Mk3 Cavalier Owners Club | Vauxhall Cavalier Dot Com

Evening all.

I remember reading somewhere a list of the design problems with the cavalier. For example the sunroof drainage and boot panel trapping water.

Does anyone a have a list or a link so can make further checks. It’s was comprehensive list of exterior and interior....

My intention is to look at all these areas and try to remedy all these problems.

If anyone knows, then that would be great.

Any thoughts or suggestions...?

I don't know the list that you are referring to, but I aware of several leak-in areas in the rear hatch area.

In fact Gary (Envoy CDX) mentioned these issues in my WIP.

I'd also look at the top of the tailgate at the umbilical cord type thing, and the tops of the c pillers They are prone to cracking and letting water in under the rubber seals.

And Cavalier 1990 mentioned this.

Not sure if it is the same on the hatch but there is a join for the back panel about half way along the boot drain, and another for the light panel about near the end of the boot lip drain area on the saloon. Mine was leaking here even though it looked ok, no visible rust or swelling, It still leaks somewhere higher up near the bottom of the back window if you park it downhill and the drain fills up at the bottom of the window. 

For my own two-penneth.

The aerial grommet can be slack and allow rain to leak in.

The foam seals on the rear light clusters become squashed over time and allow rain in behind the light clusters.

At the front end -
Check below the A pillars behind where the front doors shut.
These areas can rust and allow rain into the cabin.
On the drivers side, this can allow the engine ecu to get wet and damaged.

The drainage piping for the sunroof is an obvious one.

And the overall condition of all door seals.

Thank you - I’ve passed on the comments and others. Hopefully will get some of these addressed.

Quick update...

F28 Gear box - opened up and running gear is pretty good condition.

C20LET Engine - stripped and in a million pieces. Currently being chemical cleaned.

Locked Transfer box... shell cleaned, next in line to be inspected.

Robsey wrote: At the front end -
Check below the A pillars behind where the front doors shut.
These areas can rust and allow rain into the cabin.
On the drivers side, this can allow the engine ecu to get wet and damaged.

The drainage piping for the sunroof is an obvious one.

And the overall condition of all door seals.

I'd also check scuttle panel - it's prone to leaking into the interior.
In my case glovebox and passenger foot well
It could just as easily affect the drivers side and, as Robsey says, can affect the ecu.

Every car on the road has design problems in one way or another, nothing is perfect.

However with a little work, it's easy to remedy any issues, and with the Cavaliers being designed in such a way that maintenance is straight forward, it's easy enough to tinker with them.

With regard to the rear sunroof drains, if you pull back the side linings in the trunk around the tail light corner areas, you can see the rubber hoses leading through to the floor going through rubber grommets. If you pull the hoses out, stick your finger Inside the grommets, there is a weird "mesh" presumably to stop water and dirt splashing from the road going up there, the hoses don't go through the mesh, and any dirt or small leaves or general crap that gets in through the sunroof when it's open, can get blocked up inside the grommets. Just make sure the ends of the hoses are clear and push them through the grommets, so that the ends of the hoses aren't blocked by the mesh inside the grommet. Get under the back of the car and you will see in the corners where the drain hoses come out, again push your finger in there, you should be able to feel no restrictions and go right into the hoses. (I hope that doesn't sound too dirty).

Now any water and dirt can fall straight onto the ground out of the hoses without being restricted by mesh inside the grommets.

I was hoping to get the car back on the road, but realistically don’t see happening this part of the year.

Here’s a quick commercial update...

Shell has returned from the chemical dippers. Well it’s still one piece, but some repairs are required.

Engine wise, completely stripped and some specialists mechanical works done. Slowly being put back together

Managed to pickup a good few turbo specific parts for spares.

Been looking for a old school cassette player that came on the cav turbo. After some research I found a great condition unit - this will replace the existing modern CD player.

I even found an original cavalier turbo engine undercover - which will keep engine clean,... not sure how long far!

Now the question - do I paint the cam cover the same colour as car (satin red) or go old school original ?

The answer is -or should I say, the real question is:
How original do you want the car to be?

If you are going so original as to fit an original cassette player, then it would be sensible to paint it in standard factory colours.

But saying that - sometimes painting a few parts satin red may look better / more modern, at the risk of losing originality.

A very personal choice.
I initially reverted my car close to factory original, but after a while I missed some of my little embellishments.

You spend such an amount of money: keep it original!

The rear quarter windows can end up leaking and running into boot. 3 bolts under c panel trim, take out and put grease or silicon on to seal

Rust on front floor corners common cause of water leak and, as mentioned, under scuttle, both in each ends where inner wing drain is the sealer dries out and leaks even if it looks ok, dig it out and reseal.

Plenty other things to keep you busy with cav, or indeed any car if you are nosey, like me!

I picked up a several large boxes full of cavalier parts. Most are switches, interior / exterior trim panels,handles and some exterior trim, grills etc.

I need to collect and will display in the coming period... if anyone needs anything - I’ll list the items.

Update on rebuild ...

Cavalier turbo gone for a complete overhaul & service

Engine parts slowly being put back piece by piece... slowly zzzzZ

Would anyone know the correct colour for the cavalier turbo rocker cover?

I managed to find a picture of an original unit... to get an idea and I’m no wiser!

Mazza wrote:I picked up a several large boxes full of cavalier parts. Most are switches, interior / exterior trim panels,handles and some exterior trim, grills etc.

I need to collect and will display in the coming period... if anyone needs anything - I’ll list the items.

Update on rebuild ...

Cavalier turbo gone for a complete overhaul & service

Engine parts slowly being put back piece by piece... slowly zzzzZ

Would anyone know the correct colour for the cavalier turbo rocker cover?

I managed to find a picture of an original unit... to get an idea and I’m no wiser!

Do you know the engine code for the turbo i.e. 20xev or something similar?

I briefly seen an article in one of the German magazines about the cavalier / vectra a ... not 100% sure but there was a design which had a close resemblance to the cavalier!

There were a few subtle touches from the Saab 95, calibra and irmcher / turbo style body kit.

I thought it looked great. I swear it was a cavalier reborn!

There’s some rumours that it’s the next vectra design - so I hear!

I’ve got some pictures on my other phone...

Perhaps someone from Germany knows more on the article in the start Das Opel magazin.

The electric aerial was originally fitted to the driver side wing (near the round side light).

Gsi bumpers without fogs...
Also different style grill...
I’ll try to find out more...

cavalier1990 wrote:Do you know the engine code for the turbo i.e. 20xev or something similar?

Engine code for the turbo is C20LET.

Tobias_CDX wrote:

cavalier1990 wrote:Do you know the engine code for the turbo i.e. 20xev or something similar?

Engine code for the turbo is C20LET.

I'm not very familiar with that engine, what you could do is look up the part number and google it and likely you'll get a few pics of it up.

Going way back in the topic.
Cam cover colour is always a silver colour.
It is the plug cover colour that varies.

C20LET - Turbo is a red L shaped cover looking much like thr XE cover.
C20XE - is a red cover saying DOHC 16v
C20XEV (Ecotec) is a slim black cover that runs across the middle of the cam cover saying Ecotec ( I shaped not L shaped).

Then just for more fun the XE intake manifold may have a black beautifying cover saying SFi.
The LET may have a cover saying Turbo.

And I cannot say much about the Ecotec XEV.

As Andrew has said, a quick google of the engine code should give a whole host of images.

Thanks Robsey. I did check and managed to source one, although someone beat to the purchase. The cams covers are silver (Matt) ... but not completely solid. It’s more two tone, sprinkle of dust particles

The ht cover is red and white lettering. There isnt a standard as it varied with each car. Cars made in the uk Vauxhall letters but had Opel logos (if built in Germany). Mine was build in Germany and shipped to the uk.

I got some pictures of an original brand new unit - you’ll see what I mean.

Anyways, it’ll be a very long time before turbo is back on the road... only touched the surface as yet.

Question - I got a bluapunk CD300 player in the garage that doesn’t work. It’s pretty good condition. Is worth repairing as unsure of its value?

It is definitely worth repairing as they are virtually impossible to get hold of now.

For the true enthusiast who is looking for originality, it is the most modern unit in the range.
The most versatile is the SC804 with CD changer.

From memory the CD300 also sounded much better than my original SC303 cassette unit.

Guys any recommendations on where I can get my hybrid turbo (C20let) serviced / rebuit... and typical prices I’d be looking at.

I’ll post some pictures soon on the progress to date...

Thanks in advance.

Lots happening behind the scene - updates to follow.

Does anyone know if the cavalier turbo and calibra turbo rear chassis legs are the same...?

Or are they all the same on all cavalier / calibra models...?

I know that the Calibra is an independent rear suspension (IRS) set up.
Same as the GSi models.

No idea at all if the turbo Cavalier has rear beam or IRS set up.
If it is IRS, then you could be in with a chance.

I would seriously doubt that the chassis rails of a beam suspension Cavalier would be the same as the IRS chassis rails.

Thanks Robsey... I’ll have to do some investigation. I’m pretty sure it’s IRS as it’s an extension to the gsi.

Also It’s time to get the shell into the metal works... sills, arches, chassis rails...

All Calibra got IRS and all Cavalier 4x4 and/or GSi.

Any recommendations where I can buy original sill (inner,outer), rear arches as the fit is very good .... failing that, some good aftermarket one’s for cavalier turbo?

Also looking at replacing the bonnet as it’s got mk3 Astra gsi vents .. which I don’t like and cheaper then removing & repairing it.

I’ve alreay tried a few peeps but not such luck.

Additionally, has anyone fitted any additional support on the chassis shell while restorating?

And last question, adjustable steering column and cover it that the same unit across the cavalier range?

Mazza wrote:And last question, adjustable steering column and cover it that the same unit across the cavalier range?

I can only answer your last question, only the pre-face lift cars at the higher spec trim levels had the adjustable steering column CDX, GSI. they deleted it with the introduction of the airbags & collapsible steering columns.