Vauxhall Cavalier/OPEL

1200. 4x4 Accumulator Bulb Change

1200. This procedure is based on the specimen vehicle, a March '93 2.0l 16v Cav. Turbo, and some detail may differ to variants fitted with 4WD. It has been designed to deal specifically with the service change of an 'Accumulator bulb'. And involves removing the accumulator bulb from the vehicle and installing a new replacement.

1201. Removal - of the bulb from the vehicle.
Figure 1
A general view of the Accumulator assemblies mounted on the bulkhead
A. Pressure switch bulkhead connector (Do not disconnect)
B. txb temperature switch connector
C. Accumulator to mounting bracket bolts
D. Accumulator Bulb (No white band)
E. Accumulator control housing
F. Accumulator out to control block in (HP)
G. Steering pump to accumulator (HP)
H. Solenoid Control Block
J. Fluid Return Manifold
K. Accumulator out steering rack in (HP)
L. Steering rack fluid return connection

1202. Switch on the ignition without starting the car and with fuse 19 in place, pump the brake pedal at least 25 times & until any 'whooshing' from the accumulator ceases. Switch off the ignition and remove fuse 19.

1203. Place drip tray under the vehicle to catch any steering oil leakage.
Drip Tray
1204. (Fig.4b) shows a webbing type of oil filter removal tool located on the accumulator bulb. This is required for tightening the new bulb. For removal of the old bulb, a chain type is recommended. This is because the seal may be difficult to break and is likely to break the webbing tool. Both types are usually fitted with a 1/2" square drive attachment, to provide the required purchase.
Chain type Oil Filter removal tool (1/2" drive)
1205. You will need the services of a second pair of hands as the accumulator assembly is rubber mounted and needs to be restrained to avoid damage. The second pair of hands needs to firmly grasp the assembly while the bulb seal is broken.
CAUTION: Significant risk of damage to hands.
Second pair of hands
Leather Gloves
1206. When the seal is broken (normal right hand thread), the bulb can be unscrewed and removed.
CAUTION: Likely fluid spill.
Installation - of the new Accumulator Bulb
1220. There will be a small rubber ring with the new bulb, this should be fitted to the neck of the new bulb, it provides the high pressure seal.
Small rubber seal
1221. Screw the new bulb into place and make it as tight as possible by hand.
Figure 4b
The Accumulator block in the vice with the webbing oil filter removal tool attached.
1222. Fit the webbing type oil filter tool to the bulb at its widest point.
Webbing type Oil Filter removal tool.
1223. Using a torque wrench tighten the bulb to around 30 ft lbs.
Torque Wrench.

1224. Bleed the system, using the relevant section of this Workshop Manual.

1225. When the system is bled, test the new accumulator bulb using the 'Whoosh Test' section of this Workshop Manual.
1226. For future reference, make a note of the pass result of the 'whoosh' test.
1227. Make a note of the date and mileage of the car. This should be recorded with the vehicle documentation for future use. The service life of the new bulb is the lesser of six years or 54k miles.
1228. Finally, If the replacement bulb is a GM/OPEL item there will be a yellow sticky label. This should be attached to the car near the assembly so it is clearly visible. It is also another handy place to record the date / mileage.
1229. If the bulb has been supplied by Cav16, it will have an authenticating plasticized label. This should be nylon strapped to the accumulator assembly. The Cav16 bulbs are OEM, but do not have the customary GM white ring, but otherwise are identical. The label is to ensure that anyone spotting the bulb does not think it is the GM recall item.





September 14, 2017