Opel Kadett E

1984-1991 of release

Repair and car operation



Opel Kadett E
+ 1. Maintenance instruction
+ 2. Weekly checks and service in a way
+ 3. Maintenance
+ 4. Engine
+ 5. System of cooling, heating and ventilation
+ 6. Fuel and exhaust systems
+ 7. Start and charging system
+ 8. Ignition system
+ 9. Coupling
+ 10. Transmissions and power shafts
+ 11. Brake system
+ 12. Suspension bracket and steering
- 13. Body
   13.1. Technical characteristics
   13.2. Care of a body
   13.3. Repair of insignificant damages of a body
   13.4. Repair of strong damages of a body
   + 13.5. Cowl
   13.6. Removal and installation of forward furnish of the car
   13.7. Removal and installation of back furnish of the car
   13.8. Removal and installation of a forward wing
   13.9. Removal and installation of a fairing of a windscreen
   + 13.10. Doors
   13.11. Removal and installation of a trunk lid and торсионов
   13.12. Replacement of components of the lock of a trunk lid
   13.13. Windscreen
   13.14. Removal and installation of back being slightly opened glass
   13.15. Replacement of consolidation of back being slightly opened glass
   13.16. Replacement of an external rear-view mirror
   + 13.17. Seats
   13.18. Removal and installation of head restraints
   13.19. Removal of furnish of a luggage compartment
   13.20. Removal and installation of the central console
   13.21. Removal and installation of a ware box
   13.22. Replacement of seat belts
   13.23. Check and hatch service
   + 13.24. Electric equipment of a body
+ 14. Electric circuits



13.3. Repair of insignificant damages of a body

Processing of scratches of a body

PERFORMANCE ORDER
1. If scratch is superficial and does not reach some metal, wipe area round scratch an obnovitel of paint or fine-grained abrasive paste.
2. Wash out a surface pure water.
3. Put on scratch with a brush a thin paint coat and give the chance to it to dry.
4. Continue to put paint until scratch will not be made even to a surrounding surface.
5. Give the chance to paint to harden within 2 weeks, then polish the put paint coat to level with paint surrounding a spot.
6. In summary polish a site of a surface of a body by means of wax paste.
7. If scratch, having damaged paint, got into body metal, that, using a tip of a sharp knife, remove a rust from scratch.
8. Put the rust converter according to its instruction.
9. Further with a shpatel put on scratch shpaklevochny paste.
10. After its complete drying paint over and polish the damaged site.

Repair of dents in a body design

PERFORMANCE ORDER
1. At deep cave-in of elements of a design of a body first of all try to curve a dent back before the maximum approach to a normal form of a body. Body metal in a place of blow is exposed to a pulling therefore the complete recovery of an initial form is impossible. Optimum it is considered dent alignment approximately on 3 mm below level of a surrounding surface.
2. If there is an access to dent inside, follows accurately выстучать its soft hammer with a wooden or plastic head. During this operation it is necessary to press densely to outer side of tapped area the corresponding wooden whetstone. It is required for amortization of blows of a hammer and for prevention of a flexure of more extensive area.
3. If the dent is in that area of a body where access from a reverse side is complicated or impossible, in the deepest points of a dent drill some small openings, in openings screw up self-cutting screws and extend a dent by means of flat-nose pliers for acting heads of screws.
4. Remove paint from the damaged area and at distance of 20 mm round it. Most easily it can be executed, using a wire brush or an emery paper got on a circle, fixed in an electrodrill.
5. After alignment of a dent put on it a layer of a shpaklevka, paint and a polyrole.

Repair of the rusted openings or holes in a body design

PERFORMANCE ORDER
1. Remove paint from the damaged area and approximately on 20 mm round it.
2. Using a metal brush, clear a being showered rust from a surface of the bared metal on the damaged area.
3. Process the damaged area the rust converter according to its instruction.
4. Close an opening from a rust or a hole a metal grid or a strip of an aluminum foil. Cut out approximately corresponding to an opening form a piece of a grid, enclose it in an opening so that its edges did not act over level of the panel surrounding an opening. Fix it by means of several lumps of shpaklevochny paste on perimeter.
5. Using the screw-driver handle, level the grid ends so that it densely adjoined to body metal.
6. Further make a shpatlevka, painting and polishing of the damaged site of a body.

Shpatlevka and body painting

At performance of shpatlevochny works it is necessary to have a wide flexible plastic or nylon shpatel for giving of a surface of a shpaklevka of smoothness.

PERFORMANCE ORDER
1. Shpatlevka alignment on the damaged site of a body make so that to form it demanded and smoothness. As soon as it was possible to achieve approximately demanded contour, stop to smooth down a shpatlevka a shpatel since at too long smoothing down it will start to harden, stick on a shpatel and to roll down, therefore the surface will be damaged.
2. Drawing of the subsequent, thinner layer of a shpatlevka should be made after drying of the previous layer, repeating these operations until level of a shpatlevka will not start to act slightly over level of a processed site.
3. After shpatlevka hardening it is necessary to remove its surplus with a metal scraper or a file.
4. Further processing make, using an emery paper set. Begin processing with use of a coarse-grained emery paper and in the subsequent pass to the fine-grained. An emery paper have on flat wooden whetstone, differently it is impossible to achieve an equal surface.

Prevention

At a finishing stage of polishing it is necessary to moisten a waterproof emery paper with water periodically. It gives to a processed zashpatlevanny surface special smoothness.


5. The Zashpatlevanny dent should appear surrounded on perimeter a layer of pure metal.
6. For removal from the processed site of a dust and fats wash out a processed site water and wipe fat-free solution.
7. Raise dust on a site a thin layer of light soil. It will help to reveal all defects allowed at processing in a shpatlevka.
8. The found defects level by means of a new layer of a shpatlevka and again зашкурьте a surface.
9. Continue this procedure before receiving an ideal surface.
10. After that the area of repair is ready to final painting.

Prevention

Aerosol drawing of paint should be carried out in the warm, dry, windless and easy atmosphere.

At carrying out painting indoors it is necessary to moisten a floor of a working platform with water for hit prevention in dust air.

When coloring of only one panel other parts of a body should be covered from paint hit on them with the newspaper attached by a sticky tape.


11. Before first coat drawing взболтайте capacity with it, put a first coat on a trial surface and achieve that it laid down evenly.
12. Put a thick layer of a first coat with a way of drawing of several thin layers.
13. Polish the grounded surface a waterproof emery paper. Thus do not forget сбрызгивать ground area water and periodically to moisten in water an emery paper.
14. Before further coloring dry up a processed site.
15. Drawing of a paint coat is made by a spray. The thickness of a paint coat is reached by drawing of several thin layers.
16. Coloring is necessary for beginning from the center of painted area and to move to edges back and forth motions until all painted surface, and also about 20 mm round it will not be painted.
17. A protective film and newspapers remove 10–15 minutes later after drawing of the last paint coat.
18. Give the chance to fresh paint to harden in a current of at least 2 weeks, then by means of an obnovitel of paint or thin abrasive polishing paste level edges of the painted area to level of old paint.
19. Polish a surface.