Bodywork And Fittings - Opel Kadett Owner's Manual

Chapter 11

Bodywork and fittings

Contents
Bonnet - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Bonnet release cable - removal and refitting . . . . . . . . . . . . . . . . . . . .7
Boot lid and torsion rods - removal and refitting . . . . . . . . . . . . . . . .25
Boot lid lock components - removal and refitting . . . . . . . . . . . . . . .26
Centre console - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .35
Door - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Door exterior handle - removal and refitting . . . . . . . . . . . . . . . . . . . .15
Door inner trim panel - removal and refitting . . . . . . . . . . . . . . . . . . .12
Door lock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Door remote control handle - removal and refitting . . . . . . . . . . . . . .16
Door window - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .19
Exterior rear view mirror components - removal and refitting . . . . . .30
Front door lock cylinder - removal and refitting . . . . . . . . . . . . . . . . .17
Front seat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Front trim panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .8
Front wing - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .10
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Glovebox - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Head restraints - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .32
Luggage area trim panel removal - general information . . . . . . . . . . .34
Degrees of difficulty
Easy, suitable for Fairly easy, suitable
novice with little for beginner with
experience some experience
Specifications
Torque wrench settings
Bonnet hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate lock striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front and rear trim panel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate strut attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat belt mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear crossmember-to- lock bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear body panel-to-lock bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front seat mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front seat back-to-frame bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 General information
The main body structure is a welded
construction of individually shaped panels
which make up a 'monocoque' bodyshell,
without a separate chassis. Various areas are
strengthened to provide for suspension,
steering and engine attachments and load
distribution. The whole shell is very strong and
rigid for its weight.
The front wings are bolted in position and
can be renewed without special equipment.
Interior fittings are of an extremely high
standard, even on basic models.
Maintenance - bodywork and underframe . . . . . . . . . . . . . . . . . . . . . .2
Maintenance- hinges and locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Maintenance - upholstery and carpets . . . . . . . . . . . . . . . . . . . . . . . . .3
Major body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Minor body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Rear quarterlight (opening type) - removal and refitting . . . . . . . . . . .28
Rear quarterlight (opening type) weatherstrip - renewal . . . . . . . . . .29
Rear seat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Rear trim panel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .9
Seat belts - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Sunroof - operation and maintenance . . . . . . . . . . . . . . . . . . . . . . . .38
Tailgate - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Tailgate hinge - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .21
Tailgate lock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .23
Tailgate lock cylinder - removal and refitting . . . . . . . . . . . . . . . . . . .24
Tailgate strut - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .22
Wind deflector - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .11
Window lifting mechanism - removal and refitting . . . . . . . . . . . . . . .18
Windscreen and other fixed glass - removal and refitting . . . . . . . . .27
Fairly difficult,
suitable for competent
DIY mechanic
Nm
20
20
20
12
20
35
55
20
20
30
2 Maintenance - bodywork and
underframe
1 The general condition of a vehicle's
bodywork is the one thing that significantly
affects its value. Maintenance is easy but
needs to be regular. Neglect, particularly after
minor damage, can lead quickly to further
deterioration and costly repair bills. It is
important also to keep watch on those parts
of the vehicle not immediately visible, for
instance the underside, inside all the wheel
arches and the lower part of the engine
compartment.
Difficult, suitable for Very difficult,
experienced DIY suitable for expert
mechanic DIY or professional
lbf ft
15
15
15
9
15
25
43
15
15
22
2 The basic maintenance routine for the
bodywork is washing preferably with a lot of
water, from a hose. This will remove all the
loose solids which may have stuck to the
vehicle. It is important to flush these off in
such a way as to prevent grit from scratching
the finish. The wheel arches and underframe
need washing in the same way to remove any
accumulated mud which will retain moisture
and tend to encourage rust. Strange as it may
seem, the best time to clean the underframe
and wheel arches is in wet weather when the
mud is thoroughly wet and soft. In very wet
weather the underframe is usually cleaned of
large accumulations automatically and this is
a good time for inspection.
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