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Opel Vauxhall

Opel Vauxhall Calibra 1991 Repair Service Manual

Opel Vauxhall Calibra 1991 Repair Service Manual

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Vehicle data plateRef 390823
Brand
Opel Vauxhall
Vehicle
Cars
Models covered
Calibra, Opel, Vauxhall
Years
1991
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Opel/Vauxhall
Model:
Calibra
Year:
1991
Market:
European (Opel branding) / UK (Vauxhall branding)
Codes
Chassis Code:
Type 5000 / Manta M
👋 Introduction
Market Position
Design Philosophy:
Aerodynamic sports coupe, designed to compete with established Japanese and German sports coupes of the era.
Competitive Analysis
Key Competitors:
Toyota Celica, Mitsubishi Eclipse, Honda Prelude, Ford Probe, BMW E30/E36 Coupe, Mercedes-Benz W201/W124 Coupe.
Key Features
Aerodynamics:
Exceptional drag coefficient (Cd of 0.26), one of the lowest for a production car at the time, contributing to high top speeds and fuel efficiency.
Styling:
Distinctive wedge shape, integrated bumpers, large glasshouse, and Kamm-tail rear end.
Performance Variants:
Available with various engine options, including the powerful 2.0L 16V (C20XE), 2.5L V6 (C25XE), and later the 2.0L Turbo (C20LET) in the 'Cali-B' and 'Cali-GSI' editions.
📋 Manual Details
Coverage Areas
Product Name:
Opel Vauxhall Calibra 1991 Repair Service Manual
Description:
Service Manual Repair PDF Download
Page Count
Page Count Estimate:
Extensive (typical factory service manuals for this era range from 500-1500 pages, specific count not provided)
Manual Type
Manual Type:
Repair Service Manual / Workshop Manual
Language
Language:
English
Format
File Format:
PDF
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinZip
Operating System Compatibility:
All Versions of Windows & Mac
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, tuning, fuel injection, ignition, cooling, lubrication, exhaust
Transmission Systems:
Manual and Automatic transmission service, repair, and overhaul
Drivetrain Systems:
Front-wheel drive, all-wheel drive (including Haldex system for 4x4 variants), driveshafts, differentials
Braking Systems:
Hydraulic system, ABS (Anti-lock Braking System), brake pad/disc replacement, caliper overhaul
Steering Suspension Systems:
Power steering, suspension components (struts, springs, bushings), alignment specifications
Electrical Systems:
Wiring diagrams, battery, charging system, lighting, starter, fuse box, ECU diagnostics
Body And Chassis:
Body panel repair, interior trim, glass replacement, chassis lubrication
HVAC Systems:
Heating, Ventilation, and Air Conditioning system service and repair
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, fluid checks, tune-ups
Disassembly Assembly:
Step-by-step procedures for component removal and installation
Cleaning Reinstallation:
Specific instructions for cleaning and properly reassembling parts
Troubleshooting Diagnostics:
Guidance for identifying and resolving common problems and fault codes
Repair Procedures:
Detailed instructions for repairing various vehicle components
Technical Depth
Technical Depth:
Comprehensive; suitable for professional technicians and advanced DIYers with basic mechanical and electrical knowledge
📊 Manual Specifications
File Format
File Format Type:
PDF
Print Quality
Printable Specification:
Full Printable
Zoom Capability:
YES
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
C20NE (2.0L SOHC 8V)
Engine Displacement Common:
1998 cc
Horsepower Common:
115 PS (113 bhp; 85 kW)
Torque Common:
170 Nm (125 lb-ft) @ 2800 rpm
Performance
Performance Engine 2.0 16V:
C20XE, 1998cc, 150 PS (148 bhp; 110 kW), 196 Nm (145 lb-ft)
Performance Engine 2.5 V6:
C25XE, 2498cc, 170 PS (168 bhp; 125 kW), 227 Nm (167 lb-ft)
Fuel System
Fuel Injection System:
Bosch Motronic (specific version varies by engine)
Fuel Type:
Unleaded Petrol (95 RON recommended, 98 RON for higher performance variants)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual
Optional
Optional Transmission:
4-speed Automatic
Features
AWD System:
Optional four-wheel drive system (based on Haldex clutch technology) available on some models, particularly 2.5 V6 and later 2.0 Turbo variants.
📐 Dimensions
Exterior
Length:
4460 mm (175.6 in)
Width:
1710 mm (67.3 in)
Height:
1320 mm (52.0 in)
Wheelbase:
2530 mm (99.6 in)
Weights
Kerb Weight Approx:
1350 - 1450 kg (depending on engine and transmission)
Cargo
Boot Capacity:
340 litres
🛡️ Safety Features
Ratings
Safety Standard:
Early 1990s safety standards, generally good for its time but lacks modern advanced safety features.
Active Features
ABS:
Optional ABS (Anti-lock Braking System) on many models.
Passive Features
Airbags:
Driver airbag typically optional or standard on higher trims in later production years, passenger airbag rare for 1991.
Seatbelts:
Pre-tensioned front seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette players, often with amplifier units and basic equalizer functions. Optional CD players available.
Driver Assistance
Cruise Control:
Available as an option on higher trim levels and with certain engine variants.
Connectivity
Interior Features:
Electric windows (front), central locking, electrically adjustable mirrors (optional). Heated seats and leather upholstery available on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 km (6,000 miles) or 12 months, whichever comes first. (Refer to manual for exact specification).
Timing Belt Interval:
For C20XE and C25XE engines, typically 60,000 km (37,000 miles) or 4 years. Critical to replace if unknown.
Fluid Specifications
Engine Oil Specification:
API SG/SH, ACEA A2/A3, viscosity typically 10W-40 or 5W-40 synthetic (refer to manual for exact engine specification).
Coolant Specification:
G11 coolant (blue or green silicate-based coolant) mixed with distilled water at a 50/50 ratio.
Transmission Fluid Manual:
GL-4 gear oil, 75W-90 or 80W-90 viscosity.
Transmission Fluid Automatic:
Dexron II or Dexron III (specific type depends on gearbox model, consult manual).
Known Issues
Rust Corrosion:
Prone to rust, especially around wheel arches, sills, rear screen surround, and fuel filler neck.
Electrical Gremlins:
Can suffer from intermittent electrical issues due to age and wiring loom degradation, particularly dashboard warning lights and central locking.
Suspension Wear:
Worn suspension bushings, ball joints, and shock absorbers are common due to mileage and age.
Exhaust Manifold Cracks:
The cast iron exhaust manifold on the C20XE engine is known to develop cracks.
📚 Vehicle History
Brand Heritage
Opel Vauxhall Heritage:
Part of GM Europe, known for producing well-engineered and often sporty vehicles for the European market.
Model Evolution
Calibra Debut:
Launched in 1989 as a successor to the Opel Monza and Ford Capri competitor, instantly acclaimed for its radical styling.
Calibra 1991 Context:
Represents the early production phase of the Calibra model, establishing its distinctive design and mechanical basis.
Production
Production Years:
1989–1997
Production Locations:
Rüsselsheim am Main, Germany (Opel) and Ellesmere Port, United Kingdom (Vauxhall).
🏆 Awards & Recognition
Recognitions
Design Awards:
While specific awards for the 1991 model are not universally cited, the Calibra's radical aerodynamic design was widely praised and influential in automotive styling throughout the 1990s. It often featured in 'car of the year' polls for design.
Ratings
Performance Reviews:
Praised for its handling, comfort, and performance, especially the V6 and later Turbo models, although some critics noted a somewhat firm ride and less engaging steering than some rivals.

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