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- 1994 Omega
- Service And Repair Manual
Vauxhall 1994 Omega Service And Repair Manual
Summary of 1994 Omega
Page 2: Vauxhall/opel Omega
3510 vauxhall/opel omega vauxhall/opel omega service and repair manual mark coombs and spencer drayton models covered vauxhall omega saloon and estate models with petrol engines, including special/limited editions 1998 cc, 2498 cc & 2969 cc petrol engines does not cover diesel engine or bi-fuel (lpg...
Page 3: Contents
3510 vauxhall/opel omega contents living with your vauxhall omega introduction page 0•4 safety first! Page 0•5 roadside repairs introduction page 0•6 if your car won’t start page 0•6 jump starting page 0•7 wheel changing page 0•8 identifying leaks page 0•9 towing page 0•9 weekly checks introduction ...
Page 4: Contents
3510 vauxhall/opel omega contents repairs & overhaul engine and associated systems 2.0 litre sohc engine in-car repair procedures page 2a•1 2.0 litre dohc engine in-car repair procedures page 2b•1 2.5 and 3.0 litre engine in-car repair procedures page 2c•1 general engine overhaul procedures page 2d•...
Page 5: The Vauxhall Omega Team
0•4 introduction 3510 vauxhall/opel omega the vauxhall omega was introduced into the uk in april of 1994 as a replacement for the vauxhall carlton and senator. At its launch, the omega was available in both saloon and estate body styles with a choice of either 2.0 litre (1998 cc) or a 2.5 litre (249...
Page 6: General Hazards
Safety first! 0•5 3510 vauxhall/opel omega working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude. General hazards scalding • don’t remove the radiator or expansion tank cap while the engine is hot. • e...
Page 7: If Your Car Won’T Start
0•6 roadside repairs 3510 vauxhall/opel omega the following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair information in the main chapters. If your car won’t start and...
Page 8: Jump Starting
Roadside repairs 0•7 3510 vauxhall/opel omega jump starting will get you out of trouble, but you must correct whatever made the battery go flat in the first place. There are three possibilities: 1 the battery has been drained by repeated attempts to start, or by leaving the lights on. 2 the charging...
Page 9: Wheel Changing
0•8 roadside repairs 3510 vauxhall/opel omega wheel changing some of the details shown here will vary according to model. Warning: do not change a wheel in a situation where you risk being hit by another vehicle. On busy roads, try to stop in a lay-by or a gateway. Be wary of passing traffic while c...
Page 10: Identifying Leaks
Roadside repairs 0•9 3510 vauxhall/opel omega puddles on the garage floor or drive, or obvious wetness under the bonnet or underneath the car, suggest a leak that needs investigating. It can sometimes be difficult to decide where the leak is coming from, especially if the engine bay is very dirty al...
Page 11: Introduction
0•10 weekly checks 3510 vauxhall/opel omega there are some very simple checks which need only take a few minutes to carry out, but which could save you a lot of inconvenience and expense. These "weekly checks" require no great skill or special tools, and the small amount of time they take to perform...
Page 12: Engine Oil Level
Weekly checks 0•11 3510 vauxhall/opel omega engine oil level before you start 4 make sure that your car is on level ground. 4 check the oil level before the car is driven, or at least 5 minutes after the engine has been switched off. The correct oil modern engines place great demands on their oil. I...
Page 13: Power Steering Fluid Level
0•12 weekly checks 3510 vauxhall/opel omega brake and clutch* fluid level *on manual transmission models the brake fluid reservoir also supplies fluid to the clutch master cylinder. Warning: l brake fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pourin...
Page 14: Battery
Weekly checks 0•13 3510 vauxhall/opel omega battery caution: before carrying out any work on the vehicle battery, read the precautions given in "safety first" at the start of this manual. 4 make sure that the battery tray is in good condition, and that the clamp is tight. Corrosion on the tray, reta...
Page 15: Tyre Condition and Pressure
0•14 weekly checks 3510 vauxhall/opel omega tyre condition and pressure it is very important that tyres are in good condition, and at the correct pressure - having a tyre failure at any speed is highly dangerous. Tyre wear is influenced by driving style - harsh braking and acceleration, or fast corn...
Page 16: Wiper Blades
Weekly checks 0•15 3510 vauxhall/opel omega wiper blades check the condition of the wiper blades; if they are cracked or show any signs of deterioration, or if the glass swept area is smeared, renew them. Wiper blades should be renewed annually. 1 to remove a windscreen wiper blade, pull the arm ful...
Page 17: Lubricants and Fluids
0•16 lubricants and fluids 3510 vauxhall/opel omega lubricants and fluids engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multigrade engine oil, viscosity sae 10w/40 to 15w/50 to api sg/cd or sh/cd (duckhams qxr premium petrol engine oil or duckhams hyp...
Page 18: Tyre Pressures
Tyre pressures 0•17 3510 vauxhall/opel omega tyre pressures note: pressures apply to original-equipment tyres only and may vary if any other make or type of tyre is fitted; check with the tyre manufacturer or supplier for correct pressures if necessary. Note: tyre pressures must always be checked wi...
Page 19: Chapter 1
1•1 1 3510 vauxhall/opel omega chapter 1 routine maintenance and servicing air filter element - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 automatic transmission fluid - renewal . . . . . . . . . . . . . . . . . . . . . . . 25 automatic transmission fluid level - ch...
Page 20
Lubricants and fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to end of weekly checks on page 0•16 capacities engine oil 2.0 litre engine: sohc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 litres dohc engine: engines w...
Page 21
The maintenance intervals in this manual are provided with the assumption that you, not the dealer, will be carrying out the work. These are the minimum maintenance intervals recommended by us for vehicles driven daily. If you wish to keep your vehicle in peak condition at all times, you may wish to...
Page 22
1•4 maintenance - component location 3510 vauxhall/opel omega underbonnet view of a 2.0 litre dohc engine model 1 engine oil filler cap 2 air cleaner 3 front suspension strut upper mounting 4 brake (and clutch) fluid reservoir 5 relay box 6 cooling system expansion tank 7 battery 8 fusible link hous...
Page 23
Maintenance - component location 1•5 1 3510 vauxhall/opel omega front underbody view (2.0 litre dohc engine shown - others similar) 1 exhaust front downpipe 2 oil filter 3 engine oil drain plug 4 air conditioning system compressor 5 front suspension lower arm 6 steering outer tie rod 7 steering drop...
Page 24: Every 5000 Miles Or 6 Months
1 general information 1 this chapter is designed to help the home mechanic maintain his/her vehicle for safety, economy, long life and peak performance. 2 the chapter contains a master maintenance schedule, followed by sections dealing specifically with each task in the schedule. Visual checks, adju...
Page 25
It is screwed onto the oil pump housing, and on 2.5 and 3.0 litre engines it is screwed onto the left-hand side of the cylinder block (see illustration). 9 use an oil filter removal tool to slacken the filter initially, then unscrew it by hand the rest of the way. Empty the oil from the old filter i...
Page 26
7 proceed as described in paragraphs 2 to 4 inclusive, noting that the inspection aperture is at the rear of the caliper. 8 on completion, refit the rear roadwheels and lower the vehicle to the ground. 6 auxiliary drivebelt - check and renewal 3 check 1 although the drivebelt tension is automaticall...
Page 27
7 underbonnet/underbody hose and fluid leak - check 2 cooling system warning: refer to the safety information given in safety first and chapter 3 before disturbing any of the cooling system components. 1 carefully check the radiator and heater coolant hoses along their entire length. Renew any hose ...
Page 28
Air conditioning refrigerant warning: refer to the safety information given in safety first and chapter 3, regarding the dangers of disturbing any of the air conditioning system components. 12 the air conditioning system is filled with a liquid refrigerant, which is retained under high pressure. If ...
Page 29
7 check that the handbrake lever is still positioned on the third notch, then working underneath the vehicle, tighten the handbrake cable adjustment nut against the compensation bar, until the handbrake shoes just start to take effect - test for this by turning the brake discs by hand. 8 refit the r...
Page 30
Vertical adjustment. When adjusting the headlight aim, ensure that the facia -mounted range adjustment switch is set to position 0 (see paragraph 3). 3 all models have an electric headlight beam adjustment range system, controlled via a rotary switch in the facia*. The recommended settings are as fo...
Page 31
3 hinge the grille panel upwards to expose the pollen filter housing (see illustration). 4 release the clips at either side of the housing, then withdraw the pollen filter element (see illustrations). 5 slide the new filter element into the housing and secure it in position with the clips. 6 hinge t...
Page 32
C) undo the bolts securing the wiring harness cover to the inlet manifold and position the harness clear of the left-hand cylinder head spark plugs. D) unscrew the union nut and disconnect the braking system servo unit vacuum hose from the manifold. E) to improve access to the plugs on the right-han...
Page 33
15 remove the rubber hose (if used), and tighten the plug to the specified torque using the spark plug socket and a torque wrench. Refit the remaining spark plugs in the same manner. 16 securely reconnect the ht leads in their correct order. 17 on 2.0 litre dohc engines refit the spark plug cover an...
Page 34
26 brake fluid - renewal 3 warning: brake hydraulic fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouring it. Do not use fluid that has been standing open for some time, as it absorbs moisture from the air. Excess moisture can cause a dangerous loss o...
Page 35
18 slowly fill the system via the expansion tank filler neck, until the coolant level again reaches the kalt/cold mark on the side of the expansion tank (see illustration). All models 19 refit and tighten the expansion tank filler cap. 20 start the engine, and allow it to run until it reaches normal...
Page 36: Chapter 2 Part A:
3510 vauxhall/opel omega 2a•1 2a chapter 2 part a: 2.0 litre sohc engine in-car repair procedures general engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in-line, water-cooled. Single overhead camshaft, belt- driven, acting on ...
Page 37
Torque wrench settings nm lbf ft camshaft cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6 camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33 camshaft thrustplate bolts . . . . . . . . . . . . . . . . . ...
Page 38
1 general information how to use this chapter 1 this part of chapter 2 is devoted to in-car repair procedures for the engine. All procedures concerning engine removal and refitting, and engine block/cylinder head overhaul can be found in chapter 2d. 2 most of the operations included in this part are...
Page 39
5 using a socket and extension bar on the crankshaft sprocket bolt, turn the crankshaft whilst keeping an eye on the camshaft sprocket. Rotate the crankshaft until the timing mark on the camshaft sprocket is correctly aligned with the cutout on the top of the timing belt rear cover and the mark on t...
Page 40
3 undo the remaining retaining bolts then unclip the timing belt outer cover and remove it from the engine. Refitting 4 refitting is the reverse of removal, ensuring the auxiliary drivebelt is fitted the same way around as it was prior removal. Rear cover removal 5 remove the camshaft and crankshaft...
Page 41
Rotation, to bring the sprocket timing marks back into alignment. Check that the tensioner pointer is still correctly positioned in relation to the backplate cutout/marking (as applicable). 14 if the tensioner pointer is not correctly positioned in relation to the backplate, repeat the procedure in ...
Page 42
13 lock the crankshaft by the method used on removal, and tighten the sprocket retaining bolt to the specified stage 1 torque setting then angle-tighten the bolt through the specified stage 2 angle, using a socket and extension bar. It is recommended that an angle-measuring gauge is used during the ...
Page 43
Screwdriver. Ensure the housing is clean then press the in new seal, ensuring its sealing lip is facing inwards, until it is flush with the housing. 8 liberally lubricate the camshaft and housing bearings and the oil seal lip with fresh engine oil. 9 carefully insert the camshaft into the housing, t...
Page 44
4 remove the inlet and exhaust manifolds as described in chapter 4a. If no work is to be carried out on the cylinder head, the head can be removed complete with manifolds once the following operations have been carried out (see chapters 4a and 4b). A) remove the duct linking the air cleaner to the t...
Page 45
It is recommended that an angle-measuring gauge is used during this stage of the tightening, to ensure accuracy (see illustration). 31 working in the specified sequence, go around again and tighten all bolts through the specified stage 3 angle. 32 finally go around in the specified sequence again an...
Page 46
17 refit the flywheel lower cover plate to the transmission housing then refit the support brackets. Screw in the bolts securing the brackets to the cylinder block and transmission housing and tighten them to their specified torque settings. 18 reconnect the oil level sender wiring connector (where ...
Page 47
19 refit the pump housing retaining bolts in their original locations and tighten them to the specified torque. 20 reconnect the oil pressure sensor wiring connector. 21 refit the oil pump pick-up/strainer and sump as described in section 13. 22 refit the rear timing belt cover to the engine, tighte...
Page 48
4 lubricate the lips of the new seal with clean engine oil and ease it into position on the end of the shaft. Press the seal squarely into position until it is flush with the housing. If necessary, a suitable tubular drift, such as a socket, which bears only on the hard outer edge of the seal can be...
Page 49: Chapter 2 Part B:
3510 vauxhall/opel omega 2b•1 2b chapter 2 part b: 2.0 litre dohc engine in-car repair procedures general engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in-line, water-cooled. Double overhead camshaft, belt- driven manufacture...
Page 50
Torque wrench settings nm lbf ft camshaft bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6 camshaft cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6 camshaft sprocket bolt: stage 1 . . . . . . . . . . . . . . . . ....
Page 51
Torque wrench settings (continued) nm lbf ft oil pump pick-up/strainer bolts (continued): engines with two piece sump: pick-up-to-oil pump housing bolts . . . . . . . . . . . . . . . . . . . . . . . . . 8 6 pick-up-to-casting/balancer unit bolts: m6 bolts . . . . . . . . . . . . . . . . . . . . . . ...
Page 52
2 compression test - description and interpretation refer to chapter 2a, section 2. 3 top dead centre (tdc) for no 1 piston - locating 2 1 in its travel up and down its cylinder bore, top dead centre (tdc) is the highest point that each piston reaches as the crankshaft rotates. While each piston rea...
Page 53
Refitting 4 check that the crankshaft sprocket mark is still aligned with the mark on the oil pump housing then manoeuvre the crankshaft pulley into position. Align the notch on the pulley rim with the pointer then seat the pulley on the sprocket and tighten its retaining bolts to the specified torq...
Page 54
7 timing belt - removal and refitting 3 note: the timing belt must be removed and refitted with the engine cold. Removal 1 disconnect the battery negative terminal then position no1 cylinder at tdc on its compression stroke as described in section 3. Note: on models with a vauxhall anti-theft warnin...
Page 55
11 check the sprocket timing marks are still correctly aligned. If adjustment is necessary, release the tensioner again then disengage the belt from the sprockets and make any necessary adjustments. 12 using a socket on the crankshaft sprocket bolt, rotate the crankshaft smoothly through two complet...
Page 56
Engaged in the correct sprocket cutout then fit the washer and new retaining bolt. 9 retain the sprocket by the method used on removal, and tighten the sprocket retaining bolt to the specified stage 1 torque setting then angle-tighten the bolt through the specified stage 2 angle, using a socket and ...
Page 57
Caution: if the bearing cap bolts are carelessly slackened, the bearing caps might break. If any bearing cap breaks then the complete cylinder head assembly must be renewed; the bearing caps are matched to the head and are not available separately. 4 lift the camshaft out of the cylinder head and sl...
Page 58
A) remove the intake duct connecting the air cleaner to the throttle housing. B) disconnect the wiring connectors from the throttle potentiometer, idle speed adjuster, egr valve, purge valve, coolant temperature sensor, oxygen sensor and dis module. Unbolt the earth connection from the fuel rail and...
Page 59
24 once all bolts have been tightened to the stage 1 torque, again working in the sequence shown, tighten each bolt through its specified stage 2 angle, using a socket and extension bar. It is recommended that an angle- measuring gauge is used during this stage of the tightening, to ensure accuracy....
Page 60
28 to remove the main casting from the engine, disconnect the wiring connector from the oil temperature sensor (where fitted) then slacken and remove the bolts securing the exhaust front pipe mounting bracket in position. 29 unscrew the bolts securing the main casting flange to the transmission hous...
Page 61
11 clean the components, and carefully examine the gears, pump body and relief valve plunger for any signs of scoring or wear. Renew any component which shows signs of wear or damage; if the gears or pump housing are marked then the complete pump assembly should be renewed. 12 if the components appe...
Page 62
6 fit the spacer plate to the top of the balancer unit then refit the balancer unit to the cylinder block. Ensure the shaft gear is correctly engaged with the crankshaft gear, and screw in the new retaining bolts. 7 tighten all the bolts by hand then check that the crankshaft pulley mark and balance...
Page 63: Chapter 2 Part C:
3510 vauxhall/opel omega 2c•1 2c chapter 2 part c: 2.5 and 3.0 litre engine in-car repair procedures general engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V6 water-cooled. Double overhead camshaft, belt-driven 2.5 litre engine 3.0 litre eng...
Page 64
Torque wrench settings nm lbf ft auxiliary drivebelt tensioner bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26 baffle plate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6 camshaft bearing cap bolts . . . . . . . . . . . . . . ....
Page 65
1 general information how to use this chapter 1 this part of chapter 2 is devoted to in-car repair procedures for the engine. All procedures concerning engine removal and refitting, and engine block/cylinder head overhaul can be found in chapter 2d. 2 most of the operations included in this part are...
Page 66
C) renewal of the camshaft oil seals. D) removal and refitting of the camshafts and followers. E) removal and refitting of the sump. F) removal and refitting of the connecting rods and pistons*. G) removal and refitting of the oil pump. H) renewal of the crankshaft oil seals. I) renewal of the engin...
Page 67
8 remove the cover as described in paragraphs 3 and 4 (see illustration). Refitting right-hand cover 9 ensure the cover and cylinder head surfaces are clean and dry then fit the seals securely to the cover grooves. Fit the sealing rings to the recesses around each retaining bolt hole, holding them i...
Page 68
2 using a socket and extension bar on the crankshaft sprocket bolt, turn the crankshaft until the notch on the pulley rim is correctly aligned with the pointer on the cover. 3 slacken and remove the small retaining bolts securing the pulley to the crankshaft sprocket and remove the pulley from the e...
Page 69
9 slacken and remove the retaining bolts then remove the outer cover from the engine unit along with its seal (see illustration). Refitting 10 ensure the seal is firmly fixed to the cover prior to refitting. If necessary, glue it in position with a suitable adhesive (vauxhall recommend the use of ad...
Page 70
5 slacken the timing belt tensioner pulley nut. Using an allen key fitted to the hexagonal cutout, rotate the tensioner pulley clockwise so it is positioned just before its stop and hold it in position by securely tighten the retaining nut (see illustrations). 6 slacken the retaining bolts for the t...
Page 71
11 if the special tools are available lock the camshaft sprockets and crankshaft sprocket in position as described in paragraph 4. 12 examine the fitting marks on the outer face of the timing belt. The arrows on the belt must point in the direction of rotation and the double line on the belt should ...
Page 72
17 on all engines, ensure that the belt teeth are correctly seated centrally in the sprockets and the sprocket timing marks/belt fitting marks are correctly aligned. If adjustment is necessary, disengage the belt from the sprockets and make any necessary adjustments. 18 slacken the lower guide pulle...
Page 73
Another two complete turns (720°) in the normal direction of rotation to bring the sprocket timing marks back into alignment. 25 if the service tools are available, lock the crankshaft in position (km-800-10) and check the camshaft sprocket timing marks are correctly positioned using the timing gaug...
Page 74
7 note that there are two pairs of camshaft sprockets, one for the right-hand cylinder head and the other for the left-hand cylinder head; the right-hand cylinder head sprockets carry the identification marks 1 and 2 and the left-hand cylinder head sprockets the marks 3 and 4. The inlet and exhaust ...
Page 75
10 ensure the relevant camshaft sprocket timing marks are all correctly aligned with the cutouts on the rear cover then carefully rotate the crankshaft in the normal direction of rotation until the sprocket mark is correctly realigned with the notch on the oil pump housing. 11 refit the timing belt ...
Page 76
23 refit the timing belt as described in section 7. If a new tensioner assembly has been fitted, fit a new timing belt ensuring it is of the correct type for the tensioner. Lower guide pulley removal 24 remove the timing belt as described in section 7. 25 slacken and remove the retaining bolt and re...
Page 77
Top of the cylinder head and store each one in its respective fitted position (see illustration). Note: store all the followers the correct way up to prevent the oil draining from the hydraulic valve adjustment mechanisms. 7 if necessary, repeat the operations described in paragraphs 1 to 6 and remo...
Page 78
11 cylinder head - removal and refitting 4 removal note: the engine must be cold when removing the cylinder head. New cylinder head bolts must be used on refitting. 1 remove the battery as described in chapter 5a. Note: on models with a vauxhall anti-theft warning system (atws), the battery negative...
Page 79
18 remove the power steering pump as described in chapter 10. 19 slacken the retaining clip and disconnect the radiator upper coolant hose from the pipe at the front of the left-hand cylinder head. 20 unscrew the bolt and spacer securing the coolant pipe and engine lifting bracket to the cylinder he...
Page 80
Recover the sealing ring and discard it; a new one should be used on refitting (see illustrations). 29 remove the exhaust system right-hand front pipe as described in chapter 4a. 30 remove the exhaust camshaft as described in section 10. 31 remove the cylinder head as described in paragraphs 23 to 2...
Page 81
41 working progressively and in the sequence shown, first tighten all the cylinder head bolts to the stage 1 torque setting (see illustrations). 42 once all bolts have been tightened to the stage 1 torque, again working in the sequence shown, tighten each bolt through its specified stage 2 angle, us...
Page 82
Side of the main casting then slide off the retaining clip and push the connector into the sump (see illustration). 5 slacken and remove the sump pan retaining bolts then free it from the main casting and remove it along with its gasket. Take care not to damage the oil level sensor wiring as the pan...
Page 83
Around the areas of the oil pump housing and rear main bearing cap joints (see illustrations). 26 manoeuvre the casting into position and loosely refit all its retaining bolts. 27 working out from the centre in a diagonal sequence, progressively tighten the bolts securing the main casting to the cyl...
Page 84
Overhaul 8 undo the retaining screws and lift off the pump cover from the rear of the housing (see illustration). 9 using a suitable marker pen, mark the surface of both the pump inner and outer rotors; the marks can then be used to ensure the rotors are refitted the correct way around. On some pump...
Page 85
D) on completion prime the oil pump by filling it with clean engine oil whilst rotating the inner rotor. Refitting 15 prior to refitting it is necessary to determine which of the three possible types of oil pump assembly is fitted to your engine. The first step is to check the diameter of the oil pu...
Page 86
21 fit the timing belt lower guide pulley to the pump and tighten its retaining bolt to the specified torque. 22 refit the alternator lower mounting bolt and tighten to the specified torque (see chapter 5a). 23 wait approximately 10 minutes to allow the sealant on the pump gasket to cure then go aro...
Page 87
4 slacken the retaining clips and disconnect the coolant hoses from the cylinder head outlet (see illustration). 5 unscrew the retaining bolts and remove the coolant outlet from the cylinder heads. Recover the sealing rings and discard them; new ones must be used on refitting (see illustration). 6 u...
Page 88
14 apply a bead of suitable sealant (vauxhall recommend the use of sealant 15 03 296 - available from your vauxhall dealer), approx- imately 2 mm in diameter, to the groove on the oil cooler cover (see illustration). 15 refit the cooler assembly to the cylinder block and refit the cover retaining bo...
Page 89
Traces of locking compound from the driveplate retaining bolt threads in the crankshaft. 15 offer up the driveplate complete with the centering ring and retaining plate, making sure all components are fitted the correct way around, then screw in the new retaining bolts. 16 tighten the retaining bolt...
Page 90
10 on refitting, refit the mounting to the subframe aligning its locating lug with the subframe slot then refit the lower nut and tighten to the specified torque. 11 refit the mounting bracket (where removed) to the cylinder block and tighten its retaining bolts to the specified torque. 12 lower the...
Page 91: Chapter 2 Part D:
3510 vauxhall/opel omega 2d•1 2d chapter 2 part d: general engine overhaul procedures cylinder head 2.0 litre engine maximum gasket face distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm cylinder head height: sohc engine . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 92
Valves and guides 2.0 litre engine valve stem diameter*: sohc engine: inlet: standard (gm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.998 to 7.012 mm 1st oversize (0.075 mm - gm k1) . . . . . . . . . . . . . . . . . . . . . . . . 7.073 to 7.087 mm 2nd oversize (0...
Page 93
Valves and guides (continued) 2.5 and 3.0 litre engine valve stem diameter*: inlet: standard (gm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.955 to 5.970 mm 1st oversize (0.075 mm - gm k1) . . . . . . . . . . . . . . . . . . . . . . . . . . 6.030 to 6.045 mm ...
Page 94
Pistons and rings 2.0 litre engine piston diameter: standard: size group 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.945 to 85.955 mm size group 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.955 to 85.965 mm size ...
Page 95
Crankshaft 2.0 litre engine endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 to 0.15 mm main bearing journal diameter: standard: 1st size group (white) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.974 to 57....
Page 96
Miles of reliable service. Conversely, a neglected engine may require an overhaul very early in its life. 3 excessive oil consumption is an indication that piston rings, valve seals and/or valve guides are in need of attention. Make sure that oil leaks are not responsible before deciding that the ri...
Page 97
8 free the engine wiring harness auxiliary connections connector from the battery positive terminal so the harness is free to be removed with the engine and (where necessary) unbolt the earth lead from the front of the engine. On some models the harness is connected to the fusible link housing inste...
Page 98
Disconnect the feed pipe from the pump then plug the hose and pump unions to minimise fluid loss and prevent the entry of dirt into the system. 27 referring to chapter 4a, carry out the following procedures. A) remove the air cleaner housing and intake ducts. B) disconnect the accelerator cable and ...
Page 99
31 attach the hoist to the engine lifting brackets then remove the transmission unit as described in chapter 7a or 7b, as applicable (see illustration). 32 make a final check that any components which would prevent the removal of the engine from the car have been removed or disconnected. Ensure all ...
Page 100
A) inlet and exhaust manifolds (chapter 4a). B) timing belt, sprockets and tensioner. C) cylinder head(s). D) flywheel/driveplate. E) sump. F) oil pump. G) piston/connecting rod assemblies. H) crankshaft. 6 before beginning the dismantling and overhaul procedures, make sure that you have all of the ...
Page 101
7 examine the valve seats in each of the combustion chambers. If they are severely pitted, cracked or burned, then they will need to be renewed (if possible) or recut by an engine overhaul specialist. If they are only slightly pitted, this can be removed by grinding-in the valve heads and seats with...
Page 102
4 compress the valve spring, and locate the split collets in the recess in the valve stem (see illustration). Release the compressor, then repeat the procedure on the remaining valves. 5 with all the valves installed, using a hammer and interposed block of wood, tap the end of each valve stem to set...
Page 103
Caution: on some engines, the connecting rod/bearing cap mating surfaces are not machined flat; the big-end bearing caps are ‘cracked’ off from the rod during production and left untouched to ensure the cap and rod mate perfectly. Where this type of connecting rod is fitted, great care must be taken...
Page 104
Shells (see illustration). Remove the flywheel/driveplate end oil seal and discard it. 19 recover the upper bearing shells from the cylinder block, and tape them to their respective caps for safe-keeping. 11 cylinder block - cleaning and inspection 4 cleaning 1 remove all external components and ele...
Page 105
Chapter; if any measurement exceeds the service limit specified, the cylinder block must be rebored if possible, or renewed and new piston assemblies fitted. 14 if the cylinder bores are badly scuffed or scored, or if they are excessively worn, out-of- round or tapered, or if the piston-to-bore clea...
Page 106
14 on 2.0 and 2.5 litre engines, the gudgeon pins are an interference fit in the connecting rod small-end bearing. Therefore, piston and/or connecting rod renewal should be entrusted to a vauxhall dealer or engine repair specialist, who will have the necessary tooling to remove and install the gudge...
Page 107
At a number of points around each journal’s circumference, you will be able to determine whether or not the journal is out-of-round. Take the measurement at each end of the journal, near the webs, to determine if the journal is tapered. Compare the results obtained with those given in the specificat...
Page 108
D) sump. E) flywheel/driveplate. F) cylinder head(s). G) timing belt tensioner and sprockets, and belts. H) inlet and exhaust manifolds (chapter 4a). I) engine external components. 3 at this stage, all engine components should be absolutely clean and dry, with all faults repaired. The components sho...
Page 109
Shells. If the diameter of each corresponding crankshaft journal is measured and then subtracted from the bearing internal diameter, the result will be the main bearing running clearance. 5 the second (and more accurate) method is to use a product known as plastigauge. This consists of a fine thread...
Page 110
17 lubricate the upper shells with clean engine oil then lower the crankshaft into position (see illustration). 18 ensure the crankshaft is correctly seated then check the endfloat as described in section 13. 19 ensure the bearing shells are correctly located in the caps and refit the caps number 1 ...
Page 111
33 apply a smear of clean engine to oil to the threads and underneath the heads of the new main bearing cap bolts (see illustration). Fit the bolts tightening them all by hand. 34 working in a diagonal sequence from the centre outwards, evenly and progressively tighten the main bearing cap bolts to ...
Page 112
18 piston/connecting rod assembly - refitting and big- end running clearance check 4 note: it is recommended that new piston rings and big-end bearing shells are fitted regardless of the condition of the original ones. Selection of bearing shells 1 although the original bearing shells fitted at the ...
Page 113
13 tighten both bearing cap bolts to the specified stage 1 torque setting then tighten them through the specified stage 2 angle, and finally through the specified stage 3 angle. It is recommended that an angle-measuring gauge is used during the final stages of the tightening, to ensure accuracy (see...
Page 114: Chapter 3
3510 vauxhall/opel omega 3•1 3 chapter 3 cooling, heating and ventilation systems system type all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressurised, with cross-flow radiator, centrifugal water pump driven by timing belt, bypass thermos...
Page 115
1 general description 1 the cooling system comprises a radiator, timing belt driven coolant pump (depending on engine), a waxstat-type bypass thermostat, and a remotely-mounted plastic expansion tank. A thermostatically-controlled electric cooling fan is fitted to all models, between the front of th...
Page 116
9 on models with automatic transmission, release the hose clips and disconnect the narrow bore hoses from the transmission fluid cooler (see illustration). Plug the pipes to prevent excessive fluid loss and the ingress of debris. 10 release the spring clips at the top of the radiator, then withdraw ...
Page 117
Housing by slackening and removing the three securing nuts. Removal - models with 6-cylinder engines 6 disconnect the negative and positive cables from the battery terminals, then remove the battery as described in chapter 5a. 7 release the mounting bracket and detach secondary air cut-off valve fro...
Page 118
4 thermostat - removal, testing and refitting 3 models with 4-cylinder engines removal 1 drain the cooling system as described in chapter 1. 2 loosen the clip and disconnect the coolant hose from the thermostat housing cover. 3 unscrew the bolts and remove the cover. Note that the thermostat is inte...
Page 119
9 progressively slacken and remove the water pump retaining bolts (see illustration). Note that the bolts are of different lengths; make a note of the fitted position of each bolt to ensure correct refitting. 10 lift the coolant pump away from the engine and recover the seal (see illustrations). Ref...
Page 120
18 unplug the wiring connector from the rear of the fan control switch. 19 disconnect the vacuum control hose manifold from the rear of the control panel. 20 remove the control panel from the vehicle. Refitting 21 refitting is a reversal of the removal procedure. Air distribution unit note: on model...
Page 121
Vacuum control circuit general information 65 the heating and ventilation system is controlled by a series of valves which direct air through the required air ducts, according to the position of the control knobs on the heater control panel. The valves are actuated by vacuum supplied engine inlet ma...
Page 122
Series resistor removal 8 proceed as described in paragraphs 1 to 3 inclusive in the previous sub-section. 9 unplug the wiring harness from the blower motor series resistor at the connector (see illustration). 10 depress the retaining tabs and withdraw the resistor from the fan/motor housing (see il...
Page 123
Completion, have the refrigerant engineer fit new o-rings to the line connections and evacuate and re-charge the refrigerant circuit. Removal - models with 6-cylinder engines 15 have the air conditioning system discharged by a qualified engineer. 16 remove the battery as described in chapter 5a. 17 ...
Page 124
72 disconnect the battery negative cable and position it away from the terminal. 73 unplug the wiring from the switch at the multi-way connector. 74 unscrew the switch from the radiator. 75 refitting is a reversal of removal, but use a new switch sealing ring. On completion refill the cooling system...
Page 125
Refitting 19 turn the servo motor spindle gear fully clockwise to the end of its stop. Similarly, turn the spindle gear air distributor housing fully clockwise to the end of its stop. 20 refit the motor and tighten its securing screws. Reconnect the wiring harness. 21 refit the defroster air valve s...
Page 126: Chapter 4 Part A:
3510 vauxhall/opel omega 4a•1 4a chapter 4 part a: fuel and exhaust systems system type 2.0 litre sohc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch motronic m1.5.4* 2.0 litre dohc engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 127
Torque wrench settings nm ibf ft auxiliary drivebelt tensioner mounting bolts - 2.5 and 3.0 litre engines . 35 26 braking system vacuum hose union nut . . . . . . . . . . . . . . . . . . . . . . . . 20 15 camshaft sensor bolt: 2.0 litre dohc engine . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 128
3 accelerator cable - removal and refitting 3 removal 1 working in the engine compartment, unclip the inner cable retaining clip then slide the clip out of the end fitting and release the cable from the throttle cam (see illustration). 2 free the accelerator outer cable from its mounting bracket, ta...
Page 129
2 reaching up behind the facia, unclip the accelerator inner cable end fitting from the top of the accelerator pedal (see illustration 3.5). 3 unscrew the retaining nuts and remove the pedal assembly from the bulkhead (see illustration). 4 inspect the pedal assembly for signs of wear, paying particu...
Page 130
Fuel and exhaust systems 4a•5 4a 3510 vauxhall/opel omega 6.1 engine management system component locations - 2.0 litre sohc engine 1 idle speed adjuster valve 2 throttle potentiometer 3 evaporative emission system purge valve 4 exhaust gas recirculation (egr) valve 5 fuel pressure regulator 6 dis mo...
Page 131
2.5 and 3.0 litre engines - bosch motronic m2.8.1 or 2.8.3 system 11 all 2.5 and 3.0 litre engine models are equipped with a bosch motronic engine management (fuel injection/ignition) system (see illustration). The system is almost identical in operation to the motronic system fitted to 2.0 litre so...
Page 132
Further, a secondary air system is also incorporated. This is explained in greater detail in part b of this chapter. 13 the ecu also has full control over the multi- ram air intake system described in section 17. 14 on some later models the original m2.8.1 system was replaced with the later m2.8.3 s...
Page 133
7 fuel injection system - depressurisation 2 warning: refer to the warning note in section 1 before pro- ceeding. The following procedure will merely relieve the pressure in the fuel system - remember that fuel will still be present in the system components, and take precautions accordingly before d...
Page 134
8 carefully lift the fuel pump cover away from tank then make alignment marks between the cover and hoses/wiring. Release the retaining clips then disconnect both the hose and wiring connectors and remove the cover from the vehicle along with its sealing ring (see illustrations). Discard the sealing...
Page 135
Saloon models 6 locate the fuel pump/gauge sender unit wiring connector at the front of the fuel tank and disconnect the connector (see illustration). 7 trace the filler neck vent hose back to its connection on the right-hand side of the tank. Slacken the retaining clip and disconnect the hose so th...
Page 136
Fitted locations, then undo the retaining nuts and remove the housing from the manifold. Remove the gasket and discard it, a new one should be used on refitting. Refitting 9 refitting is the reverse of removal, bearing in mind the following points. A) ensure the mating surfaces are clean and dry the...
Page 137
20 slacken and remove the retaining bolts and separate the throttle body from the manifold (see illustration). Recover the large sealing rings from the throttle body bores and the small rings from the manifold breather passages and discard them; new sealing rings should be used on refitting. Refitti...
Page 138
16 unscrew the nuts and disconnect the fuel feed hose from its union on the rear of the fuel rail and the return pipe from the front end of the fuel rail. As the union nuts are slackened, retain the pipe end fitting with an open-ended spanner to prevent any excess strain being placed on the pipe. Pl...
Page 139
Cleaner housing and remove it from the vehicle (see illustrations). 37 carefully ease the sensor out of position, taking great care not to damage the duct. 38 refitting is the reverse of removal noting that the sensor must be fitted so that its flat edge aligns with the flat on the intake duct. Aid ...
Page 140
63 if necessary, to improve access, remove the starter motor as described in chapter 5a. 64 trace the wiring back from the sensor to its wiring connector. On early models the connector is connected to the underside of the injector wiring cover assembly (in between number 3 and 4 injectors) whereas o...
Page 141
3 slacken the union nuts securing the fuel pipes to the fuel rail whilst (where possible) retaining the fuel rail with an open-ended spanner. Unscrew the retaining bolts and remove the pipe assembly from the manifold lower section (see illustrations). 4 slacken and remove the retaining bolts then ca...
Page 142
Regulator and discard them; new ones must be used on refitting. 11 refitting is the reverse of removal, using new sealing rings and lubricating them with a smear of engine oil to ease installation. Ensure the regulator is correctly positioned then securely tighten the retaining clamp screw. On compl...
Page 143
Its sealing ring. Discard the sealing ring, a new one should be used on refitting (see illustration). 33 refitting is the reverse of removal using a new sealing ring and tightening the sensor bolt to the specified torque. Ensure the wiring is correctly routed and retained by all the necessary clips ...
Page 144
Accelerator cable from the throttle cam balljoint and unclip the cable from its mounting bracket. On models with cruise control it will also be necessary to remove the second retaining clip and detach the cruise control cable. 6 undo the retaining bolts and free the cable mounting bracket from the m...
Page 145
34 disconnect the wiring connectors from the throttle valve potentiometer, the idle speed adjuster, the inlet manifold switchover valve solenoid and the exhaust gas recirculation (egr) valve. 35 unscrew the union nut and disconnect the pipe from the egr valve then unscrew the retaining bolt and free...
Page 146
41 disconnect the injector wiring harness connector and the vacuum hose from the fuel pressure regulator (see illustration). 42 slacken and remove the retaining bolts then lift the manifold lower section away from the cylinder head. Remove the seals from the manifold flange recesses and discard them...
Page 147
2.0 litre dohc engine removal 12 remove the secondary air injection system air valve and connecting pipe as described in chapter 4b. 13 carry out the operations described in paragraphs 1 and 2. 14 undo the retaining nuts then remove the exhaust manifold and gasket from the cylinder head. Discard bot...
Page 148
27 slacken and remove the bolt securing the exhaust system right-hand front pipe to its mounting bracket then unscrew the bolts securing the pipe to the manifold. Free the pipe from the manifold taking care not to place any strain on the oxygen sensor wiring, and recover the gasket. Discard the fron...
Page 149
Then undo the retaining screws and remove the valve from the engine compartment. 7 refitting is the reverse of removal ensuring the vacuum hoses are correctly reconnected. Intake duct switchover valve housing 8 slacken the retaining clip and disconnect the idle speed adjuster hose from the intake du...
Page 150
Removal 4 each exhaust section can be removed individually, or alternatively, the complete system can be removed as a unit. Even if only one part of the system needs attention, it is often easier to remove the whole system and separate the sections on the bench. 5 to remove the system or part of the...
Page 151: Chapter 4 Part B:
3510 vauxhall/opel omega 4b•1 4b chapter 4 part b: emission control systems torque wrench settings nm lbf ft egr valve bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15 egr pipe union nuts - 2.5 and 3.0 litre engine . . . . . . . . . . . . . . . . . . ...
Page 152
Evaporative emission control 6 to minimise the escape into the atmosphere of unburned hydrocarbons, an evaporative emissions control system is also fitted to all models. The fuel tank filler cap is sealed and a charcoal canister is mounted behind the right-hand front wing. The canister collects the ...
Page 153
Out the outer section; the centre pins must be recovered so they can be reused on refitting (see illustrations). 3 slacken and remove the retaining nut and free the canister from its mounting. Mark the hoses for identification purposes then disconnect them and remove the canister from the vehicle (s...
Page 154
2.0 litre dohc engine 5 the valve is mounted on the rear of the cylinder head. Removal and refitting is as described in paragraphs 2 to 4. 2.5 and 3.0 litre engine 6 the valve is mounted onto an adaptor on the right-hand cylinder head. 7 ensure the ignition is switched off then disconnect the wiring...
Page 155
7 make alignment marks between the pump, bracket, mounting plate and rubber then free the pump wiring connector from the bracket. 8 undo the retaining bolts and remove the pump from its mounting bracket. If necessary, unscrew the retaining nuts and remove the mounting plate and rubber from the brack...
Page 156
15 undo the retaining screws and remove the valve from the engine compartment. 16 refitting is the reverse of removal ensuring the vacuum hoses are correctly reconnected. Non-return valve 17 the non-return valve is located on the top of the exhaust manifold. 18 release the retaining clip and disconn...
Page 157
34 on refitting, clean the valve threads and apply a smear of fresh sealing compound to them (vauxhall recommend the use of sealing compound 15 03 295 - available from your vauxhall dealer). Refit the valve to its pipe and tighten it to the specified torque before securely reconnecting the air hose....
Page 158
B) apply a smear of high-temperature grease (vauxhall recommend the use of assembly paste 19 48 569 - available from your vauxhall dealer) to the threads of the pipe retaining bolts and the heatshield bolts prior to refitting. C) tighten all bolts to their specified torque settings (where given). Ri...
Page 159: Chapter 5 Part A:
3510 vauxhall/opel omega 5a•1 5a chapter 5 part a: starting and charging systems system type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-volt, negative earth battery charge condition: poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 160
1 general information and precautions general information 1 the engine electrical system consists mainly of the charging and starting systems. Because of their engine-related functions, these components are covered separately from the body electrical devices such as the lights, instruments, etc (whi...
Page 161
8 if the battery is to be charged, remove it from the vehicle (section 4) and charge it as described later in this section. Standard and low maintenance battery - charging note: the following is intended as a guide only. Always refer to the manufacturer’s recommendations (often printed on a label at...
Page 162
3 slacken the retaining clips then disconnect the intake duct from the air cleaner and throttle housing and remove the duct assembly from the engine compartment. On dohc engines it will be necessary to disconnect the breather hose in order to allow the duct to be removed (see illustrations). 4 relea...
Page 163
(such as the battery negative terminal), and check that the wire is live when the ignition switch is turned to the start position. If it is, then the circuit is sound - if not the circuit wiring can be checked as described in chapter 12, section 2. 5 the solenoid contacts can be checked by connectin...
Page 164: Chapter 5 Part B:
3510 vauxhall/opel omega 5b•1 5b chapter 5 part b: ignition system system type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributorless ignition system controlled by engine management ecu firing order 2.0 litre engine . . . . . . . . . . . . . . . . . . ....
Page 165
6 if these checks fail to reveal the cause of the problem the vehicle should be taken to a suitably equipped vauxhall dealer for testing. A wiring block connector is incorporated in the engine management circuit into which a special electronic diagnostic tester can be plugged (see chapter 4a, sectio...
Page 166: Chapter 6
3510 vauxhall/opel omega 6•1 6 chapter 6 clutch type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single dry plate with diaphragm spring, hydraulically operated friction plate diameter: 2.0 litre engine models . . . . . . . . . . . . . . . . ....
Page 167
2 clutch hydraulic system - bleeding 3 warning: hydraulic fluid is poisonous; wash off immediately and thoroughly in the case of skin contact, and seek immediate medical advice if any fluid is swallowed or gets into the eyes. Certain types of hydraulic fluid are flammable, and may ignite when allowe...
Page 168
Windscreen wiper arms and the water deflector panel from the base of the wind- screen (see chapter 12, sections 15 and 16). 2 on all models, remove all traces of dirt from the outside of the master cylinder and position some cloth beneath the cylinder to catch any spilt fluid. 3 slacken the retainin...
Page 169
Refitting 10 if the pedal and bracket assembly has been dismantled, apply a smear of multi- purpose grease to the pedal pivot bolt and bushes prior to reassembly. 11 on 2.0 litre engine models, fit the return spring to the pedal then refit the assembly to the mounting bracket. Insert the pivot bolt ...
Page 170
No signs of cracks, pitting or scoring. If there is any doubt about its condition, the bearing should be renewed (see section 4). Refitting 13 on reassembly, ensure that the bearing surfaces of the flywheel and pressure plate are completely clean, smooth, and free from oil or grease. Use solvent to ...
Page 171: Chapter 7 Part A:
3510 vauxhall/opel omega 7a•1 7a chapter 7 part a: manual transmission general type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual, five forward speeds and reverse. Synchromesh on all forward speeds identification code: 2.0 and 2.5 litr...
Page 172
The transmission unit should be flushed before filling with the latest specification oil. To do this, using the latest type of oil (part number 19 40 768), refill the transmission unit so that the oil level is right up to the base of the filler plug aperture then refit the plug. Take the vehicle on ...
Page 173
6 from underneath the vehicle, using an open- ended spanner on the flats provided, turn the gearchange linkage rod fully clockwise (as viewed from the rear of the vehicle). Hold the rod in this position then tighten the rod clamp bolt first to the specified stage 1 torque and then through the specif...
Page 174
Transmission oil then carefully slide the propeller flange into position, taking care not to damage the seal lip. 9 apply a few drops of thread locking compound (vauxhall recommend the use of locking compound 15 10 181 - available from your vauxhall dealer) to the threads of the flange retaining nut...
Page 175
A) remove all traces of dirt and grease from the input shaft splines and the contact surfaces of the clutch release bearing and release cylinder. Lubricate the inner bore of the release bearing with a smear of high temperature grease (vauxhall recommend the use of lubricating paste 19 42 530 - avail...
Page 176: Chapter 7 Part B:
3510 vauxhall/opel omega 7b•1 7b chapter 7 part b: automatic transmission general type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-speed electronically-controlled automatic with three (normal, sport and winter) driving modes identifica...
Page 177
2 the normal (economy) mode is the standard mode for driving in which the transmission shifts up at relatively low engine speeds to combine reasonable performance with economy. If the transmission unit is switched into sport mode, using the button on the selector lever, the transmission shifts up on...
Page 178
Or its seal is damaged, then the filter must be renewed (the seal is not available separately). 8 remove all traces of dirt and fluid from the sump and transmission mating surfaces and wipe clean the inside of the sump(s). Remove the magnet from inside the main sump and clean all traces of metal fil...
Page 179
Refitting 3 apply a smear of multi-purpose grease to the linkage rod pivot pins. Ensure the bushes are in position then refit the rod to the transmission and selector lever and secure it in position with the retaining clips. 4 check the operation of the selector linkage and, if necessary, adjust as ...
Page 180
Lever in any position other than p (park) or n (neutral), then it is likely that the switch is faulty. If adjustment fails to correct the fault then the switch assembly must be renewed. Removal 2 position the selector lever in the n (neutral) position. Firmly apply the handbrake then jack up the rea...
Page 181
28 push the switch securely into position then clip the selector lever gaiter back onto the console. Winter mode switch removal 29 unclip the selector lever gaiter from the centre console. 30 reach in behind the console and push the switch panel out of position, disconnecting its wiring connector as...
Page 182
Clean the area around the sensor. 53 undo the retaining bolt and remove the sensor from the transmission. Remove the sealing ring from the sensor and discard it, a new one should be used on refitting. Refitting 54 fit the new sealing ring to the sensor groove and lubricate it with a smear of transmi...
Page 183
17 slacken and remove all the bolts securing the transmission housing to the engine. Note the correct fitted positions of each bolt, and the necessary brackets, as they are removed, to use as a reference on refitting. Make a final check that all components have been disconnected, and are positioned ...
Page 184: Chapter 8
3510 vauxhall/opel omega 8•1 8 chapter 8 final drive, driveshafts and propeller shaft final drive type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unsprung, attached to rear suspension crossmember and underbody. Limited slip differential op...
Page 185
Torque wrench settings nm lbf ft damping bracket to final drive unit*: stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 66 stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten a furth...
Page 186
4 unbolt the propeller shaft rear flange from the flexible drive joint and lever the propeller shaft from the joint. Support the propeller shaft on an axle stand - do not let it hang by the universal joint. 5 position a trolley jack underneath the final drive unit, and raise it until it just comes i...
Page 187
10 offer the bracket, bush and securing bolt up to the final drive casing. Insert the three bracket securing bolts and tighten them to the specified torque. 11 raise the final drive casing up into position using the trolley jack, then tighten the damper bush-to-suspension crossmember bolt and tighte...
Page 188
Great care avoid damaging the surface of the seal housing. Wipe the oil from the oil seal housing. 5 smear a little oil on the sealing lip of the new oil seal. Using suitable metal tubing drive the oil seal squarely into the casing to the previously noted position. 6 refit the driveshaft with refere...
Page 189
6 support the centre of the propeller shaft on an axle stand, then unbolt the centre bearing support bracket from the underbody, noting the location of any alignment shims (see illustration). 7 push the front section rearwards along the slider joint splines until clear of the transmission output fla...
Page 190: Chapter 9
3510 vauxhall/opel omega 9•1 9 chapter 9 braking system general system type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front and rear discs, floating front caliper, fixed rear caliper, tandem master cylinder with hydraulic system split front/rear, vac...
Page 191
Front brakes (continued) disc thickness (minimum, wear limit): up to 1998 model year: 4 cylinder engine models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mm 6 cylinder engine models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm from 1998 model year: al...
Page 192
1 general description 1 the braking system is of dual hydraulic circuit type with front and rear discs. The front and rear hydraulic circuits are operated independently, so that in the event of a failure in one circuit the remaining circuit still functions. The floor-mounted handbrake lever operates...
Page 193
11 carefully prise the inner pad from the caliper piston, which is retained by metal spring clip attached to the rear of the pad backing plate (see illustration). 4-cylinder engined models from 1998 and all 6-cylinder engined models 12 remove the dust caps from the caliper lower guide pin bolt hole,...
Page 194
From the caliper, piston and caliper mounting bracket using a stiff brush and proprietary brake component cleaning fluid - the use of other solvents or cleaning agents may cause damage to the caliper rubber seals. Apply a little high-melting-point copper brake grease to the areas on the pad backing ...
Page 195
5 remove the anti-rattle spring, then drive out the lower pad securing pin (see illustrations). 6 push the brake pads apart slightly to give a small amount of clearance then pull them from the caliper (see illustrations). If they are tight, use pliers or a pad extraction tool to remove them. Refitti...
Page 196
Side of the brake caliper. The clip is under relatively high tension and may fly off with some force when released; to prevent injury, cover the spring with a large rag before prising it from the caliper with a stout screwdriver. 3 remove the dust caps from the caliper guide pin bolt holes, then sla...
Page 197
Warning: do not use abrasives or tools to remove any material from the piston or cylinder in an attempt to effect a repair or remove corrosion - the piston and caliper body must be renewed as a complete assembly. 17 where applicable, check the condition of the guide bolts/pins and their sleeves; bot...
Page 198
Alternatively remove the cap from the hydraulic fluid reservoir and refit it with a piece of polythene sheeting covering the opening to help prevent loss of brake fluid when the caliper hose is disconnected. 3 remove the brake pads as described in section 3. 4 unscrew the union nut securing the rigi...
Page 199
It is worth mentioning that some garages may be able to regrind the discs in situ, using a specially adapted electric grinder. 4 using a dial gauge, or metal block and feeler gauges, check that the disc run-out does not exceed the amount given in specifications, measured at a radius of approximately...
Page 200
7 on later models, where the retaining pins are not cross-headed, depress the spring cups and turn them through 90° using two pairs of pliers (see illustration). This is a difficult task due to the strong spring tension and limited access - an alternative method is to use a small socket, inserted on...
Page 201
18 locate the rear (leading) shoe on the lever assembly and refit the lower return spring (see illustrations). 19 refit the hold-down spring and cup to secure the leading shoe to the backplate (see illustration). 20 refit the adjuster between the upper ends of the shoes (see illustration). 21 hook t...
Page 202
Number of turns required to remove it; record the number for use later. 7 slide the compensator bar from the threaded handbrake lever rod. 8 working at each rear brake caliper in turn, unhook the return spring from the lever on the rear of the brake backplate, then unhook the handbrake cable. 9 pull...
Page 203
11 unscrew the cap from the reservoir and allow the excess fluid to drain off. Refitting 12 refitting is a reversal of removal. After reconnecting the wiring, the operation of the sensor can be tested by suspending the reservoir cap above the reservoir, so that the float slides down to the end of it...
Page 204
18 if air is present in the brake lines, it will appear as bubbles in the expelled fluid. Repeat the steps given in the two previous paragraphs until the fluid emerging from the bleed screw is free from air bubbles. If the master cylinder has been drained and refilled and air is being bled from the ...
Page 205
Removal 4 depress the footbrake pedal several times to dissipate the vacuum in the servo unit. 5 disconnect the wiring for the brake fluid level warning lamp from the reservoir filler cap. 6 with reference to chapter 12, remove both windscreen wiper arms from their respective shafts. 7 carefully pee...
Page 206
17 anti-lock braking system/ traction control system (abs/tc) - information 4 information 1 abs is fitted as standard to all models. Traction control is fitted as standard to models with 6-cylinder engines. 2 the abs system comprises a hydraulic modulator and electronic control unit together with fo...
Page 207
20 unscrew the fixings and remove the heat shield from the side of the hydraulic modulator. 21 with reference to chapter 10 section 26 disconnect the high pressure hydraulic fluid delivery pipe from the power steering pump. Position a container underneath the disconnected union to catch escaping hyd...
Page 208: Chapter 10
3510 vauxhall/opel omega 10•1 10 chapter 10 suspension and steering front suspension type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent macpherson struts, coil springs and anti-roll bar, double-acting telescopic shock absorbers. A...
Page 209
Front wheel alignment* camber: saloon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1º40’ ± 45’ estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1º40’ ± 45’ maximum deviation, left to right ...
Page 210
Torque wrench settings (continued) nm lbf ft front suspension (continued) lower suspension arm pivot bolt (continued):* rear: stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 89 stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 211
1 general description 1 the front suspension is of independent macpherson strut type incorporating coil springs and double-acting telescopic shock absorbers. An anti-roll bar, connected to the suspension struts via drop links is mounted forward of the suspension arms. 2 the rear suspension is of ind...
Page 212
Warning: do not unscrew the damper rod nut (exposed by the removal of the upper mounting nut and plate) until spring compressors have been fitted to the suspension strut. 9 pivot the lower end of the strut away from the wheel arch, then lower it away from the upper mounting and withdraw it from unde...
Page 213
21 locate the rubber damper in the upper spring seat, then slide the upper spring seat, bump stop rubber and dust cover over the damper rod (see illustration). 22 ensure that the upper end of the coil spring abuts the stepped section of the rubber damper. 23 fit the washer and strut bearing to the s...
Page 214
Refitting 6 commence refitting by locating the arm on the underbody and inserting the new mounting bolts. Do not re-use the old mounting bolts. Insert the front mounting bolt from back to front, and insert the (shorter) rear mounting bolt from top to bottom. 7 hold the arm horizontally and tighten t...
Page 215
Refitting 4 refitting is a reversal of removal but fit new securing nuts and tighten them to the specified torque (see illustration). 8 steering knuckle - removal and refitting 3 removal 1 remove the front hub as described in section 9. 2 unbolt the brake disc shield from the steering knuckle. 3 wit...
Page 216
Refitting 9 refit the components in the reverse order to removal, noting the following points (see illustration): a) tighten all nuts and bolts to the specified torque. B) use a new hub nut and ensure that it tightened to the specified torque c) refit the brake disc and caliper as described in chapt...
Page 217
13 on models with rear suspension level control, charge the shock absorber slightly with compressed air. An exact initial pressure is not specified by the manufacturer but carefully inflate the shock absorber until it protrudes through the upper mountings. Refit the pressure line to the shock absorb...
Page 218
14 rear anti-roll bar - removal and refitting 3 removal 1 chock the front wheels, then jack up the rear of the vehicle and support securely on axle stands. 2 on models with rear suspension level control, mark the relationship between the level sensor actuator arm and the anti-roll bar drop link, to ...
Page 219
Ground. Release the handbrake and let the engine idle for while, to allow the rear suspension ride height to stabilise. Re-apply the handbrake. 20 measure the vertical distance from the ground to a convenient point on the rear bumper. 21 place a heavy load in the boot/load space. Release the handbra...
Page 220
6 the mountings must now be pulled from the subframe. The vauxhall tool for this task is shown in (see illustration). The subframe is lowered slightly and the mounting bolt inserted from the top, then the puller is assembled as shown and the nut tightened to withdraw the mounting. If a similar arran...
Page 221
15 bend back the locktab and then unscrew the steering wheel retaining nut. Remove the locktab (see illustrations). 16 remove the steering wheel from the steering column by carefully rocking it from side to side. Do not use a hammer or mallet to remove it. Guide the horn and audio control wiring thr...
Page 222
11 the upper column mounting consists of a nut and a shear bolt (see illustration). Ideally a bolt extractor should be used to remove the shear bolt by first drilling a 3.2 mm hole then using the extractor to unscrew the bolt. Alternatively, drill off the head and use grips to unscrew the remainder ...
Page 223
13 depress the locking button using a suitable tool and withdraw the contact unit from the rear of the lock cylinder housing (see illustrations). Refitting 14 refitting is a reversal of removal. 24 steering gear - removal and refitting 4 models with 4-cylinder engines removal 1 park the vehicle on a...
Page 224
34 unbolt the coolant reservoir from the bodywork and position it to one side, leaving the coolant hoses connected. 35 disconnect the fuel vapour hoses from the charcoal canister ports, as described in chapter 4b, section 4. 36 position a container beneath the steering gear to catch any spilt hydrau...
Page 225
If it is required to renew just one tie-rod end, disconnect the appropriate end only. 3 loosen the clamp bolts and unscrew the tie-rod ends from the tie-rod tube, counting the exact number of turns required to remove them. 4 to remove the centre tie-rod, the side tie-rods must first be disconnected ...
Page 226
20 have the air conditioning system recharged by a vauxhall dealer, or an air conditioning specialist. 21 pour fresh hydraulic fluid into the reservoir to the maximum level. Start the engine briefly, then switch off and top-up the fluid level. Do this several times until the level remains constant. ...
Page 227: Chapter 11
3510 vauxhall/opel omega 11•1 11 chapter 11 bodywork and fittings torque wrench settings nm lbf ft driver’s airbag unit to steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6 front seat to floorpan* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1...
Page 228
Weather, the underframe is usually cleaned of large accumulations automatically, and this is a good time for inspection. Periodically, except on vehicles with a wax- based underbody protective coating, it is a good idea to have the whole of the underframe of the vehicle steam-cleaned, engine compart...
Page 229
Before filling can take place, it will be necessary to block the hole in some way. This can be achieved by the use of aluminium or plastic mesh, or aluminium tape. Aluminium or plastic mesh, or glass-fibre matting is probably the best material to use for a large hole. Cut a piece to the approximate ...
Page 230
6 bumpers - removal and refitting 2 front bumper removal 1 remove the radiator grille as described in section 7. Remove the securing screws and detach the trim panels from the lower edge of each headlamp unit (see illustrations) . 2 remove the screws securing the lower edge of the front wheel arch l...
Page 231
Refitting 6 refitting is a reversal of removal, noting the following points. A) tighten all fixings to the correct torque, where specified. B) when refitting the headlamp trim panels, ensure that the locating lugs engage which their corresponding recesses. C) ensure that the ambient temperature sens...
Page 232
15 unscrew the securing bolts and remove the reflectors from the underside of each rear light unit (see illustration). 16 at the rear of each wheel arch, unscrew the bolts (one each side) securing the leading edge of the bumper moulding to the bodywork (see illustration). 17 remove the plastic rivet...
Page 233
Refitting 3 refitting is a reversal of removal, ensuring that the lugs on the lower edge of the grille engage correctly with the corresponding recesses in the upper edge of the bumper. 8 bonnet and support struts - removal, refitting and adjustment 2 bonnet removal 1 open the bonnet, and have an ass...
Page 234
4 remove the plastic covers from the door hinge pins (see illustration). Have an assistant support the door, then drive both hinge pins out of position using a hammer and suitable punch. Note: vauxhall/opel technicians use a special hinge pin removal tool which acts like a slide hammer. Remove the d...
Page 235
8 prise off the protective caps (where applicable) then unscrew and remove the screws from the lower and front edges of the trim panel (see illustrations). 9 use a wide-bladed screwdriver or trim removal tool to carefully prise the panel clips from the door. Unhook the top of the panel and remove it...
Page 236
18 where a manual window regulator is fitted, fully close the window and note the position of the regulator handle. The handle must now be removed from the splined shaft. To do this, locate a cloth rag between the handle and the trim panel and pull it to one side to release the spring clip. The hand...
Page 237
To carefully prise the inner trim panel clips from the inside of the rear door. Lift the panel upwards to disengage it from the door, then unplug the speaker wiring as it becomes accessible. Remove the trim panel from the vehicle (see illustrations). 21 if necessary, carefully peel the protective pl...
Page 238
13 unscrew the nuts, using a socket inserted through the aperture provided, and remove the mounting plate from the rear of the exterior door handle (see illustrations). 14 disconnect the handle link rod from the door lock by prising open the plastic clips (see illustration). 15 withdraw the handle f...
Page 239
With its mounting bracket; refer to section 24 of chapter 12. 27 remove the exterior door handle as described previously in this section. 28 where fitted, disconnect the central locking wiring from the lock by levering up the plastic retainer and separating the connector. 29 disconnect the link rods...
Page 240
Regulator to the door; there are four rivets on the front door, six on rear doors with manual actuation and five on rear doors with electric actuation. Slide the arm extensions from the channels at the bottom of the glass (see illustrations). 8 manoeuvre the regulator mechanism out through the apert...
Page 241
Channel at the trailing edge of the glass engages with the rear edge of the door (see illustrations). 20 to adjust the height of the window glass in the closed position, slacken the window glass stop bolt (see illustration) then wind the window up until its upper edge is flush with the door weather ...
Page 242
Window glass - rear door fixed quarter window removal 28 remove the rear door sash window as described previously in this section. 29 carefully prise the rubber seal away from the window aperture, then slide the glass towards the front of the door and remove it (see illustrations). Refitting 30 refi...
Page 243
On removal and tighten the mounting bolts securely. With the bootlid closed, check that it is positioned centrally within the body aperture. If adjustment is necessary, turn the adjusting bolts and rubber buffers to reposition the bootlid. Check that the striker enters the lock centrally, and if nec...
Page 244
2 unplug the tailgate wiring harness connector. 3 disconnect the tailgate washer hose. 4 have an assistant support the tailgate, then disconnect the tops of the support struts by prising out the spring clips with a small screwdriver. Lower the struts to the body. 5 extract the clips from the hinge p...
Page 245
Tailgate servo motor removal 10 open the tailgate and remove the trim panel. 11 disconnect the servo motor linkage from the lock cylinder by prising up the plastic retainer. 12 unscrew the mounting bolts. 13 disconnect the wiring connector from the motor and remove the servo motor from the tailgate....
Page 246
23 exterior mirrors and associated components - removal and refitting 3 exterior mirror housing removal 1 carefully prise off the triangular plastic cover panel at the rear of the mirror mountings, then remove the foam padding and unplug the wiring from the tweeter unit (see illustrations). 2 prise ...
Page 247
Refitting 13 refitting is a reversal of removal. Mirror door switch removal 14 carefully prise off the triangular plastic cover panel at the rear of the mirror mountings, then remove the foam padding and unplug the wiring from the tweeter unit. 15 prise the plastic cover from the inside of the inter...
Page 248
16 detach the control knob from the sunroof switch (see illustration). 17 remove the lens, then unclip the interior lamp unit from the console and disconnect the wiring (see illustrations). 18 release the control switch from the panel by depressing the clips with a screwdriver (see illustration). 19...
Page 249
26 body exterior fittings - removal and refitting 5 water deflector panel removal 1 open the bonnet then remove the windscreen wiper arms as described in chapter 12. 2 pull the rubber weatherstrip from the front of the bulkhead. 3 release the rubber sealing strip from the lower edge of the windscree...
Page 250
Specified torque in the sequence shown (see illustration) on models with mechanical seat belt tensioners, remove the forked locking tool before refitting the seat runner trim panels. Rear seat cushion removal 8 grasp the seat cushion lock straps, located at the front lower edge of the seat , and pul...
Page 251
Lower anchor from the sill. Recover the washers (see illustrations). 2 unclip and remove the b-pillar lower trim panel (see illustration). 3 unclip the alarm system interior sensor unit from the b-pillar upper trim panel and unplug the wiring at the connector (see illustration). 4 undo the screws an...
Page 252
Rear seat belt and reel - saloon models removal 9 the centre rear seat belt can be removed by unclipping the cover from the parcel shelf, unbolting the inertia reel and then depressing the locking button to release the lower belt anchor from its buckle (see illustrations). 10 the outer seat belts ar...
Page 253
22 lift the carpet trim from the floor of the loadspace, then unclip the cover from the spare wheel. 23 remove the trim panel from the side of the luggage compartment. Refitting 24 refitting is a reversal of removal. Carpets removal 25 the front and rear carpets can be removed after removing the fro...
Page 254
8 unclip the gaiter from the handbrake lever and remove it (see illustration). 9 slacken and withdraw the securing screws and lift off the centre arm rest (where fitted) (see illustrations). 10 undo the centre console securing screws, remove the support bracket, then lift the console away from the f...
Page 255
Unit cover panel to the facia - there is no need to remove the cover panel completely (see illustration). Refer to chapter 12 section 24 for details of the passenger air bag unit cover. 4 open the glovebox lid, then lift the passenger airbag unit cover panel slightly and undo the glovebox upper moun...
Page 256
17 unclip the cover panel from the left hand facia end section. 18 unclip the bulb holder from the rear of the air vent housing and position it to one side. 19 slacken and withdraw the securing screws then detach the nozzle from the left hand air vent housing (see illustrations). 20 undo the securin...
Page 257
Centre air vent housing, then undo the securing screws and remove the vent housing from the facia (see illustrations). 23 remove the instrument pack as described in chapter 12 section 9. 24 remove the heater control panel (or electronic climate control panel, as applicable) from the facia as describ...
Page 258: Chapter 12
3510 vauxhall/opel omega 12•1 12 chapter 12 body electrical system system type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-volt negative earth fuses main interior fusebox fuse rating circuits protected f1 30 . . . . . . . . . . . . . . . . . . . . . . . ....
Page 259
Fuses (continued) fuse rating circuits protected f21 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main beam (left) f22 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dipped beam (left), headligh...
Page 260
The circuit between the relevant connector and the battery is problem-free. 13 continue to check the remainder of the circuit in the same fashion. 14 when a point is reached at which no voltage is present, the problem must lie between that point and the previous test point with voltage. Most problem...
Page 261
4.12a depress the locking catches at the side of the switch unit . . . 4 switches - removal and refitting 3 ignition switch/ steering column lock cylinder 1 refer to the information given in chapter 10. Turn signal/ wiper switch assembly 2 the turn signal and wiper switch assemblies are removed iden...
Page 262
Hazard warning switch 15 it is easier to remove the hazard warning switch when in the on position. 16 carefully unclip the cover from the switch button. 17 insert screwdrivers into the channel on either side of the switch and carefully prise it from the facia, or use a small, hooked instrument or le...
Page 263
5.23 rotate the indicator bulbholder anticlockwise to release it from the rear of the light unit 4 depress and unhook the retaining clip, then withdraw the bulb from the headlight (see illustrations). 5 when handling the new bulb, use a tissue or clean cloth, to avoid touching the glass with the fin...
Page 264
24 depress and twist the bulb and remove it from the bulbholder (see illustration). 25 fit the new bulb using a reversal of the removal procedure. Front foglight 26 remove the screws and detach the grille adjacent to the relevant fog light, located in the front bumper valence (see illustration). 27 ...
Page 265
33 pull the wedge-type bulb from the bulbholder (see illustration). 34 fit the new bulb using a reversal of the removal procedure. Rear light cluster - rear wing 35 in the luggage compartment, remove the side trim cover. If working on the right-hand side, remove the first aid kit and warning triangl...
Page 266
52 remove the bulb(s) as necessary. 53 fit the new bulb using a reversal of the removal procedure. High level stop light - estate models 54 with the tailgate open, unclip the centre section of the tailgate upper trim panelling. 55 rotate the relevant bulbholder to remove it from its bayonet contacts...
Page 267
Door mounted interior light 14 carefully lever the light from the door trim panel (see illustration). 15 remove the heat shield, then remove the festoon type bulb from the spring contacts (see illustrations). 16 fit the new bulb using a reversal of the removal procedure. Make sure that the bulb is h...
Page 268
Refitting 6 refitting is a reversal of removal, but make sure that the locating lug on the headlight engages with the corresponding hole in the front valance and, on completion, have the headlight beam alignment checked at the earliest opportunity. Front direction indicator light 7 the direction ind...
Page 269
Take care not to damage the vehicle paint- work. 19 refitting is a reversal of removal. 8 headlight beam alignment - general information 5 1 accurate adjustment of the headlight beam is only possible using optical beam-setting equipment, and this work should therefore be carried out by a vauxhall/op...
Page 270
2 remove the multi-function display unit as described in section 11. 3 carefully release the clips using a screwdriver, then release the front frame from the main housing. 4 gauges within the instrument pack can be renewed, but it is recommended that this work is carried by an automotive electronics...
Page 271
12 the electronic control unit is located in front of the suspension strut upper mountings. Unclip the unit from its mounting bracket and unplug the wiring connector from it. To do this, slide the locking bar to one side and then pull the connector block squarely away from the control unit. Refittin...
Page 272
10 lift the cover from the base of the wiper arm, unscrew the retaining nut and recover the washer (see illustrations). 11 lift the blade off the glass, and pull the wiper arm off its spindle (see illustration). 12 if necessary, remove the blade from the arm with reference to weekly checks. Refittin...
Page 273
7 unscrew the bolts securing the left hand end, right hand end and centre of the wiper motor assembly to the scuttle, and withdraw the assembly from the engine compartment (see illustrations). Note that the centre securing bolt can only be accessed using an extension bar. 8 the motor can be removed ...
Page 274
4 unbolt the bumper inner section and support it away from the front of the vehicle. 5 disconnect the wiring from the top of the pump and position to one side (see illustration). Where applicable, disconnect the wiring from the level sensor on the fluid reservoir. 6 disconnect the hose from the pump...
Page 275
2 insert the two din removal tools into the holes on each side of the radio until they are felt to engage with the retaining strips. 3 push the din removal tools outwards slightly then carefully withdraw the radio/cassette/cd player from the facia (see illustration). Note the electrical and coaxial ...
Page 276
Parcel shelf speakers - saloon models removal 12 remove the rear seat cushions and back rests as described in chapter 11. 13 where applicable unbolt and remove the centre three point seat belt with reference to chapter 11. 14 remove the rear headrests, then depress the locking tabs and remove the he...
Page 277
Observed when carrying out work on a vehicle equipped with an airbag. A) do not disconnect the battery with the engine running. B) before carrying out any work in the vicinity of the airbag, removal of any of the airbag components, or any welding work on the vehicle, de-activate the system as descri...
Page 278
15 slacken and withdraw the securing screws then detach the nozzle from the left hand air vent housing. 16 undo the securing screws and remove the left hand vent housing from the facia. 17 unscrew the lower mounting screws and detach the lower edge of the hinged airbag cover from the facia. 18 using...
Page 279
Pins locate in the holes provided. Press the unit in until the clips engage. Note: the clips must not be damaged in any way. If they are, the unit must be renewed. 32 reconnect the wiring while depressing the slider. 33 refit the ignition key position indicator, then refit the steering column shroud...
Page 280
26 wiring diagrams - general information the wiring diagrams are of the current flow type, each circuit being shown in the simplest possible fashion. Note that since the diagrams were originally written in german (to the din standard), all wire colours and abbreviations used on the diagrams themselv...
Page 281
12•24 wiring diagrams 3510 vauxhall/opel omega index of circuits 100 to 1199 - early models location of applicable circuits track air conditioning 700 airbag 528 alternator 115 anti-lock braking system 122 anti-theft device 904 anti-theft warning system 928 automatic transmission 214 battery 101 bra...
Page 282
Wiring diagrams 12•25 12 3510 vauxhall/opel omega no description h40 loudspeaker - right rear door h42 automatic transmission warning light h47 anti-theft alarm horn h48 horn h51 traction control warning light h52 tweeter - left front door h53 tweeter - right front door h54 telephone h55 handset h56...
Page 283
12•26 wiring diagrams 3510 vauxhall/opel omega no description s5.2 dipped beam switch s5.3 direction indicator switch s5.4 sidelight switch s7 reversing light switch s8 brake light switch s9 windscreen wiper switch assembly s9.2 windscreen wiper interval switch s9.5 rear window washer/wiper switch s...
Page 284
Wiring diagrams 12•27 12 3510 vauxhall/opel omega current track 100 to 199 - early models.
Page 285
12•28 wiring diagrams 3510 vauxhall/opel omega current track 200 to 299 - early models.
Page 286
Wiring diagrams 12•29 12 3510 vauxhall/opel omega current track 300 to 399 - early models.
Page 287
12•30 wiring diagrams 3510 vauxhall/opel omega current track 400 to 499 - early models.
Page 288
Wiring diagrams 12•31 12 3510 vauxhall/opel omega current track 500 to 599 - early models.
Page 289
12•32 wiring diagrams 3510 vauxhall/opel omega current track 600 to 699 - early models.
Page 290
Wiring diagrams 12•33 12 3510 vauxhall/opel omega current track 700 to 799 - early models.
Page 291
12•34 wiring diagrams 3510 vauxhall/opel omega current track 800 to 899 - early models.
Page 292
Wiring diagrams 12•35 12 3510 vauxhall/opel omega current track 900 to 999 - early models.
Page 293
12•36 wiring diagrams 3510 vauxhall/opel omega current track 1000 to 1099 - early models.
Page 294
Wiring diagrams 12•37 12 3510 vauxhall/opel omega current track 1100 to 1199 - early models.
Page 295
12•38 wiring diagrams 3510 vauxhall/opel omega index of circuits 100 to 1699 - later models location of applicable circuits track air conditioning ac/ecc x 20 dth 1264 air conditioning, not x 20 dth 700 airbag 1313 airbag, side airbag 1313 alternator 112 anti-lock braking system 1406 anti-theft devi...
Page 296
Wiring diagrams 12•39 12 3510 vauxhall/opel omega no description e52 kerb light - left rear door e53 kerb light - right rear door e54 cigarette lighter light, rear e55 heating nozzle operating handle light e57 heating nozzle light, left e58 heating nozzle light, right e59 heating nozzle light, rear ...
Page 297
12•40 wiring diagrams 3510 vauxhall/opel omega no description p27 brake pad wear sensor - front left p28 brake pad wear sensor - front right p29 air intake temperature sensor p30 coolant temperature sensor p32 oxygen sensor - heated p34 throttle position sensor/potentiometer p35 crankshaft speed/pos...
Page 298
Wiring diagrams 12•41 12 3510 vauxhall/opel omega current track 100 to 199 - later models.
Page 299
12•42 wiring diagrams 3510 vauxhall/opel omega current track 200 to 299 - later models.
Page 300
Wiring diagrams 12•43 12 3510 vauxhall/opel omega current track 300 to 399 - later models.
Page 301
12•44 wiring diagrams 3510 vauxhall/opel omega current track 400 to 499 - later models.
Page 302
Wiring diagrams 12•45 12 3510 vauxhall/opel omega current track 500 to 599 - later models.
Page 303
12•46 wiring diagrams 3510 vauxhall/opel omega current track 600 to 699 - later models.
Page 304
Wiring diagrams 12•47 12 3510 vauxhall/opel omega current track 700 to 799 - later models.
Page 305
12•48 wiring diagrams 3510 vauxhall/opel omega current track 800 to 899 - later models.
Page 306
Wiring diagrams 12•49 12 3510 vauxhall/opel omega current track 900 to 999 - later models.
Page 307
12•50 wiring diagrams 3510 vauxhall/opel omega current track 1000 to 1099 - later models.
Page 308
Wiring diagrams 12•51 12 3510 vauxhall/opel omega current track 1100 to 1199 - later models.
Page 309
12•52 wiring diagrams 3510 vauxhall/opel omega current track 1200 to 1299 - later models.
Page 310
Wiring diagrams 12•53 12 3510 vauxhall/opel omega current track 1300 to 1399 - later models.
Page 311
12•54 wiring diagrams 3510 vauxhall/opel omega current track 1400 to 1499 - later models.
Page 312
Wiring diagrams 12•55 12 3510 vauxhall/opel omega current track 1500 to 1599 - later models.
Page 313
12•56 wiring diagrams 3510 vauxhall/opel omega current track 1600 to 1699 - later models.
Page 314: Dimensions and Weights
Reference ref•1 3510 vauxhall/opel omega dimensions and weights note: all figures are approximate, and may vary according to model depending on specification. Refer to manufacturer’s data for exact figures. Dimensions saloon model estate model overall length . . . . . . . . . . . . . . . . . . . . ....
Page 315
Ref•2 conversion factors 3510 vauxhall/opel omega length (distance) inches (in) x 25.4 = millimetres (mm) x 0.0394 = inches (in) feet (ft) x 0.305 = metres (m) x 3.281 = feet (ft) miles x 1.609 = kilometres (km) x 0.621 = miles volume (capacity) cubic inches (cu in; in 3 ) x 16.387 = cubic centimetr...
Page 316: Vehicle Identification
Spare parts are available from many sources, including maker’s appointed garages, accessory shops, and motor factors. To be sure of obtaining the correct parts, it will sometimes be necessary to quote the vehicle identification number. If possible, it can also be useful to take the old parts along f...
Page 317
Ref•4 general repair procedures 3510 vauxhall/opel omega whenever servicing, repair or overhaul work is carried out on the car or its components, observe the following procedures and instructions. This will assist in carrying out the operation efficiently and to a professional standard of workmanshi...
Page 318
The jack supplied with the vehicle tool kit should only be used for changing the road- wheels - see wheel changing at the front of this manual. When carrying out any other kind of work, raise the vehicle using a hydraulic (or trolley) jack, and always supplement the jack with axle stands positioned ...
Page 319
Ref•6 tools and working facilities 3510 vauxhall/opel omega introduction a selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a considerable expense, offsetting...
Page 320
Tools and working facilities ref•7 3510 vauxhall/opel omega special tools the tools in this list are those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturers’ instructions. Unless relatively difficult mechanical jobs are undertaken fre...
Page 321
Ref•8 mot test checks 3510 vauxhall/opel omega this is a guide to getting your vehicle through the mot test. Obviously it will not be possible to examine the vehicle to the same standard as the professional mot tester. However, working through the following checks will enable you to identify any pro...
Page 322
Mot test checks ref•9 3510 vauxhall/opel omega seat belts and seats note: the following checks are applicable to all seat belts, front and rear. M examine the webbing of all the belts (including rear belts if fitted) for cuts, serious fraying or deterioration. Fasten and unfasten each belt to check ...
Page 323
Ref•10 mot test checks 3510 vauxhall/opel omega exhaust system m start the engine. With your assistant holding a rag over the tailpipe, check the entire system for leaks. Repair or renew leaking sections. Jack up the front and rear of the vehicle, and securely support it on axle stands. Position the...
Page 324
Mot test checks ref•11 3510 vauxhall/opel omega m examine the handbrake mechanism, checking for frayed or broken cables, excessive corrosion, or wear or insecurity of the linkage. Check that the mechanism works on each relevant wheel, and releases fully, without binding. M it is not possible to test...
Page 325: Introduction
Engine m m engine fails to rotate when attempting to start m m engine rotates, but will not start m m engine difficult to start when cold m m engine difficult to start when hot m m starter motor noisy or excessively-rough in engagement m m engine starts, but stops immediately m m engine idles errati...
Page 326: Engine
The pages which follow provide an easy- reference guide to the more common problems which may occur during the operation of the vehicle. These problems and their possible causes are grouped under headings denoting various components or systems, such as engine, cooling system, etc. The chapter and/or...
Page 327: Cooling System
Ref•14 fault finding 3510 vauxhall/opel omega overheating m m insufficient coolant in system (weekly checks) m m thermostat faulty (chapter 3) m m radiator core blocked, or grille restricted (chapter 3) m m cooling fan faulty (chapter 3) m m inaccurate temperature gauge sender unit (chapter 3) m m a...
Page 328: Manual Transmission
Fault finding ref•15 3510 vauxhall/opel omega noisy in neutral with engine running m m input shaft bearings worn (noise apparent with clutch pedal released, but not when depressed) (chapter 7)* m m clutch release bearing worn (noise apparent with clutch pedal depressed, possibly less when released) ...
Page 329: Braking System
Ref•16 fault finding 3510 vauxhall/opel omega note: before assuming that a brake problem exists, make sure that the tyres are in good condition and correctly inflated, that the front wheel alignment is correct, and that the vehicle is not loaded with weight in an unequal manner. Apart from checking ...
Page 330: Suspension and Steering
Fault finding ref•17 3510 vauxhall/opel omega note: before diagnosing suspension or steering faults, be sure that the trouble is not due to incorrect tyre pressures, mixtures of tyre types, or binding brakes. Vehicle pulls to one side m m defective tyre (weekly checks) m m excessive wear in suspensi...
Page 331: Electrical System
Ref•18 fault finding 3510 vauxhall/opel omega note: for problems associated with the starting system, refer to the faults listed under engine earlier in this section. Battery will not hold a charge for more than a few days m m battery defective internally (chapter 5) m m battery terminal connections...
Page 332
Fault finding ref•19 3510 vauxhall/opel omega central locking system inoperative, or unsatisfactory in operation complete system failure m m blown fuse (chapter 12) m m faulty relay (chapter 12) m m broken or disconnected wiring or connections (chapter 12) m m faulty motor (chapter 11) latch locks b...
Page 333
Ref•20 glossary of technical terms 3510 vauxhall/opel omega a abs (anti-lock brake system) a system, usually electronically controlled, that senses incipient wheel lockup during braking and relieves hydraulic pressure at wheels that are about to skid. Air bag an inflatable bag hidden in the steering...
Page 334
Glossary of technical terms ref•21 3510 vauxhall/opel omega catalytic converter a silencer-like device in the exhaust system which converts certain pollutants in the exhaust gases into less harmful substances. Circlip a ring-shaped clip used to prevent endwise movement of cylindrical parts and shaft...
Page 335
Ref•22 glossary of technical terms 3510 vauxhall/opel omega g gap the distance the spark must travel in jumping from the centre electrode to the side electrode in a spark plug. Also refers to the spacing between the points in a contact breaker assembly in a conventional points- type ignition, or to ...
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Glossary of technical terms ref•23 3510 vauxhall/opel omega rotor in a distributor, the rotating device inside the cap that connects the centre electrode and the outer terminals as it turns, distributing the high voltage from the coil secondary winding to the proper spark plug. Also, that part of an...
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A abs/tc - 9•17 accelerator cable - 4a•3 pedal - 4a•3 aerial - 12•19 air cleaner assembly and intake ducts - 4a•2 air conditioning system - 3•9 air filter element - 1•12 airbag - 12•20 alternator - 5a•3, 5a•4 drivebelt - 1•8 anti-lock braking system/traction control system - 9•17 anti-roll bar - 10•...
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E electric cooling fan - 3•3 electric windows - 11•19 electrical fault-finding - 12•2 electrical systems - 0•13 electronic climate control (ecc) components - 3•11 emission control systems - 4b•1 et seq engine in-car repair procedures - 2a•1, 2b•1, 2c•1 et seq engine overhaul procedures - 2d•1 et seq...
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L leaks - 0•9, 1•9 lighting equipment check - 1•7 lock lubrication - 1•13 loudspeakers - 12•18 lower arm - 10•6 balljoint - 10•7 lubricants - 0•16, 1•2 m main bearings - 2d•17 maintenance schedule - 1•3 major body damage - 11•3 manifolds - 4a•18, 4a•21 manual transmission - 7a•1 et seq oil - 0•16, 1...
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T tailgate lock components - 11•18 support struts - 11•17 washer system - 12•16 wiper motor - 12•16 tdc for no 1 piston - 2a•3, 2b•4, 2c•4 temperature gauge sender unit - 3•6 thermostat - 3•5 throttle housing - 4a•10 timing belt - 1•15, 2a•5, 2b•6, 2c•7 covers - 2a•4, 2b•5, 2c•6 tensioner, sprockets...
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3510 vauxhall/opel omega almost every car you’ve ever loved, loathed or desired is gathered under one roof at the haynes motor museum. Over 300 immaculately presented cars and motorbikes represent every aspect of our motoring heritage, from elegant reminders of bygone days, such as the superb model ...