Opel Kadett User Manual

Chapter 1
Routine maintenance and servicing
Air cleaner filter element renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . .13
Automatic transmission fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . .33
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . . . . . . . . . . . .9
Battery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Brake pad, caliper and disc check . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Carburettor fuel inlet filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Clutch adjustment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Driveshaft CV joint and gaiter check . . . . . . . . . . . . . . . . . . . . . . . . .20
Electrical system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Engine oil and filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Fluid level checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Fuel filter renewal - fuel injection models . . . . . . . . . . . . . . . . . . . . . .25
Fuel pump filter cleaning - carburettor models . . . . . . . . . . . . . . . . .12
Handbrake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Headlamp aim check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Hinge and lock lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Hose and fluid leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Idle speed and mixture adjustments . . . . . . . . . . . . . . . . . . . . . . . . .11
Ignition system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Manual transmission oil level check . . . . . . . . . . . . . . . . . . . . . . . . . .27
Rear brake shoe, wheel cylinder and drum check . . . . . . . . . . . . . . .29
Rear wheel bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Roadwheel bolt tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Tyre checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Vauxhall Astra/Belmont maintenance schedule . . . . . . . . . . . . . . . . . .1
Wiper blade check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
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 the
manufacturer for vehicles driven daily. If you wish to keep your vehicle
in peak condition at all times, you may wish to perform some of these
procedures more often. We encourage frequent maintenance, because
it enhances the efficiency, performance and resale value of your
vehicle. If the vehicle is driven in dusty areas, used to tow a trailer, or
driven frequently at slow speeds (idling in traffic) or on short journeys,
more frequent maintenance intervals are recommended.
When the vehicle is new, it should be serviced by a factory-
authorised dealer service department, in order to preserve the factory
warranty.
1•1
Easy, suitable for
novice with little
experience
Fairly easy, suitable
for beginner with
some experience
Fairly difficult, suitable
for competent DIY
mechanic
Difficult, suitable for
experienced DIY
mechanic
Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
Contents
1
1 Vauxhall Astra/Belmont maintenance schedule

Opel Kadett Specifications

General

Brand	Opel
Model	Kadett
Category	Automobile
Language	English

Summary

Chapter 1 Routine maintenance and servicing

1 Vauxhall Astra/Belmont maintenance schedule

Routine maintenance schedule for Vauxhall Astra/Belmont vehicles, detailing tasks and intervals.

1•2 Maintenance schedule

Maintenance tasks categorized by mileage and time intervals.

1•7 Maintenance - introduction

Purpose of the chapter and general advice on planned maintenance.

1•8 Maintenance procedures

Detailed procedures for routine maintenance tasks.

7 Spark plug renewal

9 Auxiliary drivebelt check and renewal

10 Ignition system check

11 Idle speed and mixture adjustments

Procedure for adjusting idle speed and mixture.

17 Brake pad, caliper and disc check

Procedure for checking brake pads, calipers, and discs.

Chapter 2 Part A: OHV engine

2A•4 OHV engine

Procedures for OHV engine maintenance.

1 General description

6 Ancillary components - removal and refitting

Chapter 2 Part B: OHC engines

Crankshaft and bearings

Torque wrench settings (continued)

Continued torque values for OHC engine components.

1 General description

General description of the OHC engine, its systems, and components.

2 Compression test - description and interpretation

Procedure and interpretation for engine compression tests.

5 Ancillary components - removal and refitting

6 Oil pressure regulator valve - removal and refitting

Chapter 2 Part C: DOHC (16-valve) engine

General

Crankshaft

Cylinder head

2C•4 DOHC (16-valve) engine

Procedures for DOHC (16-valve) engine maintenance.

7 Camshaft toothed belt - removal, refitting and adjustment

Procedure for removing, refitting, and adjusting the camshaft toothed belt.

6 Oil pressure regulating valve - removal and refitting

Chapter 4 Part A: Fuel and exhaust systems - carburettor models

32TL Carburettor data - 12SC engine

2E3 Carburettor data - 13SC engine

1B1 Carburettor data - 13NB engine

4A•2 Fuel and exhaust systems - Carburettor models

Procedures for fuel and exhaust systems on carburettor models.

35 PDSI Carburettor data - 13N engine

2E3 Carburettor data - 16 SV engine

Idle speed adjustment data

Recommended fuel grade

4A•3 Fuel and exhaust systems - Carburettor models

Specifications and torque settings for carburettor models.

4A•4 Fuel and exhaust systems - Carburettor models

Procedures for fuel and exhaust systems on carburettor models.

1 General information

3 Air cleaner housing - removal and refitting

5 Fuel pump - testing, removal and refitting

Procedure for testing, removing, and refitting the fuel pump.

6 Fuel tank sender unit - removal and refitting

Chapter 4 Part B: Fuel and exhaust systems - fuel-injected models

System type

Fuel pump

Adjustment data

Recommended fuel

4B•2 Fuel and exhaust systems - fuel-injected models

Procedures for fuel and exhaust systems on fuel-injected models.

1 General information and precautions

General information and safety precautions for fuel system work.

2 Air cleaner housing - removal and refitting

3 Accelerator cable - removal, refitting and adjustment

Procedure for removing, refitting, and adjusting the accelerator cable.

4B•3 Fuel and exhaust systems - fuel-injected models

Procedures for fuel and exhaust systems on fuel-injected models.

5 Fuel injection system - general information

General information on fuel injection systems.

6 Fuel system - depressurisation

Procedure for depressurising the fuel system.

Chapter 5 Part A: Starting and charging systems

1 General information and precautions

General information and safety precautions for electrical system work.

3 Battery - testing and charging

Procedure for testing and charging the battery.

4 Battery - removal and refitting

5 Charging system - testing

7 Alternator - removal and refitting

8 Alternator - testing and overhaul

9 Starting system - testing

Procedure for testing the starting system.

10 Starter motor - removal and refitting

11 Starter motor - testing and overhaul

Chapter 5 Part B: Contact breaker ignition system

3 Contact breaker points - gap and dwell angle adjustment

Adjusting the contact breaker points gap and dwell angle.

4 Contact breaker points - removal and refitting

6 Distributor - removal and refitting

Procedure for removing and refitting the distributor.

7 Distributor - overhaul

8 Ignition timing - adjustment

Procedure for adjusting the ignition timing.

Chapter 5 Part C: Electronic (breakerless) ignition systems

2 Ignition system - testing

Testing the ignition system.

3 Distributor - removal and refitting

Procedure for removing and refitting the distributor.

4 Distributor - overhaul

5 Ignition timing - adjustment

Procedure for adjusting ignition timing.

6 Ignition HT coil - removal, testing and refitting

Procedure for removing, testing, and refitting the ignition HT coil.

7 Ignition module (control unit) - removal and refitting

Procedure for removing and refitting the ignition module.

Chapter 9 Braking system

Front brakes

Rear brakes

1 General description

General description of the hydraulic brake system.

2 Hydraulic system - bleeding

Procedure for bleeding the hydraulic brake system.

4 Front brake pads - renewal

Procedure for renewing front brake pads.

5 Rear brake pads - renewal

Procedure for renewing rear brake pads.

6 Rear brake shoes - renewal

7 Front brake disc - inspection, removal and refitting

Procedure for inspecting, removing, and refitting front brake discs.

8 Rear brake disc - inspection, removal and refitting

Procedure for inspecting, removing, and refitting rear brake discs.

9 Rear brake drum - removal, inspection and refitting

Procedure for removing, inspecting, and refitting rear brake drums.

10 Front brake caliper - removal, overhaul and refitting

Procedure for removing, overhauling, and refitting front brake calipers.

12 Rear wheel cylinder - removal, overhaul and refitting

Procedure for removing, overhauling, and refitting rear wheel cylinders.

13 Master cylinder - removal and refitting

Procedure for removing and refitting the master cylinder.

14 Pressure regulating valves - testing, removal and refitting

21 Anti-lock braking system (ABS) - general information

General information on the Anti-lock Braking System (ABS).

22 Anti-lock braking system (ABS) components - removal and refitting

Procedure for removing and refitting ABS components.

Electronic control unit (ECU)

Chapter 10 Suspension and steering

Wheel alignment and steering angles

10•2 Suspension and steering

Maintenance procedures for suspension and steering.

Torque wrench settings

Torque values for suspension and steering components.

Front suspension

Rear suspension

Steering

10•3 Suspension and steering

General information and diagrams for suspension and steering.

1 General information

General information on front and rear suspension systems.

1.1 Exploded view of the front suspension components

10•4 Suspension and steering

Procedures for suspension and steering components.

2 Front suspension strut - removal and refitting

Procedure for removing and refitting the front suspension strut.

3 Front hub bearings - renewal

Procedure for renewing front hub bearings.

10•5 Suspension and steering

Procedures for suspension and steering components.

4 Front suspension strut - overhaul

Procedure for overhauling the front suspension strut.

10•6 Suspension and steering

Procedures for suspension and steering components.

5 Front suspension control arm - removal and refitting

Procedure for removing and refitting the front suspension control arm.

6 Control arm bushes - renewal

7 Control arm balljoint - renewal

8 Front anti-roll bar - removal and refitting

9 Rear suspension

10 Rear hub - removal and refitting

Procedure for removing and refitting the rear hub.

11 Rear hub bearings - renewal

Procedure for renewing rear hub bearings.

10•8 Suspension and steering

Procedures for suspension and steering components.

11 Rear brake caliper - removal, overhaul and refitting

Procedure for removing, overhauling, and refitting rear brake calipers.

12 Rear shock absorbers - removal and refitting

Procedure for removing and refitting rear shock absorbers.

13 Rear anti-roll bar - removal and refitting

14 Rear springs - removal and refitting

Procedure for removing and refitting rear springs.

15 Rear axle assembly - removal and refitting

Procedure for removing and refitting the rear axle assembly.

16 Rear axle mounting bushes - renewal

17 Front brake pedal - removal and refitting

17 Brake pedal - removal and refitting

18 Handbrake cable - removal and refitting

Procedure for removing and refitting the handbrake cable.

19 Steering wheel - removal and refitting

20 Steering column - removal and refitting

22 Steering column flexible coupling - removal and refitting

23 Steering lock cylinder and ignition switch wiring block - removal and refitting

Procedure for removing and refitting steering lock cylinder and ignition switch wiring block.

24 Tie-rod balljoints - removal and refitting

25 Steering rack bellows - removal and refitting

26 Steering damper - removal and refitting

27 Steering gear - removal and refitting

Procedure for removing and refitting the steering gear.

30 Power steering pump - removal and refitting

Procedure for removing and refitting the power steering pump.

31 Power steering fluid reservoir - removal and refitting

29 Power-assisted steering - bleeding

Procedure for bleeding the power-assisted steering system.

32 Wheel alignment and steering angles - general information

General information on wheel alignment and steering angles.

Chapter 11 Bodywork and fittings

2 Maintenance - bodywork and underframe

Routine maintenance for the vehicle's bodywork and underframe.

4 Minor body damage - repair

5 Major body damage - repair

Repairs of rust holes or gashes in bodywork

Bodywork repairs - filling and respraying

6 Bonnet - removal and refitting

Procedure for removing and refitting the bonnet.

7 Bonnet release cable - removal and refitting

8 Front trim panel - removal and refitting

9 Rear trim panel - removal and refitting

10 Front wing - removal and refitting

12 Door inner trim panel - removal and refitting

Procedure for removing and refitting the door inner trim panel.

13 Door - removal and refitting

Procedure for removing and refitting the door.

14 Door lock - removal and refitting

Procedure for removing and refitting the door lock.

15 Door exterior handle - removal and refitting

16 Door remote control handle - removal and refitting

17 Front door lock cylinder - removal and refitting

18 Window lifting mechanism - removal and refitting

Procedure for removing and refitting the window lifting mechanism.

19 Door window - removal and refitting

23 Tailgate lock - removal and refitting

Chapter 12 Body electrical system

Specifications

Specifications for electrical system components.

Fuses - early models

1 General information

General information on the vehicle's electrical system.

2 Electrical fault finding - general information

General information and procedures for diagnosing electrical faults.

4 Switches - removal and refitting

Steering column switches

16 Central locking system - general information and component renewal

Driver's door switch

Driver’s door switch

Passenger door and tailgate servo motors

Boot lid servo motor (Saloon models)

17 Headlight/direction indicator lens assembly - removal and refitting

17 Headlamp/direction indicator lens assembly - removal and refitting

Headlamp

Rear lamp cluster

19 Wiper blades and arms - removal and refitting

20 Windscreen wiper motor and linkage - removal and refitting

21 Tailgate contact pins and plate - removal and refitting

20 Tailgate - removal and refitting

21 Tailgate hinge - removal and refitting

22 Tailgate strut - removal and refitting

18 Tailgate contact pins and plate - removal and refitting

24 Tailgate lock cylinder - removal and refitting

25 Boot lid and torsion rods - removal and refitting

26 Boot lid lock components - removal and refitting

31 Front seat - removal and refitting

33 Rear seat - removal and refitting

35 Centre console - removal and refitting

Chapter REF Reference

General Repair Procedures

General procedures and precautions for vehicle servicing and repair.

Fault diagnosis

Guide to diagnosing common vehicle faults and their causes.

Engine

Fault diagnosis for engine-related problems.

Cooling system

Fault diagnosis for cooling system problems.

Fuel and exhaust systems

Fault diagnosis for fuel and exhaust system problems.

Clutch

Fault diagnosis for clutch-related problems.

Manual gearbox

Fault diagnosis for manual gearbox problems.

Automatic transmission

Fault diagnosis for automatic transmission problems.

Driveshafts

Fault diagnosis for driveshaft problems.

Braking system

Fault diagnosis for braking system problems.

Suspension and steering

Fault diagnosis for suspension and steering problems.

Electrical system

Fault diagnosis for electrical system problems.

Tools and working facilities

MOT test checks

Guide to vehicle checks for MOT test.