New Cavalier Project

[rustyrescue]

Hi, i got a Cavalier this weekend and have a few little jobs to start off with...its a lovely low owner low mile 1.8 car.

1)radio code for an SC201 phillips set? plenty offering codes on Blaupunkt but not phillips.
2)Fuel filler flap needed.
3)Drivers door mirror,,manual type to paint and match.
4)side repeater light on wing.
5)first use of hazard switch and they stuck on!! seems like the switch and cant even see how to remove it yet. Wedged in with a bit of card and they stay off. Likely a switch needed.
6) the plastic dash top between the two small speakers under the screen is cracked.

Other than that it is a good service, adjust the silly high clutch pedal etc.

Any guidance welcome and especially if any of you have pats that may help me.

[Envoy CDX]

Welcome to the forum.

I can probably help / supply all of that with the exception of the radio.
Clutch pedal can be adjusted with the cable, there is a how2 somewhere, Failing that, on the F16 / F20 boxes, you can do a clutch without removing the box in under a couple of hours taking your time if you're so inclined

[rustyrescue]

Hi Envoy CDX, thanks you...yes I have looked and can see the clutch cable adjuster and have the spec for the pedal travel. I sourced a filler flap today. I will PM you when I have been through any needs.
The mirror has broken metal bar in it...all ok otherwise...but it hangs off and does not adjust one way as a result.

[Envoy CDX]

No worries, hopefully we can sort something for you.

[Robsey]

I have sent you an email with some useful info.



Hope it helps.

[ilovedmymantas]

Hi and welcome

[rustyrescue]

Thanks to you both, Robsey I e=mailed you back thanks!

[Robsey]

Yes - I received the reply, thanks.


Hopefully you will find all the answers you need.

There are lots of How 2s here on the forum, including how to dismantle many parts.

As far as plastic parts are concerned - it is good to work on them in the warm.
They are more brittle / delicate when cold.

[rustyrescue]

yes warm is good! I use a heat gun to warm stuff up carefully. Especially good on old hard motorcycle wiring looms! The headlight is out, bottom lug was off to hence why it was not seen.

[Robsey]

Daft as it may sound, a standard hair drier will be ideal for this kind of work.
Hot enough to warm the plastic, but not hot enough to melt anything.

Wiring looms - now you are in my comfort area.
Usually it is a matter of fitting fresh crimps or pins.

If the wires are "looking" old - blackened or a peculiar pink colour, then the best option is to replace any affected wires with new ones.

And because I am a bit OCD, I always solder my pins on.
I never trust crimps 100%.

But that is just me.

[rustyrescue]

I am with you Robsey....solder and heatshrink! I do indeed use a hairdryer too, My Mums 1960's Morphy Richards! one of those old snail looking ones ;0)

[Robsey]

Looking at your earlier post, and Envoys reply about clutch adjustment -

Seeing as you have a 1995 C18NZ engine, I expect you to have an F18 gearbox.
This means that it is a gear-box off job to replace the clutch, if that is the source of your high pedal position.
The clutch is the same as the Calibra - as in to suit a recessed "pot" flywheel.

Clutch travel should be 137mm ( 5 1/2" ).
Pedal to floor - to - pedal released.

Also door mirror casings...
If the casings are okay, they can be released from the broken mirror bodies and clipped onto a replacement body.
That would save having to paint your new mirrors.

viewtopic.php?f=70&t=5321

[rustyrescue]

thanks Robsey, the clutch seems to be good with a twiddle of the cable adjustment! will be certain when driven again but it bites well on the drive in a nice position. The mirror tutorial is great, when I have my replacement mirror I may well use my casing if it has no scratches on it.

[Robsey]

I used a baby's plastic feeding spoon to gently lever the mirror tangs apart.
It saves gouging, scratching or snapping anything off.