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Opel Kadett Manuals
Manuals and User Guides for Opel Kadett. We have
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Opel Kadett manuals available for free PDF download: Owner's Manual
Opel Kadett Owner's Manual (244 pages)
Opel Kadett
Brand:
Opel
| Category:
Automobile
| Size: 12.41 MB
Table of Contents
Degrees of Difficulty
1
Routine Maintenance and Servicing
1
Vauxhall Astra/Belmont Maintenance Schedule
1
Maintenance Schedule
2
Maintenance - Component Location
3
Underbonnet View of an Early 1.8 Litre Model
4
Underbonnet View of a 2.0 Litre 16-Valve Model
5
Front Underbody View of a 1.8 Litre Model - Other Models Similar
6
General Information
7
Intensive Maintenance
7
Rear Underbody View of a 1.8 Litre Model - Other Models Similar
7
Maintenance Procedures
8
Tyre Checks
8
Every 250 Miles or Weekly
8
6 Engine Oil and Filter Renewal
8
Every 9000 Miles
9
7 Spark Plug Renewal
9
Alternator/Power Steering Pump Drivebelt - Later 1.6 Litre Models
10
Auxiliary Drivebelt Check and Renewal
10
Hose and Fluid Leak Check
10
Power Steering Pump Drivebelt
10
Carburettor Models
11
Idle Speed and Mixture Adjustments
11
Ignition System Check
11
Adjusting the Idle Speed - Varajet Carburetor
12
Fuel-Injected Models
12
Idle Speed Adjusting Screw (A) - 1B1 Carburetor
12
Mixture (CO) Adjustment Screw - 32TL Carburetor
12
Wiper Blade Check
13
Automatic Transmission Fluid Level Check
13
Fuel Pump Filter Cleaning
13
Electrical System Check
13
Exhaust System Check
14
Handbrake Adjustment
14
Hinge and Lock Lubrication
14
Rear Wheel Bearing Adjustment
14
Air Cleaner Filter Element Renewal
15
Check the Operation and Performance of the Braking System
15
Every 18 000 Miles
15
Road Test
15
Fuel Filter Renewal - Fuel Injection Models
16
Manual Transmission Oil Level Check
17
Headlamp Aim Check
17
Clutch Adjustment Check
17
Carburettor Fuel Inlet Filter Cleaning
17
Brake Fluid Renewal
17
Coolant Renewal
18
Cooling System Draining
18
Cooling System Flushing
18
Every 2 Years
18
Maintenance Procedures
18
Table of Contents
19
Automatic Transmission Fluid Renewal
19
Every 36 000 Miles
19
Specifications
19
OHV Engine
20
Specifications
20
Piston Rings
21
Ancillary Components - Removal and Refitting
23
Compression Test - Description and Interpretation
23
Operations Possible with the Engine in the Car
23
Operations Requiring Engine Removal
23
Cylinder Head - Removal and Refitting
24
Valve Clearances - Adjustment
24
Cylinder Head - Overhaul
25
Cylinder Head and Pistons - Decarbonising
26
Oil Pump - Overhaul
27
Oil Pump - Removal and Refitting
27
Sump - Removal and Refitting
27
Timing Gear Components - Removal and Refitting
28
Pistons and Connecting Rods - Removal and Refitting
29
Flywheel - Removal and Refitting
30
Engine/Transmission Mountings - Removal and Refitting
30
Camshaft and Tappets - Removal and Refitting
31
Crankshaft and Main Bearings - Removal and Refitting
31
Crankshaft Rear Oil Seal - Removal and Refitting
31
Big-End and Main Bearing Shells
32
Crankshaft
32
Engine Components - Examination and Renovation
32
Camshaft and Bearings
33
Connecting Rods
33
Cylinder Bores
33
Timing Chain Sprockets and Tensioner
33
Engine - Initial Start-Up after Overhaul
34
Engine - Removal and Refitting
34
Engine Lubrication System - General Description
34
OHC Engines
35
Specifications
35
Cylinder Head
36
Lubrication System
38
Camshaft Toothed Belt - Removal, Refitting and Adjustment
39
General Description
39
Oil Pressure Regulator Valve - Removal and Refitting
39
Camshaft - Removal and Refitting
42
DOHC (16-Valve) Engine
51
Cooling, Heating and Ventilation Systems
62
Cooling System Hoses - Disconnection and Renewal
63
Radiator - Removal, Inspection and Refitting
63
Thermostat - Removal, Testing and Refitting
63
Water Pump - Removal and Refitting
65
Radiator Electric Cooling Fan - Testing, Removal and Refitting
65
Cooling System Electrical Switches - Testing, Removal and Refitting
66
Heater Components - Removal and Refitting
66
Heater/Ventilation System - General Information
66
Exploded View of Heater Components
67
Blower Motor
68
Heater Matrix
68
Air Distribution Housing
69
Vents and Grilles - Removal and Refitting
69
Fuel and Exhaust Systems - Carburettor Models
70
Idle Speed
72
To 850 Rpm
72
Unleaded Petrol - General Information and Usage
73
Air Cleaner Housing - Removal and Refitting
73
Fuel System
73
Air Cleaner Air Temperature Control System - General Information
74
Fuel Pump - Testing, Removal and Refitting
74
Fuel Tank Sender Unit - Removal and Refitting
74
Accelerator Cable - Removal, Refitting and Adjustment
75
Fuel Tank - Removal and Refitting
75
Accelerator Pedal - Removal and Refitting
76
Carburettor - Description
76
Choke Cable - Removal, Refitting and Adjustment
76
TL Carburettor - Adjustments
76
1B1 Carburettor - Adjustments
77
Fast Idle
77
Idle Speed and Mixture
77
PDSI Carburettor - Adjustments
77
2E3 Carburettor - Adjustments
78
Choke Unit Cover
78
Choke Valve Gap
78
Vacuum Pull-Down Unit
78
Choke Pull-Down
79
Fast Idle Cam Position
79
Throttle Damper Adjustment - Automatic Transmission Models
79
Throttle Valve Fast Idle Gap
79
Automatic Choke Carburettor
80
Varajet Ll Carburettor - Adjustments
80
Carburettor - Removal and Refitting
81
Idle Cut-Off Solenoid - Description and Testing
81
Part Load Regulator Screw Adjustment
81
Throttle Damper Adjustment
81
32 TL Carburettor - Overhaul
82
35 PDSI Carburettor - Overhaul
83
Exploded View of 35 PDSI Carburettor
84
1B1 Carburettor - Overhaul
85
2E3 Carburettor - Overhaul
86
Varajet II Carburettor - Overhaul
86
Exploded View of Varajet Carburettor
87
Exhaust Manifold - Removal and Refitting
88
Inlet Manifold - Removal and Refitting
88
Exhaust System - Inspection, Removal and Refitting
89
Inlet Manifold Pre-Heater (1.6 Litre Models with Automatic Transmission) - General Information, Removal and Refitting
89
Fuel and Exhaust Systems - Fuel-Injected Models
90
Less than 1.0
90
Litre Models: 8-Valve Models
90
To 780 Rpm
90
To 850 Rpm
90
To 880 Rpm
90
To 900 Rpm
90
To 990 Rpm
90
Exploded View of the Throttle Body/Injector Housing Assembly - 1.4 and 1.6 Litre Models
95
Single-Point Fuel Injection System Components and Location on 1.4 Litre Model
95
Pressure Regulator
96
Throttle Body/Injector Housing Unit
96
Coolant Temperature Sensor
97
Fuel Injectors
97
Inlet Manifold Pressure Sensor
97
Road Speed Sensor
97
Auxiliary Air Valve
98
Control Relay
98
Fuel Injectors - Motronic M2.5
99
Fuel Injectors - Motronic ML4.1 and M1.5
99
Battery Check
104
Starting and Charging Systems
104
Battery - Testing and Charging
105
Electrical Fault Finding - General Information
105
Maintenance-Free Battery - Testing
105
Standard and Low Maintenance Battery - Charging
105
Alternator - Removal and Refitting
106
Battery - Removal and Refitting
106
Charging System - Testing
106
Starting System - Testing
106
Oil Level Sensor (16-Valve Models) - Removal and Refitting
107
Oil Pressure Warning Light Switch/Gauge Sender - Removal and Refitting
107
Starter Motor - Removal and Refitting
107
Starter Motor - Testing and Overhaul
107
Contact Breaker Ignition System
108
Contact Breaker Points - Gap and Dwell Angle Adjustment
109
Engine Fails to Start
109
Engine Misfires
109
Ignition System - Testing
109
Condenser - Testing, Removal and Refitting
110
Contact Breaker Points - Removal and Refitting
110
Distributor - Overhaul
111
Distributor - Removal and Refitting
111
Ignition Timing - Adjustment
112
Ignition HT Coil - Removal, Testing and Refitting
113
Electronic (Breakerless) Ignition Systems
114
Carburettor Models
115
16-Valve Models
115
Spark Plugs
116
Exploded View of the Bosch Breakerless Type Distributor - 1.6 Litre (16SH Engine) and 1.8 Litre (18E Engine) Models
120
Ignition Module (Control Unit) - Removal and Refitting
121
Braking System
122
Fluid Level Checks
122
Bleeding - Basic (Two-Man) Method
124
Bleeding - Using a One-Way Valve Kit
124
Bleeding Sequence
124
Hydraulic System - Bleeding
124
Front Brake Pads - Renewal
125
GMF and Early ATE Type Caliper
125
Hydraulic Pipes and Hoses - Renewal
125
Later ATE Type Caliper
126
Rear Brake Pads - Renewal
126
Rear Brake Components with Drum Removed
127
Rear Brake Shoes - Renewal
127
Front Brake Disc - Inspection, Removal and Refitting
128
Handbrake Adjustment
128
Rear Brake Disc - Inspection, Removal and Refitting
129
Rear Brake Drum - Removal, Inspection and Refitting
129
Front Brake Caliper - Removal, Overhaul and Refitting
130
GMF Type Caliper
131
Rear Brake Caliper - Removal, Overhaul and Refitting
131
Master Cylinder - Removal and Refitting
132
Rear Wheel Cylinder - Removal, Overhaul and Refitting
132
ATE Type Cylinder
133
Exploded View of ATE Master Cylinder
133
GMF Type Cylinder
133
Exploded View of GMF Master Cylinder
134
Pressure Regulating Valves - Testing, Removal and Refitting
134
Brake Servo Vacuum Hose and Non-Return Valve - Renewal
135
Left-Hand Drive
135
Right-Hand Drive
135
Vacuum Servo Unit - Testing, Removal and Refitting
135
Brake Pedal - Removal and Refitting
136
Handbrake Cable - Removal and Refitting
136
Handbrake Lever - Removal and Refitting
136
Anti-Lock Braking System (ABS) - General Information
137
Handbrake Shoes (Rear Disc Brake Models) - Renewal
137
ABS Surge Arrester Relay
138
Anti-Lock Braking System (ABS) Components - Removal and Refitting
138
Electronic Control Unit (ECU)
138
Wheel Speed Sensor
138
ABS Hydraulic Unit Removal and Refitting
139
Suspension and Steering
140
Exploded View of the Front Suspension Components
142
Exploded View of Rear Suspension Components
143
Front Suspension Strut - Removal and Refitting
143
Front Suspension Strut - Overhaul
144
Control Arm Balljoint - Renewal
145
Control Arm Bushes - Renewal
145
Front Anti-Roll Bar - Removal and Refitting
145
Front Suspension Control Arm - Removal and Refitting
145
Rear Hub - Removal and Refitting
146
Rear Hub Bearings - Adjustment
146
Rear Hub Bearings - Renewal
146
Hatchback and Saloon
147
Main Roll Bar
147
Rear Anti-Roll Bar - Removal and Refitting
147
Rear Shock Absorbers -Removal and Refitting
147
Auxiliary Anti-Roll Bar - 2.0 Litre 16- Valve Models
148
Rear Axle Assembly - Removal and Refitting
148
Rear Springs - Removal and Refitting
148
Leaf Spring Rear Suspension Components (Astramax) - Removal and Refitting
149
Rear Axle Mounting Bushes - Renewal
149
Bump Stop
150
Level Control System - Description and Maintenance
150
Steering Column - Removal and Refitting
150
Steering Wheel - Removal and Refitting
150
Steering Column - Overhaul
151
Steering Column Flexible Coupling - Removal and Refitting
151
Steering Lock Cylinder and Ignition Switch Wiring Block - Removal and Refitting
151
Steering Gear - Removal and Refitting
152
Steering Rack Bellows - Removal and Refitting
152
Tie-Rod Balljoints - Removal and Refitting
152
Power Steering Fluid Reservoir - Removal and Refitting
153
Wheel Alignment and Steering Angles - General Information
154
Power Steering Pump - Removal and Refitting
153
Power-Assisted Steering - Bleeding
153
Steering Gear - Overhaul
153
Toe Adjustment Points (Only One Side Shown)
154
Bodywork and Fittings
155
Maintenance - Upholstery and Carpets
156
Minor Body Damage - Repair
156
Repairs of Dents in Bodywork
156
Repairs of Minor Scratches in Bodywork
156
Bodywork Repairs - Filling and Respraying
157
Plastic Components
157
Repairs of Rust Holes or Gashes in Bodywork
157
Bonnet - Removal and Refitting
158
Bonnet Release Cable - Removal and Refitting
158
Front Trim Panel - Removal and Refitting
158
Major Body Damage - Repair
158
Front Trim Panel Mounting Points
159
Front Wing - Removal and Refitting
159
Rear Trim Panel - Removal and Refitting
159
Door - Removal and Refitting
160
Door Inner Trim Panel - Removal and Refitting
160
Door Exterior Handle - Removal and Refitting
161
Door Lock - Removal and Refitting
161
Door Remote Control Handle - Removal and Refitting
161
Window Lifting Mechanism - Removal and Refitting
161
Door Window - Removal and Refitting
162
Tailgate - Removal and Refitting
162
Tailgate Hinge - Removal and Refitting
162
Tailgate Strut - Removal and Refitting
162
Boot Lid and Torsion Rods - Removal and Refitting
163
Tailgate Lock - Removal and Refitting
163
Tailgate Lock Cylinder - Removal and Refitting
163
Boot Lid Lock Components - Removal and Refitting
164
Exterior Rear View Mirror Components - Removal and Refitting
164
Rear Quarterlight (Opening Type) - Removal and Refitting
164
Windscreen and Other Fixed Glass - Removal and Refitting
164
Front Seat - Removal and Refitting
165
Head Restraints - Removal and Refitting
165
Rear Seat - Removal and Refitting
165
Centre Console - Removal and Refitting
166
Luggage Area Trim Panel Removal - General Information
166
Glovebox - Removal and Refitting
167
Seat Belts - General
167
Sunroof - Operation and Maintenance
168
Body Electrical System
169
Finding a Short Circuit
171
Finding an Earth Fault
171
Finding an Open Circuit
171
Fuses and Relays - General Information
171
Foglamp Switch
172
Lighting Master Switch
172
Steering Column Switches
172
Switches - Removal and Refitting
172
Cigarette Lighter - Removal and Refitting
173
Clock - Removal and Refitting
173
Horn(S) - Removal and Refitting
173
Instrument Panel - Removal and Refitting
173
Bulbs - Renewal
174
Instrument Panel - Dismantling and Reassembly
174
Speedometer Cable - Removal and Refitting
174
Front Direction Indicator
175
Headlamp
175
Rear Lamp Cluster
175
Sidelamp (Front Parking Lamp)
175
Headlamp/Direction Indicator Lens Assembly - Removal and Refitting
176
Interior Lamps
176
Number Plate Lamp
176
Switch Illumination Bulbs
176
Component Renewal
177
Headlamp Beam Adjustment - General Information
177
Headlamp DIM-Dip System (UK Models Only) - General Information
177
Trip Computer - General Information and Component Renewal
177
Central Locking System - General Information and Component Renewal
178
Computer Display Lighting
178
Driver’s Door Switch
178
Passenger Door and Tailgate Servo Motors
178
Heated Seats - General Information
179
Tailgate Contact Pins and Plate - Removal and Refitting
179
Windscreen Wiper Motor and Linkage - Removal and Refitting
179
Wiper Blades and Arms - Removal and Refitting
179
Rear Window Wiper Motor - Removal and Refitting
180
Check Control System - General Information
181
Headlamp Washer System - General Information
181
Radio/Cassette Unit - Removal and Refitting
181
Windscreen/Rear Window Washer System - General Information
181
Loudspeakers - Removal and Refitting
182
Radio Aerial - Removal and Refitting
182
Key to Diagram 1 - All Models to 1986 (Not All Items Are Fitted to All Models)
183
Key to Diagram 3 - All Models from 1990
201
Dimensions and Weights
218
Conversion Factors
219
Buying Spare Parts
220
Vehicle Identification Numbers
220
General Repair Procedures
221
Joint Mating Faces and Gaskets
221
Oil Seals
221
Screw Threads and Fastenings
221
Maintenance and Minor Repair Tool Kit
222
Repair and Overhaul Tool Kit
222
Tools and Working Facilities
222
Buying Tools
223
Care and Maintenance of Tools
223
Special Tools
223
Working Facilities
223
Footbrake
224
Handbrake
224
MOT Test Checks
224
Steering Wheel and Column
224
Electrical Equipment
225
Seat Belts and Seats
225
Shock Absorbers
225
Vehicle Identification
225
Exhaust System
226
Front and Rear Suspension and Wheel Bearings
226
Springs and Shock Absorbers
226
Steering Mechanism
226
Body Corrosion
227
CO Emissions (Mixture)
227
Fuel and Exhaust Systems
227
Wheels and Tyres
227
Fault Diagnosis
228
Automatic Transmission Fluid
228
Engine Fails to Rotate When Attempting to Start
229
Engine Rotates, but will Not Start
229
Engine Difficult to Start When Cold
229
Engine Difficult to Start When Hot
229
Fault Diagnosis
229
Engine Hesitates on Acceleration
230
Engine Stalls
230
Engine Backfires
230
External Coolant Leakage
230
Cooling System
230
Excessive Fuel Consumption
231
Fuel Leakage And/Or Fuel Odour
231
Excessive Noise or Fumes from Exhaust System
231
Clutch Fails to Disengage (Unable to Select Gears)
231
Manual Gearbox
231
Automatic Transmission Fluid Leakage
232
Clicking or Knocking Noise on Turns (at Slow Speed on Full-Lock)
232
Vibration When Accelerating or Decelerating
232
Vehicle Pulls to One Side under Braking
232
Braking System
232
Wheel Wobble and Vibration
233
Wandering or General Instability
233
Excessively-Stiff Steering
233
Battery will Not Hold a Charge for more than a few Days
233
Suspension and Steering
233
Electrical System
233
Ignition/No-Charge Warning Light Fails to Come on
234
Lights Inoperative
234
Horn Inoperative, or Unsatisfactory in Operation
234
Windscreen/Tailgate Washers Inoperative, or Unsatisfactory in Operation
234
Glossary of Technical Terms
235
Index
240
Hose and Fluid Leak Check
241
Road Test
242
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Opel Kadett Owner's Manual (40 pages)
2 door sedan sport coupe caravan
Brand:
Opel
| Category:
Automobile
| Size: 2.57 MB
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