the connections.
3 The fuses are of the ‘blade’ type. Their
the tester bulb lighting or a voltmeter reading,
5 To find the source of an intermittent wiring
ratings are printed on their backs and
as applicable), this means that there is a short
fault
(usually due to a poor or dirty
additionally they are colour-coded. A blown
circuit.
connection, or damaged wiring insulation), a
fuse may be recognised by its melted or
19 If no voltage is present, but the fuse still
`wiggle’ test can be performed on the wiring.
missing wire link.
blows with the load(s) connected, this
This involves wiggling the wiring by hand to
4 When renewing a fuse, switch off the
indicates an internal fault in the load(s).
see if the fault occurs as the wiring is moved.
circuit(s) concerned first. If the new fuse blows
It should be possible to narrow down the
Finding an earth fault
immediately when switching on, find and
source of the fault to a particular section of
rectify the cause. The most usual cause of a
20 The battery negative terminal is
wiring. This method of testing can be used in
blown fuse if a short-circuit to earth
connected to
`earth’
- the metal of the
conjunction with any of the tests described in
somewhere along the wire feeding the
the following sub-Sections.
engine/transmission and the car body - and
component concerned. The wire may be
most systems are wired so that they only
6 Apart from problems due to poor
disconnected, trapped or frayed. Pay special
connections, two basic types of fault can
receive a positive feed, the current returning
attention to wire runs through grommets,
occur in an electrical circuit - open circuit, or
via the metal of the car body. This means that
under carpets etc.
short circuit.
the component mounting and the body form
5 Where a blown fuse serves more than one
7 Open circuit faults are caused by a break
part of that circuit. Loose or corroded
component, the defective circuit can be
somewhere in the circuit, which prevents
mountings can therefore cause a range of
traced by switching on each component in
current from flowing. An open circuit fault will
electrical faults, ranging from total failure of a
turn until the replacement fuse blows.
circuit, to a puzzling partial fault. In particular,
prevent a component from working, but will
6 Never attempt to bypass a fuse with silver
not cause the relevant circuit fuse to blow.
lights may shine dimly
(especially when
foil or wire, nor fit a fuse of a higher rating than
another circuit sharing the same earth point is
8 Short circuit faults are caused by a `short’
specified. Serious damage, or even fire, may
somewhere in the circuit, which allows the
in operation), motors (eg. wiper motors or the
result.
current flowing in the circuit to `escape’ along
radiator cooling fan motor) may run slowly,
an alternative route, usually to earth. Short
and the operation of one circuit may have an
circuit faults are normally caused by a
apparently unrelated effect on another. Note
breakdown in wiring insulation, which allows a
that on many vehicles, earth straps are used
feed wire to touch either another wire, or an
between certain components, such as the
earthed component such as the bodyshell. A
engine/transmission and the body, usually
short circuit fault will normally cause the
where there is no metal-to-metal contact
relevant circuit fuse to blow.
between components due to flexible rubber
mountings, etc.
Finding an open circuit
21 To check whether a component is
9 To check for an open circuit, connect one
properly earthed, disconnect the battery and
lead of a circuit tester or voltmeter to either
connect one lead of an ohmmeter to a known
the negative battery terminal or a known good
good earth point. Connect the other lead to
12
earth.
the wire or earth connection being tested. The
10 Connect the other lead to a connector in
resistance reading should be zero; if not,
3.1 Removing the cover from the fuse/relay
the circuit being tested, preferably nearest to
check the connection as follows:
box
the battery or fuse.
22 If an earth connection is thought to be
12•4 Body electrical system
3.8a Relay identification
3.7a Headlamp washer relay and fuse
3.7b Removing the headlamp washer fuse
A Flasher unit
B Heated rear window relay
7 Models with a full range of optional
Hazard warning switch
C Windscreen wiper relay/delay unit
equipment may carry one or two fuses on the
4 This is removed and refitted in the same
D Front foglamp relay
other side of the fuse/relay box. When a
way as the lighting master switch.
headlamp washer system is fitted, its fuse and
relay are mounted under the bonnet on the
Foglamp switch
left-hand
suspension
turret
(see
5 Carefully prise the switch from its location,
illustrations).
disconnect its wires and withdraw it (see
8 All models have some relays on the
illustration).
accessible side of the fuse/relay box;
6 Refit in the reverse order to removal.
according to equipment level, some other
relays may be found on the reverse side.
Instrument illumination control
Unclip the box to gain access. The relays are
7 Remove the instrument panel surround, as
as shown (see illustrations)..
described in Section 8.
9 A relay is essentially an electrically-
8 Slacken the securing screw and remove the
operated switch. If a circuit served by a relay
illumination control (see illustration).
becomes inoperative, remember that the relay
could be at fault. Test by substitution of a
9 Refit in the reverse order to removal.
known good relay.
3.8b Fuse and relay identification (reverse
Heater blower/heated rear
side of fusebox)
window switch
E Trip computer relay
4 Switches - removal and refitting
10 This switch is released in a similar way to
F Rear wiper relay (not GTE)
the lighting master switch. If the switch
G Day running lamp relay (not UK)
cannot be released, withdraw the heater
H Headlamp cut-out (not UK)
1 Before removing a switch, disconnect the
control panel, as described in Chapter 3.
I
“Lights-on” warning buzzer
battery negative lead.
11 Refit in the reverse order to removal.
19 Central locking fuse
Lighting master switch
20 Electric window winder fuse
Steering column switches
2 Release the spring clips at the side of the
12 Although not strictly necessary, access
switch by pressing them with a bent
will be improved if the steering wheel is
withdraw either of the multi-function switches.
screwdriver or similar tool. Draw the switch
removed, as described in Chapter
10.
In practice it was found necessary, when the
out of the facia, disconnect its wiring plug and
Otherwise, remove the wheel centre trim.
adjustable wheel was fitted, to undo the two
remove it (see illustration). If the switch
13 Remove the upper and lower switch
switch housing screws and draw the switch
cannot be released, remove the instrument
panel surround, as described in Section 8.
shrouds. These are held in place by eight
assembly up the column slightly. The switch
3 To refit, connect the wiring plug to the
screws with the fixed type steering wheel, or
in question can then be unplugged, unclipped
switch and press the switch home until the
five screws with the adjustable wheel.
and removed (see illustrations).
clips snap into place.
14 In theory it is now possible to unclip and
15 Refit in the reverse order to removal.
4.2 Removing the lighting master switch -
4.5 Removing a foglamp switch
4.8 Removing the instrument illumination
one of the spring clips is arrowed
control
Body electrical system 12•5
Refitting
3 Refit in the reverse order to removal.
7 Cigarette lighter - removal and
refitting
Removal
1 Disconnect the battery earth lead.
2 Extract the heater element from the lighter
socket.
3 Carefully prise the lighter socket out of the
4.14a Drawing the steering column
4.14b Unclipping a steering column switch
illuminating ring. Unplug the socket and
switches up the column
- assembly removed for clarity
remove it.
Ignition/starter switch
26 Refit in the reverse order to removal.
Refitting
Check for correct operation before refitting
16 Refer to Chapter 5.
4 Refit in the reverse order to removal. When
any trim.
inserting the socket into the illuminating ring,
Stop-lamp switch
make sure that the ring lugs pass over a
17 Remove the stop-lamp switch by turning
smooth part of the socket; twist the socket
5 Horn(s) - removal and refitting
it
90° left or right and withdrawing it from its
clockwise when home to engage the lugs.
bracket.
18 Before fitting the stop-lamp switch, pull its
8 Instrument panel - removal and
plunger out as far as it will go. The switch will
Removal
adjust itself once it is fitted.
refitting
1 The horn itself is located in front of the
radiator, unless an oil cooler is fitted, when it
Handbrake warning switch
is located behind the battery. Disconnect and
Removal
19 Proceed as described in Chapter
9,
unbolt the horn to remove it; remove the front
Section 19, but without disconnecting the
trim panel if necessary for access.
1 Disconnect the battery earth lead.
handbrake lever from the yoke.
2 On models with twin horns, the second
2 Remove the horn push from the steering
horn is mounted behind the front grille on the
wheel.
Electric mirror switch
left-hand side. To gain access to it, either the
3 Remove the steering column switch upper
20 Free the rear half of the centre console, as
front grille or the radiator must be removed.
shroud, which is secured by four screws.
described in Chapter 11.
3 If the horn does not work, check with a 12
Unlock the steering and turn the wheel as
21 Disconnect and unclip the switch.
volt test lamp that voltage is present at the
necessary to gain access to two of the
22 Refit in the reverse order to removal.
horn terminals when the horn push is
screws.
operated. If the horn itself is defective it must
4 Remove the four screws which secure the
Electric window winder switch
be renewed.
instrument panel surround and bottom trim
23 Proceed as described above for the
strip. There are two screws at the top and one
Refitting
electric mirror switch.
in each bottom corner; they may be covered
4 Refit in the reverse order to removal.
by cosmetic caps (see illustration).
Interior light switches
5 Withdraw the instrument panel surround,
24 The main interior light is operated by door
disconnecting the wires from the various
plunger switches. Similar switches control the
6 Clock - removal and refitting
switches (see illustration).
luggage area and glovebox light, when fitted.
6 Except on the LCD instrument panel,
25 Removal is similar in every case. After
disconnect the speedometer cable by
displacing any trim which may be in the way,
Removal
depressing its retaining clip and pulling it
the switch is unscrewed or unclipped and
away from the speedometer.
withdrawn from its location
(see
1 Disconnect the battery earth lead.
illustrations). The electrical lead(s) can then
2 Carefully pull the clock from its location.
7 Remove the single securing screw and
be unplugged and the switch removed. Tape
Disconnect the supply and illumination leads
withdraw the instrument panel
(see
the wires if necessary to avoid losing them
from the clock and remove it
(see
illustrations). Disconnect the electrical leads
inside the switch hole.
illustration).
if the panel is to be removed completely,
12
4.25a Glovebox light switch unclipped from
4.25b Luggage area light switch (arrowed)
6.2 Removing the clock
its location
next to contact plate on tailgate sill
12•6 Body electrical system
8.4 Removing an instrument panel
8.5 Withdrawing the instrument panel
8.7a Removing the instrument panel
surround screw
surround
securing screw
making notes if there is any possibility of
confusion later. When an econometer is fitted,
disconnect the vacuum hose.
Refitting
8 Refit in the reverse order of removal. On
models with an LCD display, prior to refitting,
ensure that the speedometer frequency code
switch is set to the correct position
(see
illustration). On models with 175/70 R 13 or
185/60 R 14 tyres set the switch to position 1,
and on all other models set the switch to
position 2.
8.7b Withdrawing the instrument panel
8.8 LCD instrument frequency code switch
9 Instrument panel - dismantling
shown in position 1
and reassembly
this
- just withdraw it far enough to gain
3 Working under the bonnet, free the cable
access to the printed circuit.
grommet from the bulkhead and draw the
1 No attempt must be made to dismantle the
4 The printed circuit can be renewed if all the
cable into the engine bay. Recover the
LCD type instrument panel: its bulbs can be
instruments etc are transferred from the old
grommet.
renewed, but that is all. Consult a GM dealer if
one.
4 Undo the knurled nut which secures the
an instrument fault is suspected: special test
cable to the transmission (or trip computer
equipment is required for accurate diagnosis.
speed sender, when fitted). Remove the
2 Individual instruments can be removed
10 Speedometer cable - removal
cable.
from the conventional instrument panel after
and refitting
removing the cover, which is secured by two
Refitting
screws at the top and three lugs at the
5 Refit in the reverse order to removal. The
bottom. The instruments are secured by
Removal
cable must not be kinked or made to bend
screws or nuts (see illustration).
1 A mechanical cable is not used with the
sharply. If lubricant is applied to the inner
3 Illumination and warning lamp bulbs can be
LCD instrument panel; the electrical sender
cable, do not put any on the top 15 cm or so,
removed by turning the combined bulb and
bolts onto the gearbox in the same position as
in case it gets into the speedometer head.
holder anti-clockwise and withdrawing it from
the conventional cable.
the rear of the panel. There is no need to
2 To renew a mechanical cable, first
remove the instrument panel completely to do
disconnect it from the speedometer head. If it
11 Bulbs - renewal
is not possible to reach up behind the
instrument panel, partly withdraw it, as
described in Section 8 (see illustration).
General
1 Whenever a bulb is renewed, note the
following points.
a) Disconnect the battery negative lead
before starting work.
b) Remember that if the light has just been
in use the bulb may be extremely hot.
c) Always check the bulb contacts and
holder, ensuring that there is clean metal-
to-metal contact between the bulb and its
live(s) and earth. Clean off any corrosion
9.2 Instrument panel rear view (typical)
or dirt before fitting a new bulb.
A Speedometer retaining screws
d) Wherever bayonet-type bulbs are fitted
B Fuel/temperature gauge retaining nuts
(see Specifications) ensure that the live
C Tachometer retaining nuts
10.2 Speedometer cable at instrument
contact(s) bear firmly against the bulb
D Instrument voltage stabiliser
panel end
contact.
Body electrical system 12•7
11.2a Disconnecting the headlamp wiring
11.2b Rubber cover removed to expose the
11.3 Removing a headlamp bulb
plug
spring clip
e) Always ensure that the new bulb is of the
Sidelamp (front parking lamp)
12 Unclip and remove the bulb, separating its
correct rating and that it is completely
electrical connector at the first junction, not at
6 Open the bonnet and disconnect the wiring
clean before fitting it; this applies
the bulb itself.
plug from the sidelamp bulb holder.
particularly to headlight/foglight bulbs.
13 Do not touch the bulb glass: see
7 Remove the bulb holder by depressing it
paragraph 4.
Headlamp
and twisting it anti-clockwise
(see
14 Connect the new bulb. secure it and refit
2 Open the bonnet and disconnect the wiring
illustration).
the lamp cover.
plug from the rear of the headlamp unit.
8 Extract the old bulb from the holder and
Remove the rubber cover to expose the
insert the new one. Refit and reconnect the
Rear lamp cluster
spring clip which secures the bulb
(see
bulb holder.
15 Remove the trim panel or access cover
illustrations).
Front direction indicator
from the area of the rear lamp cluster.
3 Release the spring clip and withdraw the
16 Disconnect the wiring plug, depress the
bulb (see illustration). Be careful if it has just
9 Open the bonnet. Remove the bulb holder
bulb holder retaining lug And withdraw the
been in use, it may be very hot.
by squeezing its legs together and twisting it
bulb holder (see illustrations).
4 Do not touch the bulb glass with the
anti-clockwise (see illustration).
17 The rear lamp unit itself can be removed
fingers: traces of grease can blacken the
10 Fit the new bulb and refit the bulb holder.
glass and shorten bulb life. Use a clean cloth
after undoing the three retaining screws (two
moistened with methylated spirit to clean a
Front foglamp
on Estates) (see illustrations).
bulb which has been accidentally touched.
18 Refit in the reverse order to removal. If the
11 Working under the front bumper, remove
5 Fit the new bulb in the reverse order to
lamp unit has been removed, make sure its
the rear cover from the lamp unit by twisting it
removal. Make sure that the lugs on the bulb
retaining plates are correctly fitted before
anti-clockwise.
engage in the recesses in the bulb holder.
tightening the retaining screws.
11.7 Removing a sidelamp bulb and holder
11.9 Removing a direction indicator bulb
11.16a Rear lamp cluster wiring plug (A)
and holder
and retaining lug (B)
12
11.16b Rear lamp cluster bulbs and holder
11.17a Rear lamp unit retaining screws
11.17b Removing a rear lamp lens
(arrowed) Hatchback