Instruction/ maintenance manual of the product 1900 GT (1973) Opel
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IMPORTANT SAFETY NOTICE Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service procedures recommended by BUICK and described in this service manual are effective methods for performing service operations.
/ I / j BUICK MOTOR DIVISION GENERAL MOTORS CORPORATION IFLINT, MICHIGAN 48550 , 0 GENERAL MOTORS CORPORATION, 1972 Litho in U.S.A..
1973 GT OPEL 1900 MANTA CHASSIS SERVICE MANUAL This manual contains service information for the 1973 Opel 1900, Manta and GT models. Refer to the introduction for a description of the arrangement of this manual for locating desired information easily.
The 1973 Opel Chassis Service MayI has been completely revised with respect to layout, format and information content in a” attempt to provide you “The Technician” with a tiore logical and usable publication. An example of the new grouping layout 6 exhibited on the preceding page.
INTRODUCTION The 1973 Opel Service Manual includes information on the Opel 1900, Manta and GT. It is organized to correspond with current servicing tech- niques. The various chassis components and systems have been classified into the nine (9) GROUPS.
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GENERAL INFORMATION GROUP 0 Section OA OB oc Title Page General Information OA-1 Vehicle Lifting Points 06-4 Maintenance and Lubrication. OC-5.
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GENERAL INt=ORMATION OA-1 GENERAL INFORMATION KEYS AND LOCKS Every key has a number engraved on one side which identities the key blank manufacturer. On the oppo- site side of GT keys, is a removable adhesive foil on which, the profile and cutting code letters and num- bers are imprinted.
sOA- 1973 OPEL SERVICE MANUAL _ MODEL DESIGNATIONS OLll - OPEL 1900 2DR SEDAN OL60 - OPEL 1900 4DR SEDAN OL15 OPEL 1900 3DR WAGON MANTA 2 DR SPT. CPE. OL77 - c MANTA 2DR RALLYE SPT.
GENERAL INFORMATION OA-3 EXTERIOR PAINT MODELS coda coda Name Name 51 51 53 53 54 54 57 57 57L 57L 57R 77 57R 77 C C Alpine White Alpine White 0 0 strata Blue Strato Blue F F Glacier Blue Glacier Blue.
08-4 VEHICLE LIFTING ~ ~ VEHICLE LIFTING ALL; MODELS ALL OPEL DO NOT LIFT OR SUPPORT GT (ONLY) AT TRACK-BAR ATTACHMENT TO AXLE. i F IT n II II NOTE: SUPPORTS MUST BE POSITIONED Sd AS TO DISTRIBUTE LOAD AND SUPPORT VtiHICLE IN A STABLE MANNER.
LUBRICATION AND MAINTENANCE OC-5 LUBRICATION AND MAINTENANCE LO Engine Oil ,current “ISCOI- ifVl SE’ -u9 Lubriplate’ ,9F Hvdraulic Brake Fluid - Delco supreme NO.
CC-6 1973 OPEL SERVICE ‘MANUAL LUBRICATION AND GENERAL MAINTENANCE Every 4 months or 3,OW mile3 ~ 1 *Engine Oil EMISSION CONTROL MAINTENANCE Every 24 months or 31 1 Engine Conpression 24,ooO ~ 32 heI cap, Tank and Lines EVsN 24.
LUBRICATION AND MAINTENANCE OC-7 SERVICES LUBE AND GENERAL MAINTENANCE Vehicle operation under conditions such as heavy dust, continuous short trips, use of other than un- leaded or low lead fuels or pulling trailers, is not considered normal use and therefore more frequent maintenance will be required.
I oC-9 1973 OPEL SERVICE MANUAL Figure OC-5 Brake Master Cylinder I Figure OC-6 Tire Rotation Methods when the clutch pedal has in excess of 1 l/4 inch fr& travel. See Figure OC-7. Rear Axle Change lubricant every 12,ooO miies when vehicle is used for pulling a trailer.
LUBRICATION AND MAINTENANCE OC-9 4. Remove dipstick and wipe clean. 5. Reinsert dipstick untip cap seats. 6. Remove dipstick and note reading. If fluid level is at, or below the ADD mark, add sufficient fluid to rais the level to the FULL mark. One pint raises the level from ADD to FULL.
CC-10 1973 OPEL SERVICE MANUAL wiper blades. Check amount and direction of fluid sprayed by washers during use., E. Defrosters - Check performance by moving con- trols to “DEF” and noting am$nmt of air directed against the windshield.
LUBRICATION AND MAINTENANCE OC-11 Throttle Linkage Check for damaged or missing parts, interference or binding. Any deficiencies should be corrected with- out delay.
! OC-12 1973 OPEL SERVICE MANUAL i Exhaust Gas Recirculation Systep Check system operation at 12 &onth/12,000 mile intervals. Clean valve and EGR &usages if required; A valve with a damaged diaphragm must be re- placed.
ELECTRICAL GROUP 1 Section IA IB IC ID IE IF IG IH II IJ Title Battery and Cables . . . . . . Starting System . . . . . . . . . . . . Ignition System , . Charging System Washers and Wipers ., Lighting Systems Signal Systems instrument Panel ......... Gauges .
lA- 2 1973 OPEL SERVICE MANUAL BATER~ AND CABLES ALL/ MODELS C+NTENTIi Subject DESCRIPTION AND OPERATION: General Battery Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS: Battery and Cables - Trouble Diagno:sis .
BATTERY AND CABLES - ALL MODELS lA- 3 lost as the result of charging and discharging, and it must be replaced before the electrolyte level falls to the tops:of the separators. If the water is not replaced and the plates become exposed, they may become permanently sulphated, which would impair the per- forma”& of the plates.
1A. 4 1973 OPEL SERVICE MANUAL gravity corrected to 80 degrees F.’ shows more than a thirty point (.030) drop from the initial tilling with electrolyte, or if one or more cells’gas violently after addition of electrolyte, the batteiy should be fulty charged before use.
BATTERY AND CABLES - ALL MODELS lA- 5 and terminal connections should not exceed 2/10 volt. 5. Connedt voltmeter positive lead to ground on en- gine. At&h prod to voltmeter negative lead and apply prod to center of battery negative post.
j / lA- 6 1973 OPEL SERVICE MANUAL Do not overfill, as electrolyte may be sprayed out by gassing or may overtlow due to heat expansion dur: ing charging.
BATTERY AND CABLES - ALL MODELS lA- 7 421 Test F$ocedure 1. Visual Inspection - The first step in testing the Energizer br 12-V& Battery should be a visual in- spection which very often will save time, labor and expense in determining the condition.
1A. 8 1873 OPEL SERVICE MANUAL ELECTROLYTE SPECIFIC GRAVITY TEMPERATURE (F) CORRECTION -+0&&n _ THERMOMETER 30” EXAMPLE A: --,012 ---,016 ---,026 - -.02h - -.028 - -.032 ~ -.036 Y EXAMPLE 6: TEMPERATURE = 120” i. TEMPERATURE = -0” F. HYDROMETER = ,,230 HYDRdiETER = 1.
BATTERY AND CABLES - ALL MODELS lA- 9 plus 61 terminal of the voltage regulator and protects the circuit to the generator telltale light. BATTERY RECHARGING There are two separate methods of recharging batter- ies which giffer basically in the rate of charge.
1 B- 10 1973 OPEL SERVICE #MANUAL STARTlhG SYSTEM / ALL MODEILS CONTENTS Subject DESCRIPTION AND OPERATION: Starting System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS: Starting System Diagnosis, .
I STARTING SYSTEM lB- 11 but also in the condition of related units, such as battery, switches, electrical wiring and wiring connections. Condition Possible Cause Correction When ignition switch is 1. Battery discharged. 1. Charge battery. on, cranking motor locks up or dra’gs.
19- 12 1973 OPEL SERVICE MANUAL : Condition Posiible Cause Correction 4. Voltage drop. 1. Check wiring and wiring connections. 5. Overrun&g clutch slips. 1. Replace overrunning clutch. The cranking motor keeps on rotating after ignition switch is off.
STARTING SYSTEM lB- 13 4. Connect test equipment and, with transmission in neutral, turn engine over until voltage stabilizes. Note read.ings. 5. Current draw should be between 90-130 amperes. I 3. Remove end frame from field frame and pull both insulating tubes out of field frame.
lB- 14 1973 OPEL SERVICE MANUAL ! 6. Remove shift lever shaft and: lift armature aid shift lever assembly. 7. Drive back retaining ring on armature shaft. See Figure lB-5. 8. Take the lock ring, retaining ring, and over&- ning clutch and pinion off armature shaft.
STARTING SYSTEM lS- 15 2. Unscrew the four (4) pole shoe attaching bolts and take field coils out of field frame. See Figure lB-9. 3. To ensure proper installation of the pole shoes, align shoes exactly parallel with the armature shaft prior to tightening attaching bolts.
lB- 16 1973 OPEL SERVICE MANUAL 8. Making sure that brush holder is aligned at right angles to the field frame, rivet brush holder to field frame. See Figure lB-14. RIVET Figure 18.14 Riveting Brush Holder to Frame i Replacing Bushings If sintered bronze bushings in.
STARTING SYSTEM lB- 17 7. Seal area between solenoid and frame. See Figure lB-17. 8. With brushes and spring in housings held in place with a 29 @llimeter socket, slide frame assembly in position. 9. Install i+ulating sleeves in field frame. 10. Install knd frame and replace through bolts and tighten bolts.
1 C- 18 1973 OPEL SERVICE MANUAL IGNITIPN SYSTEM CbNTENTS Subject DESCRIPTION AND OPERATION: Ignition System .................................................................. Ignition Switc,h ..........................................................
I I IGNITION SYSTEM lC- 19 11. (Startx position.) The ignition key must be released as soon as engine starts. The switch then returns aujomatically to the on position. IGNITION GOIL The ignition coil consists of a laminated non- mag- netic iron (core enclosed by two coils; the primary winding and the secondary winding.
I i lC- 20 1973 OPEL SERVICE MANUAL There is also a plastic hood slipped over the distrivu- tar cap with an outlet for the ignition cables as an added protection against moisture from the outside. See Figure lC-2. Figure lC-2 Ignition Distributor With Hood Installed MAINTENANCE AND ADJUSTMENTS CONTACT POINT REPLACEMENT Removing Contact Points 1.
IGNITION SYSTEM lC-21 4. Rota&distributor counterclockwise slightly until contact pbints just start to open. This must be done very carefully or engine will not start. 5. Install distributor cap. Make sure spark plug wires are correctly installed in distributor cap, through clip and on spark plugs.
lC- 22 1973 OPEL SERVICE MANUAL j 3. Start engine and disconnect a wire from a spark plug. Read output voltage of disconnected spark plug circuit. Reading should exceed 20 KV (20,poO volts). I CHECK DISTRIBUTOR ! 1. Clean distributor cap and inspect it for cracks or tracking.
IGNITION SYSTEM lC- 23 9. Install:spark plugs using a 13/16 deep socket, an extension and a torque wrench. Tighten to 22-29 Ib.ft. 1 MAJOR REPAIR DlSTRlBtiTOR OVERHAUL Distributbr Removal 1. Remove fuel pump. This is necessary because the fuel punp will block the distributor drive gear, thereby preventing removal of the distributor.
1 C- 24 1973 OPEL SERVliTE MANUAL 2. Push retaining ring out of groove in distribitor shaft. See Figure lC-10. I 3. Push up on distributor shaft. Remove breaker plate from distributor housing. Remove breaker points from breaker plate. See Figure lC-I 1.
IGNITION SYSTEM 1C. 25 4. Oil sliding parts of breaker plate at “B”. Oil felt in cam at “c”. Apply a thin layer of high melting point grease to the cam, using a finger at “A”. See Figure K-14. / 5. Adjust breaker point gap to ,016 inches. 6.
lC- 26 1973 OPEL SERVICE MANUAL / SPECIFICATIONS IGNITION COIL Ignition Coil Number .,.: .......................... . ...................................................................... K12 V Ignition Coil Current Draw, Amperes at 12.5 Volts Engine Stopped .
IGNITION SYSTEM lC- 27 9 3OlC19 Figure 1 C-l 3 Distributor Exploded.
lD- 28 1973 OPEL SERVldE MANUAL .CHARG;ING SYSTEM I CQNTENTS Subjyct’ DESCRIPTION 4ND OPERATION‘: Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM lD- 29 REGULAiOR DESCRIPTION The regulator contains only one unit - a double con- tact voltage regulator. See Figure lD-2. I Figure 1 D-2 Voltage Regulator Since th< alternator field is grounded inside the alter- nator, the voltage contacts are in series with the field.
i 1 D- 30 1973 OPEL SERVICE MANUAL 6. Make sure all electrical accessories are turned (lff. Start engine with battery post adapter switch closed; open switch as soon as engine iS: started. 7. Adjust engine speed to 2500 RPM. 8. Turn tester control knob to “LOAD” position aid adjust knob to obtain highest possible ammeter r&d- ing.
CHARGING SYSTEM lD- 31 Alternator Disassembly 1. Remove nut and alternator pulley. See Figure lD-6. Remove pulley and fan from rotor shaft. 2. Mark ‘drive end frame, stator and rear end frame to ensurd correct installation of parts on reassembly. Remove drive end frame.
1 D- 32 1973 OPEL SERVICE MANUAL 12. Unsolder brushes, if they are worn to a length of 3/8 inch or less. Solder new brushes in place. To do this, hold connecting wire in flat-nosed pliers to pre: vent solder from flowing between wire strands, oth- erwise the wire strands will become rigid and the brushes unserviceable.
CHARGING SYSTEM lD- 33 Figure lD-17 Checking Rotor for Ground Eigure lD-18 Checking Rotor for Short Fibwe 1 D-l 9 Checking Stator for Ground 16. Check stator windings for a short, using a low reading ohmmeter. Check two phases at a time by holding ohmmeter prods alternately on winding ends.
1 D- 34 1973 OPEL SERVICE MANUAL ! I one direction, but should not light at all in the otlier direction. Diodes in each set of three should p&s current and block current in the ‘same directions As the others in the set. See Figure lD-21. Removing Diodes / Positive Diodes 1.
CHARGING SYSTEM lD- 35 ’ Figure lD-25 Installing Diode I 7. Instail rotor together with drive end frame into stator and assemble generator in reverse order of disasse+bly. Make sure marks made during disas- sembly +-ire aligned. 8. Insta!l pulley and fan.
I ; I 1 D- 36 1973 OPEL SERVICE MANUAL I ‘ Figure 1 D-27 Alternator - Exploded View 301D27.
WINDSHIELD WIPERS lE- 37 WINDSHEILD WIPERS ALL MODELS CONTENTS Subject DESCRIPTION AND OPERATION: Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS: Windshield Wiper . . . . .
1 E- 38 1973 OPEL SERVICE MANUAL 4. Turn switch on to see if wiper niotor will function with wiper linkage’detached. If wiper motor will ndt run, disconnect connector at wiper motor and co?- nect hot lead from battery to terminal No. 53 on wiper motor.
WINDSHIELD WIPERS lE- 39 Figure 1 E-4 Removing Wiper Arms-GT wiper transmission and drop wiper transmissions from defleCtor panels. See Figure lE-4. 3. Remowscrews from left and center deflector pan- els. See Figures lE-5 and 6. Figure l$-5 Removing Screws from Left Deflector I Pa%?1 .
1 E- 40 1973 OPEL SERVICE MANUAL Disassembly I 1. Remove two (2) motor housing attaching screw$ (Item No. 4) and two (2) angle brackets (Item No. 3). See Figure lE-9. Figure 1 E-S Removing Motor Housing Attaching SCFS”JS Figure 1 E-l 0 Transmission and Armature Removed from Motor Housing 2.
WINDSHIELD WIPERS lE-41 Figurk 1 E-l 3 Cut Off Positive Brush Leads i Figure iE-14 Remove Negative Brush Retaining S.X?W I Cleaning apd Inspection of Parts With the ekception of electrical parts and bushings, clean all components in a cleaning solvent.
1 E- 42 1973 OPEL SERVICE MANUAL Figure 1 E-l 7 Solder Positive Brush Lead to Brush Holder 9. Install motor housing over armature so that large drain hole on housing is facing downward when mb- tor assembly is installed in car. InSert angle brackets into motor housing and tighten attaching screws.
WINDSHIELD WIPERS lE-43 SPEhFlCATlONS I GENEPAL SPECIFICATIONS iRated Voltage . ..__.,,,.,,,......................................,.,,... ~ __..__...__...._..................................... 12 VDC ,Test Voltage ___.................................
1 E- 44 1973 OPEL SERVICE MANUAL ) ‘30 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. ATTACHING SCREWS 16. NEGATIVE BRUSH TRANSMISSION COVER 17. ATTACHING SCREW HEX. NUT THREADED END ~ 18. RETAiNING PLATE 19. POSlilVE BRUSH PLAY PIN 20. WIRE’ GASKET 21.
LIGHTING SYSTEMS lF-45 LIGHTING SYSTEMS CONTENTS Subject DESCRIPTION AND OPERATION: Lighting Systems ................................................................ DIAGNOSIS: MAINTENANCT AND ADJUSTMENTS: Headlamp Aiming .............................
1F. 46 1973 OPEL SERVICE MANUAL ’ / Headlight High-Low Beam Control and Passing : Signal I When the headlights have been switched on, high and low beam selection is made by raising the direc- tional signal lever toward steering wheel. Each ti& the lever is raised, beam position, will change.
LIGHTING SYSTEMS lF-47 2. Install switch in panel. 3. Replace instrument cluster cover. EXTERIOR LIGHTS Models 51-53-54 Headlamp Sealed Beam Unit Removal 1. Remove two screws on headlight ring. 2. Remove four screws holding headlight retainer to body.
1~- 48 1973 OPEL SERVICE: MANUAL / 3. Disassemble headlight assembly from retaini+g ring. See Figure lF-4. i t Figure 1 F-4 - Headlight Assembly - Models 57.57R Installation 1. Assemble headlight to retaining rings.; 2. Install to body from inside engine compartmept with four (4) screws.
LIGHTING SYSTEMS lF-49 2. Take Le:s off housing. See Figure lF-7. 3. Remove housing. 1 Installation; I 1. Install le$ in housing. 2. Replace +. Model 54 ; , 1, Remove Ilamp lens from outside. / 2. Remove kear quarter trim pad. / 3. Remove ifour screws from inside car.
1 F- 50 1973 OPEL SERVlCE,MANUAL Installation 1. Connect wiring harness. 2. Replace housing with two (2) screws. 3. Rep&e lens. Rear Removal Remove two screws from support bracket aed remove housing and lens. See Figure lF-10. ,&y.. .2&L&-i -: ,.
I 2. Install Switch to door jam. I EXTERlOd LIGHTS. GT LIGHTING SYSTEMS lF- 51 Removing~Parking-Light Housing 1. Remove lamp lens. 2. Remove lamp housing. 3. Discon$ect electrical wires. See Figure lF-13. lnstallatioh 1. Con& electrical wires. 2. Install famp housing and lens.
1 F- 52 1973 OPEL SERVICE’MANUAL : 2. Remove lamp housing. 1 3. Disconnect electrical wires. See Figure lF-100.’ Figure 1 F-l 7 Rear Directional Signal. Stop and Tail’ Lamp Installation 1. Connect electrical wires. 2. Install lamp housing and lens.
I LIGHTING SYSTEMS lF- 53 / Removal if Back-Up Lamp 1. Remode back-up lens. 2. Remo+ lamp housing. 3. Discodnect electrical wires. See Figure lF-20 Removal of Headlamp Switch 1. Completely remove left headlamp and headlamp housing. 2. Remove switch from base plate.
lG- 54 1973 OPEL SERVICE’ MANtiAL / SIGNAL SYSTEMS CdNTENTS 9 Subject DESCRIPTION AND OPERAT!ON: Directional Signal Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . .
Tigure lG-2 Horn Button and Contact HAZARD; WARNING FLASHER The hazard warning flasher is operated by the button on the toi, of the steering column. When the button is press&@ down and released, all four turn signal lights WIU flash. To turn the flasher system off, press down oni the button and release.
: lG- 56 1973 OPEL SERVICE MANUAL I FUSE qOSlTlON 1 2 3 4 5 6 AMPS. 5 5 8 15 15 8 ClRClJlT$ PROTECTED OPEL 1900 & ‘MANTA (51,53,54,57,57R) LEFT PARkING LIGHT, LEFTTAIL LIGHT, LEFTSIDE MARKER LIG.
, I I INSTRUMENT PANEL lH- 57 / / Subject Page No. INSTRUMENT PANEL CONTENTS DESCRIPTION AND OPERATION: Instrument Panel - Opel 1900 - Manta . . . . . . . . . . . . . . . . . . . . . . Instrument Panel - GT . . . . . . . . . . . . . . . . . . . . . . .
1 H- 58 1973 OPEL SERVICE MANUAL / -FOG LIGHT SWITCH IRALLYEi HEADLIGHT HIGH BEAM INDICATOR -HAZARD WARNING FLASHER INDICATOR SYSTEM WARN,NG LlGHT L WINDSHIELD WIPER SWlTCH -1 LFUEL &,UGE LHEATER.
/ I I INSTRUMENT PANEL lH- 59 Figure 1 H-2 - GT Instrument and Switch Arrangement The Wihdshield Wipers have two-speed operation. By pushing the lower half of the switch inward to the first stop, the wipers will operate at half speed and by deprbssing to the second stop will provide full speed oieration.
/ I 1 H- 60 1973 OPEL SEW& MANUAL 1. Remove headlight switch button by depressing retaining clip on shaft and pulling back on switch knob. See Figure lH-3. Figure 1 H-5 - Removing Cluster Screws Figure lH-3 - Removing Headlight Switch Knob, 2. Remove two (2) plugs on cluster panel.
I I I INSTRUMENT PANEL lH- 61 Figwe 1 H-7 - Disconnecting Cluster Wires 4. Install instrument cluster trim plate and replace two screw and plugs. 5. Con&t speed0 cable by turning coupling clock- wise. 1 6. Install light .switch button and heater control knobs.
1 H- 62 1973 OPEL SERVICE, MANUAL 4. Remove flasher unit. See Figure IH-12. 5. Position steering so that wheels are straight ahead. 6. Pull off heads of both tear bolts by first drilling a 3/16 inch pilot hole and then using a stud extractor to remove tear bolts.
I , INSTRUMENT PANEL lH-63 Figure l;H-15 Removing Instrument Cluster Assembly Fibure 1 H-l 6 Disconnecting Radio Wires 14. Disdonnect antenna lead-in at right lower corner of radio! 15. Pull’ cluster housing out and turn sideways to remove &~y instrument gauge or switches.
lti- 64 1973 OPEL SERVICE MANUAL j Removal of Cigar Lighter GT / 1. Remove instrument housing. I ’ 2. Disconnect electrical wire. 3. Remove hex nut on back of cigar lighter base’.’ 4. Remove cigar lighter base. Installation 1. Install cigar lighter base.
GAUGES CONTENTS Subject DESCRIPTION AND OPERATION: DIAGNOSIS: Temperature and Fuel Gauge System - Opel 1900 - Manta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Gauge - GT . . . . . . . . . . . . . . . . . .
ll- 66 1973 OPEL SERVICE MANUAL i Condition Possible Cause Correction Gas gauge does not read full when tank tilled 1. Tank unit misadjusted 1. Install 40 ohm resistor between connector and ground I (disconnect from unit). If dash unit reads full within one pointer width.
I GAUGES 1 I- 67 I I Condition Car &s out of gas with gauge indicating fuel in tank. 1 I I I I I Possible Cause 1. Tank unit misadjusted 2. Defective voltage stabilizer. Correction 1. Follow corrective action as stated above (obtain empty reading on dash) 1.
1 I- 68 1973 OPEL SERVICE MANUAL 2. Pull voltage stabilizer of back of printed circhit. See Figure 11-l. ! L-_ -~~---,~ . _ ^__, _-_~ Figure 1 l-3 - Speedometer Attaching Screws Figure 11-l -Voltage Stabilizer installation 2. Install six (6) screws holding instrument cluster lens in housing.
I I GAUGES 1 I- 69 I I 3. Replace instrument housing. Installation Fiemoving~Temperature Indicator or Fuel Gauge 1. Remov+ instrument cluster housing. 2. Remov; six screws and remove both instrument cluster le+ See Figure 11-2. 3. Pull v&age stabilizer off printed circuit and remove fohr instrument attaching screws, as shown in Figure 111-5.
lb 70 1973 OPEL SERVlCE!MANUAL Removing Oil Pressure Sending Upit 1. Disconnect wire from sending Fit. 2. Unscrew oil pressure sending u?it from block. St& Figure 11-7. / Figure 11.7 - Oil Pressure Sending Unit Installation 1. Replace oil pressure sending unit into block.
I I GAUGES ll- 71 Figure 1 IL10 Rear View of Temperature Indicator and I I Fuel Gauge Dash Unit I Install&m 1. Connekt wires and install unit. 2. Install! instrument cluster housing. I Removal of Electric Clock 1. Remoie instrument housing. Figuy 1 I-1 1 Rear View of Electrical Clock I 2.
1 J- 72 1973 OPEL SERVICE MANUAL I WIRING IDIAGRAMS CONTENTS Subject 1973 WIRING DIAGRAMS: Windshield Wiper and Horn:- Opel 1900 - Manta ........... . ............... ......... I.. . ........... ........... ................... Windshield Wiper and Horn’- Rallye .
I / WIRING DIAGRAMS 13-73 I Seat Belt Warning System (Automatic Page No. Transmission) . GT ....................................................... lJ- 99 Heated Rear Glass . Opel 1900 . Manta ................... 15-100 Heated Rear Glass . GT ........
j / 1J. 74 1973 OPEL SERVICE MANUAL i I; m Figure 13-1 Windshield Wiper and Horn - Opel 1900 - Manta.
I I WIRING DIAGRAMS lJ- 75 Figure lJ-2 Windshield Wiper and Horn - Rallye.
1 J. 76 1973 OPEL SERVICE IMANUAL : L J Figure lJ-3 Wind$hield Wiper and Horn - Gl.
! I I I , WIRING DIAGRAMS 1J. 77 I I Figure 1 J-4 Turn Signal and Hazard Flasher . Opel 1900 - Manta I.
I i -- L I . lJ- 78 1873 OPEL SERVICE~MANUAL ’ Figure lJ-5 Turn Signal and Hazard Flasher - GT.
I WIRING DIAGRAMS 15.79 I I Figure lJ-6 Oil. Fuel. Temp. Tach, Stop and Brake Warning Light. GT I.
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I WIRING DIAGRAMS lJ- 81 r Figure 1 J-8 Blower and Lighter - GT.
I I lJ- 82 1973 OPEL SERVICE MANUAL Figure’lJ-9 indicator Lights and Gauges - Opel 1900 Manta.
I I WIRING DIAGRAMS IJ-83 I Figure 1 J-10 Indicator Lights and Gauges - Ratlye.
r 2UREDp I M BRNIWHI BUZZER 3 CLOSED POSlTlONl /- 14 RED - TO STEERING COLUMN CONN. 20 RED 12 RED FROM BATTERY- -18 GRAY- -12 RED -I J DOME LIGHT &SWITCH 1 1 .
==EhMB SWITCH R,GHiDOOR------------------ 301J12.
1 J- 86 1973 OPEL SERVICE MANUAL i Figure 1 J-l 3; Headlamps - Opel 1900.
I I I WIRING DIAGRAMS lJ- 87 Figure lJ-14 Headlamps Manta.
1 J- 88 1973 OPEL SERVICE MANUAL ! I 1. Figure lJ-15’Headlamp and Fog Lights - Rallye.
301516.
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WIRING DIAGRAMS lJ- 91 R Figure lJ-18 Right Parking, Tail and Instrument Panel Lighting -Opel 1900. Manta.
1 J- 92 1973 OPEL SERVICE> MANUAL d 5 Figure 1~19 Starting, lgniiion and Charging Opel 1900 Manta.
I I WIRING DIAGRAMS lJ- 93 I Figure lJ-20 Starting, Ignition and Charging GT.
1 J- 94 1973 OPEL SERVICE MANUAL i I I Figure lJ-21 Instrument Panel GT.
I / I 1 I WIRING DIAGRAMS lJ-95 - Figure lJ-22 A/C Generator and Regulator -All Models.
301523.
WIRING DIAGRAMS lJ- 97 c I & N / I I Figure 1 J-24 Seat Belt Warning System (Automatic Transmission) Opel 1900 Manta.
I I I - 10 RED AMP GAGE 301J25.
WIRING DIAGRAMS lJ-99 Figure lJ-26 Seat Belt Warning System (Automatic Transmissionl - GT.
lJ-100 1973 OPEL SERVICES MANUAL I Figure 1 J-27 Heated Rear Glass - Opel 1900 - Manta.
I WIRING DIAGRAMS 1 J-101.
1 J-102 1973 OPEL 9ER”IC; MANUAL ;.
GROUP 2 [I L RnnV I- ---. anln I T..Y I- BUMPERS I I- L L Section 2A 2B 2C 2D 2E 2F 2G 2H Title General Information Frame and Body Mountings . . . . . . . . . . . . . . . . . . . . Windows and Window Moldings Doors _................................ Rear Compartment Lid Roof and Sun Roof Seats, Interior Trim and Headlining Bumpers .
I 2A- 2 1973 OPEL SERVICE MANUAL GENERAL INFORlVlATION CONTENTS Subject Page No. DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: Paint Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION ZA- 3 ded with rubber, and volatile cleaners are generally solvents for rubber. The application of too much cleaner may destroy these rubber pads. Do not use volatile cleaners on vinyl coated fabrics. Procedure For Cleaning Vinyl Fabrics With Synthetic Detergents 1.
fabric to dry thoroughly; then rub lightly with a clean cloth dipped in a volatile cleaner. This is the only further treatment recommended. Soap and water are not recommended since they will probably set the stain and cause a permanent dis- coloration.
SPECIAL BODY TOOLS GENERAL INFORMATION 2A- 5 W REGULATOR INING INSTALLER) J-21828 & J-21549 2A-1.
2B- 6 1973 OPEL SERVICE MANUAL OPEL 1900, MANTA AND GT FRAME AND BODY MOUNTINGS CONTENTS Subject DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: (Not Applicable) SPECIFICATIONS: Frame and Body Mounting Specifications .
FRAME AND BODY MOUNTINGS 28. 7 A B C D E F G H I .I K L M N 0 P Q R S 1 12” 25-l/4” 22-314” SO-5/16” 50-5/16” 49-l/8” 59-l IS” 35-314” 32” 36-l/8” 28-19132” 39-118” 15-118” 12-2132” lo-3/4” 6 II 6” .
28. B 1973 OPEL SERVICE MANUAL A B C D E F G H I J K-L M N 1 O-9/ 16” 14-9116” 71.7116” 90-l/2” S-3/16” 1 l-S/V 21-9/l 6” 30” 24-314” 30-9/l 6” 38-l/2” 36-3/V 17-5116” Figure 28-.
WINDOWS AND WINDOW MOLDINGS 2c-9 WINDOWS AND WINDOW MOLDINGS CONTENTS Subject DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Removal and Installation Windshield Reveal Molding .
2c-10 1973 OPEL SERVICE MANUAL REMOVAL AND INSTALLATION OF WINDSHIELD OR BACK WINDOW-WINDSHIELD SHOWN 1. Flap back windshield wiper arms, 2. Beginning at one end, pull molding out of rubber channel. 3. Beginning at one corner, push out windshield together with rubber channel.
WINDOWS AND WINDOW MOLDINGS 2c-11 8. With a sealer gun, apply window sealing com- pound between outside of windshield and rubber channel. See Figure 2C-8. Figure 2C-8 Applying Sealing Compound Outside of Windshield REMOVAL AND INSTALLATION OF FRONT DOOR SASH WINDOW 1.
2C- 12 1973 OPEL SERVICE MANUAL 3. Install quarter window and fasten chromed mold- ing. See Figure 2C-10. REMOVAL AND INSTALLATION OF REAR QUARTER WINDOW OPEL 1900. MANTA 1. Unscrew rear quarter window Iqck. See Figure 2c-11. Figure 2C-1 1 Quarter Window Lock Attaching Screws 2.
DOORS CONTENTS Subject DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Front Door - Removal and Installation Door Lock Striker ........................................
2D-14 1973 OPEL SERVICE MANUAL Figure 20.4 Position of Tool on Slide Lock Spring 2. Remove door inside handle escutcheon. 3. Remove lock knob. 4. Remove arm rest. See Figure 2D-5. Figure 20-2 Door Striker Figure 20-5 Removing Arm Rest Figure 20.3 lnsarting Tool Between Handle and Nylon Disc 5.
dOORS 2D-15 3. Unhook con&cting rod out of old support and hook into new support and door lock. the water deflector foil is inserted in lower door slot. See Figure 2D-6. Reverse procedure for installation. 2D-i- Figure 2D-7 Removing Support 4. Screw support onto door inner panel so that it can be shifted in both holes.
2D-16 1973 OPEL SERVICE MANUAL 2. Remove door lock knob. 3. Remove door inside handle. 4. Adjust sash window so that the main lever with toothed segment are in alignment with the front re- taining plate. See Figure 2D-9. Figure 2D-9 Aligning Main Lever With Front Retaining Plate 5.
DOORS 2D-17 Figure ZD-12 Guide Rail Bolt Figure 2D-13 Lock Retaining Screws 6. On Models 57, 57L and 57R, do not unscrew window guide rail. Unscrew lock and, with actuating lever engaged, remove lock from behind guide rail. See Figure 2D-14. Installation 1.
2D-18 1973 OPEL SERVICE MANUAL 2. With window closed, unscrew hex nut and remove door outside handle. See Figure 2D-15. 3. Clamp door outside handle in a vise provided with protective jaws. 4. With ‘a screwdriver, lift cylinder lock ring out of handle.
Figure ZD-19 Installing Weatherstrip 3. Remove door inside handle. 4. Remove door belt reveal molding. 5. Remove window lifter. 6. Remove sash window guide rails. 7. Remove door lock. 8. Remove door outside handle, 9. Grind off door check link pin and remove door check link.
2D-20 1973 OPEL SERVICE MANUAL 2. Remove door sash window. Figure 2D-23 Guide Rail Screws 3. Pull guide rail towards the top out of door. 4. Position sash window so that cable retainer can be unscrewed through access hole. Pull out sash win- dow towards the top.
DOORS ZD- 21 RIGHT LEFT ~- ZD-27 Figure ZD-27 Cables Wound On Regulators Installation - Right Door In clockwise direction, wind cable onto pulley up to the shoulder and clamp it behind lug. See Figure 2D-27. REMOVING AND INSTALLING ’ TAILGATE HINGES Removal 1.
ZE-22 1973 OPEL SERVICE MANUAL ’ REAR COMPARTMENT LID CONTENTS Subject DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Removal and Installation Weatherstrip . . . . .
REAR COMPARTMENT LID 2E- 23 inch deep socket, and remove it, together with inter- mediate ring. See Figure 2E-4. Fiyure ZE-4 Removing Lock Cylinder Nut Installation 1. Install lock cylinder nut, together with intermedi- ate ring, and fasten with a 13/16 inch deep socket.
2F-24 1973 OPEL SERVICE MANUAL ROOF AND SUN ROOF CONTENTS ,., Subject DESC,RIF?TION AND OPERATION: (Not Applicable) DIAGNOSIS: Sun Roof Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROOF AND SUN ROOF ZF-25 Condition Callse Correction Sun roof lifts up on one side only. Lifter wedge welded to under- Remove sun roof panel and bend side of sun roof panel does lifter wedge so that it squarely hits not run up ramp welded in ramp. The only adjustment for center of sun roof track.
2F-26 1973 OPEL SERVICE MANUAL MAINTENANCE AND ADJUSTMENTS ADJUSTING HEIGHT OF SUN ROOF PANEL Adjust height of sun roof as follows: 1. Opel sun roof to half open position and pry apart sun roof frame from sun roof panel (see Figure 2F-1). Figure ZF-1 Separating Sun Roof Frame From Sun Roof Panel 2.
ROOF AND SUN ROOF 2F-27 not the case, take off crank handle and cable crank (see Figure 2F-4) and physically reposition lifters to be approximately 90 degrees to guide rails and to contact guide stops. Rotate cable crank to its fully clockwise limit alad reinstall.
2F-28 1973 OPEL SERVICE MANUAL guides to height adjustment rings, loosen second screw (see Figure 2F-6), and swing guides away from guide rail. NOTE: When swinging front guides inboard, be careful not to change position of height adjustment rings.
ROOF AND SUN ROOF 2F-29 Installation of Sun Roof Frame 1. Slide sun roof frame into lower slot of guide rails, position fully rearward and reattach guide rails to roof. NOTE: Be sure guide rail retainers at rear of guide rails are positioned with their dowels in bores of roof frame.
2F-30 1973 OPEL SERVICE MANUAL 3. Unscrew and remove upper and lower corner plates (see Figure 2F-8). 4. Unscrew and remove left and right upper cable shields ans pull cable ends out of cable box. 5. Pull cable and rear lifter guides out of left and right guide rails.
2. Press off snap ring holding drive pinion in place and remove drive pinion (see Figure 2F-10). Installation 1. Install drive pinion reverse of removal. NOTE: If drive pinion is to be replaced, also replace both cables to insure smooth operation of sun roof.
2F-32 1973 OPEL SERVICE MANUAL 3. Carefully detach a portion of headlining around window corner post involved. 4. Detach water drain hose from sun roof hose iit- ting. 5. Remove cowl side kickpads. 6. Pull out from upper end front water drain hose. Installation of Front Water Drain Hose 1.
SEATS, INTERIOR TRIM AND HEADLINING 26-33 SEATS, INTERIOR TRIM AND HEADLINING CONTENTS Subject Page No. DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Removal and Installation Front Seat .
26-34 1973 OPEL SERVICE MANUAL a 13/16 inch deep socket, and remove. See Figure 2G-6. Figure ZG-4 Seat to Underbody Hook Figure ZG-5 Seat Back Metal Tabs 3. Remove seat back towards the top. REMOVAL AND INSTALLATION OF GLOVE COMPARTMENT DOOR LOCK 1. Unscrew nut of glove compartment lid lock, using Figure ZG-6 Removing Glove Compartment Lock 2.
SEATS, INTERIOR TRIM AND HEADLINING ZG-35 2. Push off side panel trim pad. Trim pad is held in position by a retaining button. REMOVAL AND INSTALLATION OF HEADLINING Removal 1.
2G-36 1973 OPEL SERVICE MANUAL 3. Install and align the remaining five listing wires. If required, caulk retainers of 2nd and 5th listing wires so that wires run in a straight line transversally under the roof. See Figure 2G-9. Figure ZG-10 3rd. 4th and 6th Listing Wire Attachment 4.
SEATS, INTERIOR TRIM AND HEADLINING 20.37 8. If wagon, install front window and quarter win- dows. It other than wagon, install front and rear windows. 9. Install coat hooks, assist straps, interior lamp, sun visors, and rear view mirror. 10. Install parcel shelf and plastic retainers (sedans only).
2H-38 1973 OPEL SERVICE MANUAL BUMPERS CONTENTS Subject DESCRIPTION AND OPERATION: Protective Moldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * . . . . . . . . . . . . . . . . . DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Removal and Installation 1900 - Manta .
BUMPERS 21-1-39 --.. ,2H-3 i Figure ZH-3 Bumper Bracket Screws Figure ZH-4 Bumper Attaching Screws REMOVAL AND INSTALLATION OF FRONT REMOVAL AND INSTALLATION OF FRONT BUMPER ASSEMBLY (GT) BUMPER ASSEMBLY (GT) 1. Remove grille. 1. Remove grille. 2. Disconnect bumper at points shown in Figure 2H-5 and remove bumper.
z-l-40 1973 OPEL SERVICE MANUAL 2. Install grille. REMOVAL AND INSTALLATION OF REAR BUMPER ASSEMBLY (GT) Removal 1. Remove tail lamp assembly. See Figure 2H-6. 2. Remove bumper attaching nuts accessible through lamp opening. See Figure 2H-7. Installation 1.
3116” SPACER SAFET‘;. CHAIN PLATE (Dl -l/Z x 3 INSTALLATION INSTRUCTIONS 1969 - 73 OPEL GT TRAILER HITCH LESS BALL GROUP 7.068 STEP 1. REMOVE ONE RIGHT HAND AND ONE LEFT HAND TAIL LAMP ASSEMBLY, STEP 2. PLACE TIE BAR (C) UNDER THE REAR BODY PANEL BY PULLING DOWN ON THE EXHAUST PIPES AND SLIDING THE TIE BAR OVER THE PIPES AND INTO POSITION.
FLV TRlJNK PLAT DRAW BAR 16x1-1/2 - DRAW‘ BAR EXTENSION -%G SAFETY CHAIN PLATE 6 INSTALLATION INSTRUCTIONS 1971 - 72 - 73 OPEL 1900 SERIES S/W GROUP NO. 7.068 REMOVE LICENSE PLATE STEP 1. ASSEMBLE HITCH AS ILLUSTRATED. HOLD HITCH IS POSITION WITH FLOOR PLATE RESTING AGAINST THE CROSS FRAME IN FRONT OF GAS TANK.
AFETY CHAIN PLATE INSTALLATION INSTRUCTIONS 1971-72-73 OPEL 50 SER.. LESS S/WAGON CAR TRAILER HITCH GROUP NO. 7.068 STEP 1. REMOVE LICENSE PLATE, ASSEMBLE V-BAR AND SAFETY CHAIN PLATE TO DRAW BAR AS ILLUSTRATED. HOLD HITCH IN POSITION WITH THE DRAW EAR LEVEL AND THE V-BAR RESTING ON THE REAR BODY PANEL.
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I GROUP 3 SUSPENSION AND STEERING I Section Title Page No 3A Front Suspension . . . . . . . . . . 3A- 2 3B Steering Linkages 38-l 9 3C Front End Alignment 3C-22 3D Steering Gear .._........ 3D-27 Steering Column 3E 1900 - Manta ,._________... 3E-35 GT .
3A- 2 1973 OPEL SERVICE MANUAL FRONT SUSPENSION CONTENTS Subject DESCRIPTION AND OPERATION: Suspension Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: Front Wheel Bearing Adjustments .
FRONT SUSPENSION 3A- 3 4RM “PPtR BALL SHOCK ABSORBER UPPER CONTROL, UPPER CONTROL ARM SHAFT “:,‘,:“,‘,“,“, ,“pd,,‘, T / RUBBER BUMPER CROSSMEMBER ROTOR / LOWER BALL JOINT FRONT SPRING Figure 3A-2 GT Front Suspension (Disc Brakes) the upper and lower control arm are not in parallel (anti- dive).
3A- 4 1973 OPEL SERVICE MANUAL The two cross-members to body supports are at- tached to the horizontal part of the cross-member with two bolts. The oufererbolt serves simultaneously as support for the lower control arm. As the bolt is inserted from the front, the cross-member to body support can be removed without the lower control arm.
FRONT SUSPENSION 3A- 5 Figure 3A-6 GT Steering Mast Joint 2. Install Hooks J-23697 before jacking up car to assure proper loading of suspension bushings and mounts. See Figure 3A-7. 3. Raise front of vehicle and support with stands. 4. Remove front wheels.
3A- 6 1973 OPEL SERVICE MANUAL Figure 3A-10 Steering Mast Clamp Bolt assembly at the cross member to body support from frame and let it down onto jack.
FRONT SUSPENSION 3A- 7 Figure 3A-12 Front Suspension Attaching Points Always use new self-locking nuts. 7. Reinstall guard plate. 8. Crosswise torque wheel nuts to 65 ft.lbs. UPPER BALL JOINT REMOVAL AND INSTALLATION Removal I. Place jack under spring eye and raise car.
3A. 8 1973 OPEL SERVICE MANUAL HOUSING Figure 3A-14 Lower Ball Joint 1 CHECKING I Figure 3A-15 Ball Joint Checking Gauge Installed 3. Remove cotter pin from castle nut on ball joint stud and back off castle nut two (2) turns. Hit ball stud a sharp blow to break it loose.
FRONT SUSPENSION 3A- 9 8. Press ball stud out of lower control arm. Removal Opel 1900 - Manta Before raising vehicle, install Hooks J-23697 on re- spective vehicle side to cross member and upper con- trol arm. See Figure 3A-7. 1. Raise car and support at rear of front frame rails.
3A- 10 1973 OPEL SERVICE MANUAL Figure 3A-18 Lower Ball Joint Notch Opel 1900 - Manta UPPER CONTROL ARM REMOVAL AND INSTALLATION Removal GT 1. Raise car and support at rear of front frame rails. 2. Remove front wheel. 3. Install spring compressor and compress spring until there is 3-l/8” between compressor and lower spring leaf.
FRONT SUSPENSION 3A- 11 UPPER CONTROL ARM SHAFT INNER SLEEVE OUTER SLEEVE RUBBER DAMPENIN GUIDE SLEEVE ABSORBER SUPPOR SHOCK ABSORBER SUPPORT ON FRONT SUSPENSION CROSS MEMBER - TOOTHED WASHER l- UPPER CONTROL ARM RUBBER BUSHINGS PLATE WASHER Figure 3A-19 Upper Control Arm Shaft and Bushings placement part of lesser quality or substitute design.
3A- 12 1973 OPEL SERVICE MANUAL Figure 3A-20 Lower Control Arln Attachment jack so that spring and lower control arm assembly is removed from the front cross member and steering knuckle. 8. Lower jack, spring compressor, and front spring with control arm assembly.
FRONT SUSPENSION 3A- 13 6. Reconnect shock absorber to lower control arm and torque to 30 Ib.ft. 7. Remove spring compressor. 8. Install front wheel, and lower the car.
3A. 14 1973 OPEL SERVkE MANUAL Figure 3A-22 Caliper Removed and Hung by Wire steering knuckle. Swing steering arm and tie rod to the side. 7. Remove castle nut cotter pin, unscrew nut and pull steering knuckle off lower control arm ball joint.
FRONT SUSPENSION 3A- 15 SHOCK ABSORBER REMOVAL AND INSTALLATION Removal Opel 1900. Manta 1. Raise car and support with stands. 2. Remove upper attaching nuts from shock ab- sorber. 3. Remove lower attaching nut, lockwasher, and bolt. 4. Compress shock absorber and remove from car.
3A- 16 1973 OPEL SERVICE MANUAL INNER RUBBER STUD. 1 /2” E / PLASTIC COVER DAMPENING RING RETAINER RUBBER DAMPENING RING- -z SELF-LOCKING NUT UPPER RUBBER GROMMET RETAINER LOWER RUBI GROMMET RETAINER WHEEL HOUSE SHOCK ABSORBER SHOCK ABSORBER SA-25 Figure 3A-25 Shock Absorber Upper Attachment 7.
FRONT SUSPENSION 3A- 17 Torque values must be used as specified during reas- sembly to assure proper retention of these parts. 1. Attach lower control arm to front spring eye. Torque bolts to 18 lb.ft. 2. Install spring compressor on spring and compress spring to appropriate length.
3A- 16 1973 OPEL SERVICE MANUAL SPECIFICATIONS Torque Specifications Use a reliable torque wrench to tighten all parts listed to insure proper tightness without straining or distorting parts.
STEERING LINKAGE 38.19 STEERING LINKAGE CONTENTS Subject DESCRIPTION AND OPERATION: Description and Operation of Tie Rods . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Removal and Installation of Tie Rods .
Figure 38-3 Bellows Removed From Tie Rod GT 5. On the Opel 1900 - Manta, unscrew tie rod from axial joint. It is important that rack be held secure with open end wrench to prevent damage to rack teeth. 38. 20 1973 OPEL SERWCE MANUAL Figure 38.4 Removing Tie Rods.
STEERING LINKAGE 38-21 4. Attach rubber bellows to axial joint using hose Clamp. DISASSEMBLY AND REASSEMBLY OF TIE RODS The ball joint of the tie rod end on the Opel 1900 _ Manta is maintenance free and must not be disassem- bled. Disassembly - GT ?. Loosen tie rod clamp bolt and unscrew outer tie rod ball stud from tie rod.
3C-22 1973 OPEL SERVICE MANUAL . FRONT END ALIGNMENT CONTENTS Subject Page No. DESCRIPTION AND OPERATION: Front Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . ..“........................... DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: Inspection Before Checking Front Wheel Alignment Adjusting Caster .
FRONT END ALIGNMENT 3C-23 ing geometry, the following checks and inspections must be made to insure correctness of alignment equipment readings and alignment adjustments. 1. The front tires should have approximately the same wear and all tires must be inflated to specified pressures (see Wheel and Tire Specifications - Sec- tion 3G).
3C-24 1973 OPEL SERVICE MANUAL NOTE: FRONT OF CAR 4 Figure 3C-3 Upper Control Arm Shaft and Bushings x.3 Figure 3C-4 Supporting Vehicle at Both Lower Control Arms (B) (rear) between upper control arm and shock ab- sorber support. See Figure 3C-5. 5. One .
FRONT END ALIGNMENT 3C-25 Figure 3C-6 Adjusting Toe-In (GT) ADJUSTING CAMBER Camber is adjusted by turning the upper ball joint flange 180 degrees. This means that only two possi- ble camber adjustments can be made.
3C-26 1973 OPEL SERVICE MANUAL 1. Loosen lock nut of left and right tie rod and slacken back nut. 2. Remove hose clamp for rubber bellows attach- ment from respective axial joint and adjust toe-in by turning axial joint. When doing this, observe that the rubber bellows, having a tight seat on thejoint, is not twisted.
STEERING GEAR ASSEMBLY 3D. 27 STEERING GEAR ASSEMBLY CONTENTS Subject DESCRIPTION AND OPERATION: Description and Operation of Steering Gear . . . . . . . . . . . . DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: Adjustment of Steering Gear . .
3D. 28 1973 OPEL SERVICE MANUAL r L FLEXIBLE COUPLING SHAFT. NEEDLE BEARING L LPINION BUSHING O-RING SEAL Figure 3D-2 Steering Gear Assembly - End View 3D-2 RACK GUIDE r BUSHING Figure 3D-3 Steering Gear Assembly Front View until a resistance is felt.
STEERING GEAR ASSEMBLY 30-29 2. Loosen clamp securing flexible coupling to steer- ing shaft. 4. Remove stop bolt (see Figure 3D-4) from under- side of steering column (secures steering shaft bush- ing to mast jacket), and pull steering wheel rearward approximately three inches.
3D- 30 1973 OPEL SERVICE MANUAL Figure 3D-8 - Removing Clamp Bolt 3. Remove cotter pin located on left and right tie rod end and unscrew nut. 4. Using Tool J-21687, press tie rod ends out of steering arms. 5. Disconnect steering gear housing from front sus- pension cross member and remove steering gear together with tie rods.
STEERING GEAR ASSEMBLY 3D- 31 Figure 3D-9 Removing Tie Rods 5. Remove pinion shaft from gear assembly, and then withdraw rack from gear assembly. 6. From steering gear housing remove “0” rings from retainer and pinion bushing. Also take out thrust washer.
3D- 32 1973 OPEL SERVICE MANUAL Figure 3D-13 Steering Gear Housing With Rack Check to insure that three air channels of sintered metal bushing (See Figure 3D-17) are not obstructed by lubricant. If air channels are blocked, a vacuum condition in the bellows may result during operation of the gear assembly.
STEERING GEAR ASSEMBLY 30.33 ble steering gear lubricant. Fill long end of housing bly. Under such circumstances, the bellows will be with approximately 1 3/4 oz. steering gear lubricant. drawn inward and jam into the rack teeth. 3. Reassemble pinion shaft into gear assembly so that spline in pinion shaft meshes with twelfth tooth of the rack.
3D- 34 1973 OPEL SERVICE MANUAL I LOCK PLATE 7, @-, FLEXIBLE COUPLING NUT FLEXIBLE COUPLING -/ BOLT PINION SHAFI RUBBER BOOT es+-- RETAINER ew O-RING ‘lNTERED METAL BUSHING 1 y STEERING GEAR HOUSING.
OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY 3E.35 I I OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY CONTENTS Subject Page No. DESCRIPTION AND OPERATION: Description and Operation of Directional Signal Lever . . . . . . . . . . . . . . . . . . . . . . .
3E- 36 1973 OPEL SERVICE MANUAL and ignition switch in RUN position, the fog lights are automatically switched off. Direction signals work in the normal manner; pushing the lever up for right turn signal and pulling the lever down for left turn signal.
OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY 3E- 37 Figure 3E-5 Steering Column Assembly With Gear replacement of steering column or steering ignition lock parts. Removal (Opel 1900 . Manta) 1. Disconnect battery. 2. From underside of car, remove clamp screw of upper steering mast out of universal joint flange.
3E- 38 ,1973 OPEL SERVICE MANUAL ponents and systems, and/or could result in major repair expense. They must be replaced with one or the same part number or with an equivalent part if replacement becomes necessary. Do not use a re- placement part of lesser quality or substitute design.
OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY 3E- 39 ~~~A~SEMBLY AND ~EASBEMBL~ 0~ DIRECTIONAL SIGNAL SWITCH This procedure may be performed with the steering column assembly removed or installed in the car. Disassembly (Opel 1900. Manta) 1. Remove steering wheel (see paragraph above).
3E- 40 1973 OPEL SERVICE MANUAL on steering and ignition lock bracket using a new tear-off bolt (hexagon head tears ofD. 3. Disconnect slide-off base, install upper half of sig- nal switch housing cover, and loosely reattach slide- off base. 4. Attach steering mast jacket at front of dash panel.
OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY 3E- 41 SPECIFICATIONS Steering Column Tightening Specifications Part Location Toraue 1b.k. Nut Steering Wheel Retaining (1900 - Manta) .._......._...,,.... Bolt Steering Column Flexible Coupling (1900 - Manta) .
3E- 42 1973 OPEL SERVICE MANUAL GT STEERING COLUMN ASSEMBLY CONTENTS Subject DESCRIPTION AND OPERATION: Description of Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Removal and Installation of Steering Wheel .
GT STEERING COLUMN ASSEMBLY 3E- 43 UPPER STEERING COLUMN ASSEMBLY- -A UPPER UNIVERSAL JOINT- STEERING -CENTER STEERING SHAFT LOWER UNIVERSAL JOINT Figure 3E-15 GT Steering Column Assembly _-- 7 FORCE .
3E. 44 1973 OPEL SERVICE’MANUAL Figure 3E-17 Steering Column Bracket installed in a car it is no more susceptible to damage through usage than an ordinary column; however, when the column is removed, special care must be taken in handling this assembly.
GT STEERING COLUMN ASSEMBLY 3E- 45 loose must never be done. The only recommendation for freeing frozen steering wheels is to use a penetrat- ing lubricant. Installation 1. Before installing steering wheel, lubricate return pin and slide area on direction signal switch return cams and horn ring contact.
I 3E. 46 1973 OPEL SERVICE MANUAL Figure 3E-19 Steering Column Attachments 3. Install new tear bolts and tighten until hex head of bolt is tom off. 4. Reconnect ignition and direction signal wire sets.
GT STEERING COLUMN ASSEMBLY 3E- 47 2. Disconnect ignition (white) wire set plug. 3. Remove steering lock retaining screw. See Figure 3E-20. Figure 3E-20 Steering Lock Retaining Screw 4. Remove direction signal switch lever. 5. Remove three screws securing signal switch cover to housing.
3E- 48 1973 OPEL SERVICE MANUAL Figure 3E-24 Removing Electrical Unit Before installing electrical unit be sore unit is in RUN position. Using a Philips screwdriver, turn in- ner sleeve to the tight until a springy resistance is felt. See Figure 3E-25.
GT STEERING COLUMN ASSEMBLY 3E- 49 4. Install ignition switch and steering lock REMOVAL AND INSTALLATION OF STEERING COLUMN LOWER BEARING The following is with steering column assembly removed. 1. Remove steering wheel. 2. Remove screws securing lower bearing housing to mast jacket.
1 3E. 50 1973 OPEL SERVICE MANUAL PART Bolt Bolt LOCATION Steering Wheel Upper Universal Joint - Lower Clamp Upper Universal Joint - Hex Head Lower Universal Joint TORQUE LB.
REAR SUSPENSION 3F- 51 REAR SUSPENSION CONTENTS Subject DESCRIPTION AND OPERATION: Description and Operation of Rear Suspension . . . . . . DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Rear Shock Absorber Removal and Replacement .
3F. 52 1973 OPEL SERVICE MANUAL 3. Install rubber grommet, retainer and self-locking nut at top of shock absorber. Torque to 10 lb. ft. Always use new self-locking nuts.
REAR SUSPENSION 3F- 53 7. Remove jack stands. LOWER CONTROL ARM REPLACEMENT Removal This operation can be performed with the vehicle standing at curb height or elevated. 1. Disconnect parking brake cable from support bracket on control arm. 2. Loosen and remove front and rear control arm attaching bolts and remove control arm.
3F- 54 1973 OPEL SERVICE MANUAL / UPPER RUBBER DAMPER RING COIL SPRING TRACK ROD LOWER RUBBER ’ DAMPER RING REAR AX;E ASSEMBLY COIL SPRING SEAT STABILIZER ROD $3 SHOCK ABSORBER LOWER CONTROL ARM Figure 3F.
WHEELS AND TIRES 3G- 55 WHEELS AND TIRES CONTENTS Subject DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: Car Roughness and Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormal Tire Wear . . . . . .
3G- 56 1973 OPEL SERVICE MANUAL parking brake cable. Spin the other wheel using the same procedure. By spinning the wheels, the offending tire will cause vibration that may be felt by touching the bumper or fender. By the process of elimination, proceed on STATIC UNBALANCE DYNAMIC UNBALANCE ‘I.
WHEELS AND TIRES 3G- 57 Figure 3G-4 Checking Lateral Runout ,050 inch Lateral - Tire/Wheel Assembly If the tire and wheel runouts are beyond any of the maximum totals above, the tire should be reposi- tioned 180 degrees opposite its original location on the wheel.
3G- 58 1873 OPEL SERVICE MANUAL Tire Wear Irregularities An additional cause of vibrations may sometimes be tire wear irregularities. These can also produce noise disturbances, and can be generally corrected by rotating the tires, Figure 3G-6. Before proceeding further, locate and correct the cause of the irregular tire wear.
WHEELS AND TIRES 3G- 59 TREAD CONTAil WITH ROAD I UNDERINFLAlIONI UNDERINFLATION TREAD CONTACT WITH ROAD PROPER INFLATION TREAD CON& WI;,, ROAD lOVERINFLATION OVERINFLATION DERS OF TREAD WORN CENTER OF TREAD WOI FEATHERED EDGE .
36. 60 1973 OPEL SERVICE MANUAL severe or careless driver. Rapid acceleration and de- celeration, severe application of brakes, taking turns at excessive speed, high-speed driving, and striking curbs or other obstructions which lead to misalign- ment are driving habits which will shorten the life of any tire.
WHEELS AND TIRES 3G- 61 Cornering Tread Wear The modern independently-sprung automobile al- lows the driver to negotiate turns at a high rate of speed with a greater feeling of safety. This fact is responsible for a comparatively new type of tread wear that can easily be mistaken for toe or camber wear.
3G- 62 1973 OPEL SERVICE MANUAL 1. Clean rims thoroughly, using No. 3 coarse steel wool to remove all oxidized rubber, soap solution, etc. Remove rust with wire brush. 2. Inspect butt weld and other areas of rim contacted by tire beads to make certain there is no groove or high spot.
WHEELS AND TIRES 36-63 would require inflation pressures above the maximum allowable, speed must be limited to 75 miles per hour. 3. Cool tire inflation pressure: After vehicle has been inoperative for 3 hours or more, or driven less than one mile. Hot tire inflation pressure: After vehicle has been driven 10 miles or more at 60-70 MPH.
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GROUP 4 PROPELLER SHAFT AND DIFFERENTIAL Title Page No. Propeller Shaft and Central Joint . . . . . . . . . . . . . . . 4A-2 Rear Axle . . . . . . . . .
4A- 2 1973 OPEL SERVICE MANUAL PROPELLER SHAFT AND CENTRAL JOINT CONTENTS Subject DESCRIPTION AND OPERATION: Propeller Shaft and Central Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: ’ Propeller Shaft Removal and Installation .
PROPELLER SHAFT AND CENTRAL JOINT 4A- 3 MAJOR REPAIR PROPELLER SHAFT REMOVAL AND INSTALLATION Removal 1. Raise rear of car and support on jack stands at rear jack brackets. 2. Disconnect parking brake cable equalizer from rod. 3. On the Opel 1900 and Manta, unhook parking brake cable from floor panel.
4A- 4 1973 OPEL SERVICE MANUAL Figure 4A-3 Removing Pinion Flange bracket to support cushion bolts and pull central joint support from torque tube. See Figure 4A-5; Assembly of Central Joint CAUTION: .
PROPELLER SHAFT AND CENTRAL JOINT 4A- 5 1. Check condition of support cushions. If new cush- ions are installed, torque to 29 lb. ft. See Figure 4A-6. 2. Install ball bearing into rubber cushion with the flange facing toward front of car. Pack area in front of bearing with water resistant grease.
4A- 6 1973 OPEL SERVICE MANUAL SPECIFICATIONS PROPELLER SHAFT AND CENTRAL JOINT SPECIFICATIONS Tightening Specifications ~ Use a reliable to’rque wrench. Specifications are for clean and lightly-oiled threads. Part Bolt Bolt Bolt Torque Bolt Location Drive Pinion Extension Shaft Flange to Universal Joint .
REAR AXLE CONTENTS Subject Page No. DESCRIPTION AND OPERATION: Rear Axle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B- 7 DIAGNOSIS: Rear Axle Trouble Diagnosis . . . . . . .
4S- 9 1973 OPEL SERVICE MANUAL DIAGNOSIS DIFFERENTIAL TROUBLE DIAGNOSIS Condition Possible Cause 1. Noise is the same in 1. a) Road noise. “Drive” or “Coast”. b) Tire noise. c) Front wheel bearing noise. d) Front or rear U-joint angle too great.
REAR AXLE 48. 9 MAJOR REPAIR REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY Removal 1. Raise rear of car with floor jack under differential carrier and position jack stand under jack bracket on each side of car. Remove rear wheel assemblies and one brake drum.
4B- 10 1973 OPEL SERVICE MANUAL Figure 48-Z Removing Rear Axle Assembly an equiva/entpart ifreplacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper reten- tion of these parts.
REAR AXLE 40- 11 Figure 48-3 Removing Axle Bearing Retaining Ring seat and lateral runout of axle shaft flange near larg est diameter. Permissible radial runout is .002”, and permissible “lateral runout is .OO4”. An axle shaft which exceeds these tolerances, or one which has been otherwise damaged during removal, must be replaced.
4S- 12 1973 OPEL SERVICE MANUAL 12. Insert adapter J-2241-1 1 in differential case bear- ing hub and remove side bearings using puller J- 22588 with adapter leg J-22939. See Figure 4B-6. 13. Remove the differential case to ring gear bolts and tap ring gear off case using a soft faced hammer.
2. Using Special Tool J-22932 hold barrel spline and remove pinion preload nut. See Figure 4B-8. 4. Remove drive pinion by tapping rearward with a soft faced hammer. 3. With the aid of Special Tool J-22937 remove barrel spline from drive pinion. See Figure 4B-9.
46. 14 1973 OPEL SERVICE MANUAL 2. Install rear pinion bearing outer race (without shims) using installer J-7818 and driver handle J- 8092. See Figure 4B-12.
J-781 B INSTALLER i UNDERLINED 4B16 Figure 46-16 - Pinion Gear Reference Number NOTE: The digit “1’: when written in German, resembles the digit “7, However, the digit “7: when written in German, always hasa horizontal line drawn rhrough it ,‘Z”).
48. 16 1973 OPEL SERVICE MANUAL protruding to install the pinion preload nut. Do not use Installer J-22938 to adjust pinion preload. See Figure 4B-20. Assembly and Installation of Differential Case. Opel 1900 and Manta 1. Install side gears without thrust washers or shims.
6. Before installing, shims must be measured to in- sure that the proper thickness is being used. Install shims of correct thickness to obtain desired clearance and reassemble and install pinion shaft lock pin. In- stall thrust washers with concave side towards differ- ential case.
48. 18 1973 OPEL SERVICE MANUAL Figure 48.26 Checking Torque to Rotate Gear in;! surfaces are free of burrs or foreign material. Tighten bolts to 47 lb.
REAR AXLE 48.19 FEELER DIAL INDICATOR DIFFERENTIAL Figure 48.29 Removing Differential Case and End Play using installer J-22919, driver handle J-8092 and pi- lot J-2241-11. 16. Install torque tube assembly. 17. Install axle shafts. 13. Position case assembly and outer races in the carrier.
49- 20 1973 OPEL SERVICE MANUAL IN. LB. TORQUE Figure 48.30 Checking Side Bearing Preload 4. With the use of a feeler gauge, check clearance between differential side gears and case.
REAR AXLE 48.21 FEELER DIFFERENTIAL DIAL INDICATOR SIDE BEARINGS Figure 48.34 Removing Differential Case and End Play 8. Determine differential side bearing preload and backlash as follows: d. Adjust feeler gauge thickness from side to side until ring gear backlash is 004” to ,008” (.
48. 22 1973 OPEL SERVICE MANUAL 9. Position case assembly and outer races in the car- rier. Use a soft-faced hammer to drive the case into the carrier until the side bearing outer races bottom in their bores. 10. Install side bearing caps in their original location and torque the bolts to 33 lb.
REAR AXLE 49.23 Adjusting end Fitting Specifications Pinion Bearing Preload With New Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Lb.In. Preload With Reused Bearings __.._..I...................,.................,,.................
49- 24 1973 OPEL SERVICE MANUAL Torque Lb.Ft. 1.9 Nut and Bolt Propshaft to Drive Pinion Shaft Extension Flange ...... 11 Nut Flange to Drive Shaft Extension ........................................ 87 Bolt Ring Gear to Case ..........................
DIFFERENTIAL COVER AND SIDE BEARING CAP COVER GASKET DRIVE PINION SlDE,BEARlNG / ; GEAR REAR PINION BEARING x PRELOAD NUT , DIFFERENTIAL CASE SIDE GEAR PINION GEAR THRUST WASHER AXLE SHAFT BEARING RETAINER FLAT WASHER TORQUE TUBE 40.
MM Inches .Ol .ocQ4 .02 .ooot? .03 .OOlZ .04 .0016 .05 .0020 .06 .0024 .07 .0028 .08 .0032 .09 .0035 .lO .0039 .ll .0043 .12 .ow7 .I3 .0051 .14 .0055 .15 .0059 .16 .OM3 .17 JO67 .18 .0071 .19 .0075 .20 JO79 .21 .0083 .22 .0087 MM Inches MM Inches MM Inches MM Inches MM Inches 23 .
I REAR AXLE 48.27 J-21691-6 J-22935 J-22936 J-22919 J-22931 J-8872 J-2241-1 I J-7818 J-22938 J-24093 J-22937 J-22588 Figure 48.39 Differential Special Tools.
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BRAKES GROUP 5 Section 5A 5B 5C Title Brake Booster and Master Cylinder Disc Brakes .._.__.._____ Drum Brakes . . . . . . . . . . . . . Page No. 5A- 2 5B-10 5C-22.
CONTENTS Subject Page No. DESCRIPTION AND OPERATION: Power Brake Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER BRAKE BOOSTER AND MASTER CYLINDER 5A- 3 Figure 5A-2 Exploded View Master Cylinder (Opel 1900 and Manta) held in position by a retaining plate. The front brake circuit is connected to the brake fluid container by a hose and a connector. See Figure 5A-4.
5A- 4 1973 OPEL SERVICE MANUAL Figure 5A-4 Brake Pedal and Master Cylinder Attachment (GT) v1 I cy 1 THRUST SPRING 2 VALVE SEAT 3 HOUSING Figure 5A-5 Vacuum Control Valve DIAGNOSIS POWER BRAKE UNIT TROUBLE DIAGNOSIS Condition Possible Cause Correction Hard Pedal 1.
POWER BRAKE BOOSTER AND MASTER CYLINDER 5A- 5 Condition Grabby Brakes (Apparent Off- and On Condition) Possible Cause 1. Broken or damaged hydraulic brake lines. Correction 1. Inspect and replace, as “CXXSSary. 2. Insufficient fluid in master cylinder.
5A- 6 1973 OPEL SERVICE MANUAL ing on dusty and sandy roads - the filter and sound deadener should occasionally be replaced. To do so, brake booster has to be removed without detaching brake master cylinder. Proceed as follows: 1. Remove protective cap (boot).
POWER BRAKE BOOSTER AND MASTER CYLINDER 5A- 7 cylinder to brake booster and torque nuts to 14 Ib.ft. on the GT and 12 lb.ft. on the Opel 1900 and Manta. 2. Position assembly into brake booster bracket and, on the GT only, thread piston push rod onto the thrust rod.
5A- 8 1973 OPEL SERVICE MANUAL 4. If required, adjust mechanically actuated stop light switch. Pedal travel of 5/S” to 1” should actu- ate switch. Add or subtract washers between bracket and switch to obtain proper adjustment. 5. Road test car for proper brake performance.
POWER BRAKE BOOSTER AND MASTER CYLINDER 5A- 9 NOTE: Snap ring should not be reused. 5. Remove primary and secondary pistons from cyl- inder. 6. Remove check valve by unscrewing check valve connection. Cleaning and Checking 1. Clean parts with genuine brake fluid, Delco Su- preme No.
5B- 10 1973 OPEL SERVICE MANUAL DISC BRAKES CONTENTS Subject DESCRIPTION AND OPERATION: Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISC BRAKES 5B- 11 rLF 5. 2. RUBBER FLUID SEALS 6. 3. HOLLOW PISTONS 7. AL5 3 Figure 58.21 Left Front Disc Brake - Emloded View the piston circumference by its inherent tension. See Figure 5B-21. Both pistons are hollow. The open end of each piston faces the brake disc.
5B- 12 1973 OPEL SERVICE MANUAL A = BRAKE ON THE RUBBER FLUID SEAL TIGHTLY GRIPPING PISTON IS DEFLECTED IN DIRECTION OF PISTON TRAVEL A FRICTION PAD BRAKE DISC RUBBER FLUID SEAL BRAKE I I CALIPER I PISTON I CE BETWEEN RUNNING CLEARAN FRICTION PAD AND BRAKE DISC B = BRAKE OFF B THE PISTON IS RETRACTED BY THE AMOUNT OF RUBBER FLUID SEAL DEFLECTION.
DISC BRAKES 5B- 13 Condition Possible Cause Correction 2. Front end out of line. 2. Check and align to manufac- turer’s specifications. 3. Unmatched tires on same axle. 3. Tires with approximately the same amount of tread should be used on the same axle.
5B- 14 1973 OPEL SERVICE MANUAL Condition Possible Cause Correction 2. Partial system failure. 2. Check front and rear brake system and repair, if necessary. Also, check brake warning light, if a failed system is found and light did not function. 3. Excessively worn shoe and lining.
DISC BRAKES 5B- 15 Condition Possible Cause 2. Binding brake pedal mechanism. Correction 2. Check and lubricate, if necessary. 3. Corroded caliper assembly.
5B- 19 i973 OPEL SERVICE MANUAL Figure 56-24 Removing Dowel Pins Figure 56-25 Removing Friction Pads 4. Check rubber seals for wear. If rubber seals are hardened, brittle or cracked, they must be replaced as follows: (a) Remove brake caliper from steering knuckle and brake disc.
DISC BRAKES 58.17 a tine cut file. Do not use any solvent except dena- tured alcohol. Do not use a metaIJic scraper too/. 8. With a punch, drive one dowel pin from inboard side through caliper and friction pads to stop. Install new cross-shaped retaining spring under installed dowel pin, then install second dowel pin.
58-18 1973 OPEL SERVICE MANUAL Figure 58.28 Brake Caliper to Steering Knuckle Attaching Bolts wheel. Disconnect brake caliper with friction pads from steering knuckle and support the assembly as shown in Figure 5B-29. Figure 58.29 Supporting Brake Caliper 2.
DISC BRAKES 5B- 19 CAUTION: Fasteners in Steps 7 and 9 are important attachingparts in that they cooId affect theperfom- ante of vital components and systems, and/or couJd resuJt in major repair expense. They must be re- placed with one of the same part number or with an equivaJent part if repJacement becomes necessary.
58.20 1973 OPEL SERVICE MANUAL half, and blow out pistons, carefully regulating air flow. When removing pistons, proceed with extreme caution and always keep the fingers ofthe hand hold- ing the brake caliper away from the piston. Figure 55.33 Removing Caliper Rim Half Piston Figure 58-34 Removing Caliper Mounting Half Piston 4.
DISC BRAKES 5B- 21 caliper half collars and the clamp rings are correctly positioned on rubber seals. 12. Install brake caliper on steering knuckle, torqu- ing bolts to 72 lb.ft. or with an equivalent part, if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design.
5C- 22 1973 OPEL SERVICE MANUAL DRUM BRAKES CONTENTS Subject DESCRIPTION AND OPERATION: Description of Brake Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation of Hydraulic Service Brake . . . . . . . . . . . . . . . . .
DRUM BRAKES 5C- 23 Parking Brake Control System The hand-operated parking brake lever is mounted between the front seats on the propeller shaft tunnel. A paw1 is riveted into the parking brake lever and is actuated by a control rod provided with a spring loaded push button.
5C- 24 1973 OPEL SERVICE MANUAL -~ - -----*““Y BRAKE LIC Figure 5C-43 Parking Brake Equalizer (Opel 1900 and Mallta) Figure 5C-45 Brake and Clutch Pedal Arrangement - GT Figure 5C-44 Parking Brake Equalizer (GT) The brake pedal on the GT is suspended from a pivot shaft.
DRUM BRAKES 5C- 25 PISTON CYLINDER HOUSING BLEEDER VALVE SC-47 Figure 5C-47 Wheel Cylinder Exploded View cups are of a special heat resisting rubber. The against the ends of the shoes.
5C- 26 1973 OPEL SERVICE MANUAL.
DRUM BRAKES 5C- 27 MAINTENANCE AND ADJUSTMENTS BRAKE ADJUSTMENT Preliminary Checks 1. Depress brake pedal firmly. If pedal travels to within two inches of toeboard and has a hard feel, brake shoes require adjustment or relining. However, if pedal has a spongy feel, brake system needs bleed- ing.
5C- 28 1973 OPEL SERVICE MANUAL Figure 5C-51 Rear Wheel Brake Adjustment disconnected, or when cables have been stretched through extended use. Need for parking brake ad- justment is indicated if the service brake operates with good reserve, but the parking brake handle can be engaged, more than eight ratchet clicks under heavy pressure.
DRUM BRAKES BC- 29 at a time to avoid getting fluid level in reservoir dangerously low. The correct sequence for bleeding is bleed the wheel cylinder or caliper nearest the master cylinder first in either circuit. Do not perform bleeding operation while any brake drum is removed.
Figure 5C-53 Rear Brake Assembly 10. Check all backing plate attaching bolts to make sure they are tight. Using line emery cloth, clean all rust and dirt from shoe contact surfaces on plate.
DRUM BRAKES 5c- 31 remove grooves, and the ridges in the lining should be lightly removed with a lining grinder. If brake linings are more than half worn, but do not need replacement, the drum should be polished with fine emery cloth but should not be rebored.
5C- 32 1973 OPEL SERVICE MANUAL Never use copper tubing because copper is subject to fatigue cracking which would result in brake failure. 2. Cut tubing to length. The correct length may be determined by measuring the old pipe using a cord and adding l/8” for each double lap flare.
GROUP 6 ENGINE Section 6A 6B 6C 6D - 6E 6F 6G Title ‘age No. Engine Mechanical and Mounts All Models Cooling System All Models . . . . . . . . . . . . . . . . . . . . . . Fuel System All Models . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Systems All Models .
6A- 2 1973 OPEL SERVICE MANUAL ENGINE CONTENTS Subject DESCRIPTION AND OPERATION: Engine Construction .......................................................... Lubrication System ............................................................ DIAGNOSIS: Excessive Oil Consumption .
ENGINE MECHANICAL AND MOUNTS 6A- 3 Figure 6A-1 Side Cross Section View of Engine This engine has full skirt “Autothermic” type pistons with two horizontal slots in oil control ring groove, which partly separate head and skirt to maintain good contact with the cylinder walls throughout the entire temperature range.
6A. 4 1973 OPEL SERVICE MANUAL hand side above crankshaft sprocket, has a plunger head with oil- proof and wear-resistant synthetic rubber pad, which is pressed against chain by both spring and oil pressure.
ENGINE MECHANICAL AND MOUNTS 6A- 5 incorporating a gear-type pump driven by the dis- tributor shaft. The pump body forms part of the timing case. A passage cast in cylinder block and a suction pipe connect the pump to the screen cover assembly in the sump of the oil pan.
6A. 6 1973 OPEL SERVICE MANUAL DIAGNOSIS EXCESSIVE OIL CONSUMPTION Condition Correction External Oil Leaks at: Tighten attaching bolts. If leaks Rocker Arm Covers persist, remove cover (or pan), Crankcase Front Cover check sealing surfaces for burrs Oil Pan and Gasket or scoring, replace gasket, and seal bolts with silastic sealer or equivalent.
ENGINE MECHANICAL AND MOUNTS 6A- 7 Pour penetrating oil over the valve spring cap and engine off. It makes no difference whether the engine allow it to drain down the valve stem.
6A- 8 1973 OPEL SERVICE MANUAL Actual adjustment is made by backing off adjusting nut at the rocker arm until clearance exists between the valve stem, rocker arm, and lifter. Then slowly tighten adjusting nut until clearance is eliminated. When clearance is eliminated, turn adjusting nut one full turn (clockwise).
ENGINE MECHANICAL AND MOUNTS 6A- 9 The engine does not rest on the front suspension cross member as in the Opel 1900 and Manta but on a separate cross member. On removal and installa- tion of the engine the front suspension cross member need not be detached.
6A- 10 1973 OPEL SERVICE MANUAL Fig. 6A.12 Transmission Cross Member Installation (Opel 1900 and Manta) 1. Lower engine and transmissior assembly into car. 2. Install components as remov&d in steps .1 through 19 above. Installation (GT) 1. Install bell housing, transmission and starter.
ENGINE MECHANICAL AND MOUNTS 6A- 11 a. Attach left chain to alternator support rear bolt. b. Bolt right chain to existing threaded hole at lower right front of engine. 2. Assemble loose ends of chain to support device J- bolts and adjust to remove engine weight from motor mounts.
6A- 12 1973 OPEL SERVICE MANUAL INTAKE AND EXHAUST MANIFOLD REMOVAL AND INSTALLATION Removal 1. Disconnect battery. 2. Remove air cleaner. 3. Disconnect throttle linkage at carburetor. 4. Disconnect vacuum advance line at carburetor. 5. Remove fuel line at carburetor inlet.
RECESSES VERTICAL FOR REMOVAL OF LEFT ROW OF CYLINDER HEAD BOLTS 6A-16 Figure 6A-18 Recesses in Camshaft 2. Clean piston tops and combustion chambers. Thoroughly clean all gasket surfaces on the cylinder block and cylinder head. 3. Lightly lubricate cylinder walls with engine oil.
6A. 14 1973 OPEL SERVICE MANUAL wire brushes for removing carbon, avoid scratching valve seats and valve faces. A soft wire brush such as J-8089 is suitable for this purpose. Figure 6A-21 Removing Valve Cap Retainers 5. Clean carbon and gum deposits from valve guide bores.
ENGINE MECHANICAL AND MOUNTS 6A- 15 New inlet valves must not be refaced or lapped with grinding compound. The correct angle for the intake and exhaust valve head is 44 degrees. 10. Install cylinder head. 11. Adjust valve clearance. See MAINTENANCE AND ADJUSTMENTS.
6A- 16 1973 OPEL SERVICE MANUAL Inspection of Connecting Rod Bearings and Crankshaft Journals Remove oil pan. After removal of oil pan, disconnect two connecting rods at a time from crankshaft and inspect the bear- ings and crankpin journals.
ENGINE MECHANICAL AND MOUNTS 6A- 17 seating and to prevent turning. The ends of she//s must never be tiled flush with parting surface of crankcase or bearing cap.
6A- 18 1973 OPEL SERVICE MANUAL pressure. If heavy pressure is required, shell was not started squarely and will be distorted if force into place. 12. Place lower bearing shell in bearing cap, then check clearance with plastic-type gauge, as previ- ously described.
ENGINE MECHANICAL AND MOUNTS 6A- 19 sion. When replacing flywheel use new bolts and torque to 43 lb.ft. PISTON, RINGS AND CONNECTING RODS Removal and Disassembly of Piston and Rod Assemblies 1. Drain oil. 2. Remove oil pan. 3. Remove cylinder head. 4.
6A. 20 1973 OPEL SERVICE MANUAL diameter at the right angle to the piston pin is greater than the diameter parallel to the piston pin. When a piston is checked for size, it must be measured with micrometers applied to the skirt at ,points 90 degrees to the piston pin.
ENGINE MECHANICAL AND MOUNTS 6A- 21 2.. Expand a telescope gage to fit the cylinder bore at right angles to the piston pin 2-l/2” from top. See Figure 6A-33. cylinders, the glazed cylinder walls should be slightly dulled without increasing the bore diameter by means of the finest grade honing stones.
6A- 22 1973 OPEL SERVICE MANUAL I. NO. I COMPRESSION - GAP IN FRONT 2. NO. 2 COMPRESSION - GAP IN REAR 3. UPPER STEEL BAND - I - 2 IN.TOWARDS THE LEFT OF INTERMEDIATE RING GAP 4. INTERMEDIATE RING - GAP IN FRONT 5. LOWER STEEL BAND - I - 2 IN.TOWARDS THE RIGHT OF INTERMEDIATE RING GAP.
ENGINE MECHANICAL AND MOUNTS 6A- 23 1. NOTCH IN PISTON HEAD POINTING TOWARD THE FRONT 2. OIL HOLE IN CONNECTING ROD POINTING TOWARD THE RIGHT (MANIFOLD SIDE) 3. NOTCH IN CONNECTING ROD CAP POINTING TOWARD THE REAR 6A-36 Figure 6A-39 Piston and Rod Assembly by oompressing the rings with a “wrap around” com- pressor.
6A- 24 1973 OPEL SERVICE: MANUAL on front side of timing chain to permit reinstallation in original position. Timing Chain Cover and Timing Chain installation Reinstall timing chain cover by reversing removal procedures, pay particular attention to the following points.
ENGINE MECHANICAL AND MOUNTS 6A- 25 1, CAMSHAFT SPROCKET 2. CAMSHAFT SPROCKET SUPPORT 3. LONG DAMPER BLOCK 4. CRANKSHAFT SPROCKET 5. CHAIN AND DAMPER BLOCK IN PARALLEL 6. CRANKSHAFT KEY 7. PAINT MARK ON FRONT 8. TIMING CHAIN 9. MARK ON CAMSHAFT SPROCKET SUPPORT IO.
6A- 26 1973 OPEL SERVICE MANUAL rear of cylinder head. Remove camshaft toward front, supporting camshaft with one hand through access hole and taking care not to damage bearing surfaces. See Figure 6A-43. 1 2 345 6 I. OLD PRESSURE 4. COVER GASKET RELIEF ~~- SSEMBLY 5.
ENGINE MECHANICAL AND MOUNTS 6A- 27 With feeler gauge, check gear backlash. It should be between .I?04 in. and .C!OS in. See Figure 6A-46. 3. Remove (2) bolts holding pipe and screen assem- bly to cylinder block.
6A- 28 1973 OPEL SERVICE MANUAL Part Connecting Rod Bolts .......................................................... Crankshaft Main Bearing Bolts .......................................... Flywheel to Crankshaft Attaching Bolts ......................
ENGINE MECHANICAL AND MOUNTS 6A- 29 Cooling System - Type ,._...___..___..___........................... Liquid Cooling With Circulating Pump Filler Cap Type - Pressure _,._.,,._.,,...,,.........,..,.....,.,.................,,.........................
GA. xl 1973 OPEL SERVICE MANUAL Valve Seat and Correction Angle in Cylinder Head Intake Valve Seat Angle ..,._,..__....,,..,,,..,.,.,.,..............,............................................................... 45” Outer Correction .,,,.,,._.,._.
ENGINE MECHANICAL AND MOUNTS 6A- 31.
66.32 1973 OPEL SERVICE MANUAL COOLING SYSTEM CONTENTS Subject DESCRIPTION AND OPERATION: Cooling System and Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: Checking and Filling Cooling System .
COOLING SYSTEM 6B- 33 remove drain plug on right.side of cylinder block. Set heater temperature control valve at full heat posi- tion. After the cooling system is drained, and plugs reinstalled, fill the system with clean water.
6B- 34 1973 OPEL SERVICE MANUAL test by partially draining the cooling system and dis- connecting the water outlet housing from the ther- mostat housing which is mounted on the right front side of cylinder head. The standard thermostat valve should start to open at 189 degrees F and fully open at approximately 212 degrees F.
COOLING SYSTEM 6B- 35 SPECIFICATIONS 1973 COOLING SYSTEM CAPACITIES Cooling System - Type . . . . . . . . . . . . . . . . . . . . . . Liquid Filler Cap Type - Pressure _.._..__........_.._.,,.,,..,,.,,..,.,,..,,,.,,,.., Water Temperature Control Thermostat Open At __.
6C- 36 1973 OPEL SERVICE MANUAL FUEL SYSTEM ALL MODELS CONTENTS Subject DESCRIPTION AND OPERATION: Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM SC- 37 must always be removed before the distributor can be removed. EVAPORATION CONTROL SYSTEM 1. The function of the fuel evaporation control sys- tem is to absorb the fuel vapors develo.
6C- 38 1973 OPEL SERVICE MANUAL CAUTION: Because the fuel pump is below fuel tank level, fuel will drain from the tank. when the supply hne is disconnected from the fuel pump. 1. Pull fuel supply line and rubber connector from fuel pump. Plug rubber connector to prevent fuel loss.
FUEL SYSTEM SC- 39 MAJOR REPAIR FUEL TANK OPEL 1900 AND MANTA The fuel tank is located below the luggage compart- ment floor panel and is attached with a strap. The plastic tank vent hoses join in a connector from where the fuel vapors escape through a fourth ho% attached to the upper flange of the tank.
6C- 40 1973 OPEL SERVICE MANUAL Figure K-8 Fuel Line Attachment at Tank 6. Remove spare tire support attaching brackets. Spare tire hold-down and support attaching brackets are ;attached to the rear wheel house panel and are Figure 6C-1 1 Tank Vent and Filler Hoses Figure 6C-9 Spare Tire Hold-Down and Brackets G.
FUEL SYSTEM 6C- 41 covered with sound deadening compound. See Fig- ure 6C-10. 7. Remove fuel tank vent hose and tiller hose. See Figure 6C- 11. 8. Remove fuel tank attaching bolts and gauge wire and remove tank. Installation 1. Install tank and tighten attaching bolts.
6D. 42 1973 OPEL SERVICE MANUAL EXHAUST SYSTEMS ALL MODELS CONTENTS Subject DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Page No. Exhaust System (All Models) . . . .
EXHAUST SYSTEMS 6D- 43 6D-4 Figure 6D-1 Opel 1900 and Manta Exhaust System G.T. - EXHAUST SYSTEM KEJ 1 2 3 4 5 6 7 DESCRIPTION MUFFLER, FRT. W/CTR. EXHAUST PIPE, FRT. EXHAUST MUFFLER, RR. W/TAIL PIPE BUMPER, MUFFLER SUSPENSION - RR. BOW. MUFFLER SUSPENSION - RR.
SE- 44 1973 OPEL SERVICE MANUAL CARBURETOR AND THROTTLE LINKAGE ALL MODELS CONTENTS Subject DESCRIPTION AND OPERATION: Carburetor . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR AND THROTTLE LINKAGE 6E- 45 1 2 3 45 6 7 8 Sectional View Of 19 US Carburetor (both barrels) 1 PIug(transition channels, secondary barrel) 6 Float chamber 2 Carburetor cover 7 Idle air pass.
6E. 46 1973 OPEL SERVICE MANUAL Sectional View Of Carburetor 1 Carburetor cover 2 Vent valve 3 Ball valve (pressure valve) 4 Injection tube 5 Primary venturi 6 Choke valve 7 Vent iet 8 Air correction .
CARBURETOR AND THROTTLE LINKAGE 65 47 Figure 6E.3 Secondary Vacuum Diaphragm Figure 6E-4 Automatic Choke System Figure 6E-5 Idle System in a richer mixture. When the throttle valve is opened, fuel is also drawn from the upper ports, providing a good transfer from the idle system to the main metering jet system.
6~. 46, 1973 OPEL SERVICE MANUAL ary barrel, it is provided with g transfer system. When the secondary throttle valve starts to open, two‘ports (which are normally just above the closed valve) are uncovered, causing fuel to feed into the secondary bore just before the secondary nozzle starts feeding.
CARBURETOR AND THROTTLE LINKAGE 6E- 49 DIAGNOSIS CARBURETOR Condition I Hesitation or Stall Upon Light Acceleration Correction 1. Check spark plugs and plug gap. Plug gap should be ,030 in. 2. Check dwell and timing. 3. Adjust carburetor. 4. Accelerator pump should discharge fuel between throttle plate and venturi wall with engine off.
6E- 50 1973 OPEL SERVICE MANUAL MAINTENANCE AND ADJUSTMENTS IDLE SPEED ADJUSTMENT Note: Idle speeds of 600 to 800 R.P.M. are normal for engines with less than 3,ooO miles. Prior to making any adjustment to the carburetor, the following items must be checked for proper oper- ation and/or setting: 1.
CARBURETOR AND THROTTLE LINKAGE 6E- 51 water, adjust the throttle stop screw to read 6 inches of water (3 inches down and 3 inches up). 4. Disconnect manometer and reconnect the vacuum advance hose. 5. Adjust idle air speed screw and mixture screw to obtain maximum idle at 850 to 900 R.
6E. 52 1973 OPEL SERVICE MANUAL Figure 6E-15 Adjusting Accelerator Cable Depress accelerator pedal until pedal lever touches floor mat. The carburetor throttle valve must now be completely opened. MAJOR REPAIR REMOVE AND INSTALL CARBURETOR 1. Remove air cleaner.
CARBURETOR AND THROTTLE LINKAGE 6E- 63 4. Adjust engine idle speed and mixture CAUTION: : Make sure choke valve opens fully before starting idle adjustment. THROTTLE LINKAGE REMOVAL Removal Opel 1900 and Manta Series 1. Remove control wire from bracket and unhook it from segmental disc.
6E- 54 1973 OPEL SERVICE MANUAL Figure 6E-21 Removing Vacuum Case Lever 5. Unscrew vacuum diaphragm cover from choke housing. See Figure 6E-22. Figure 6E-22 Removing Vacuum Diaphragm Cover 6. Unscrew retaining ring from automatic choke body and take off cover.
CARBURETOR AND THROTTLE LINKAGE 6E- 55 float chamber. Clean all parts and blow out with compressed air. Replace gaskets and seal rings. 14. Check actuating parts in automatic choke body, including diaphragm, for wear. Check pull rod for free operation.
6E- 56 1973 OPEL SERVICE MANUAL valve stop screw. Loosen the stop screw until the valve is completely closed. Turn the screw in l/4 turn from closed position, hold, and tighten lock nut. This is done to insure that the throttle blade will not stick closed.
CARBURETOR AND THROTTLE LINKAGE 6E- 57 ACCELERATOR PUMP PRESSURE RELIEF VALVE SEAT ALVE VENT DISCHARGE (AIR BUBBLES FROM THIS HOLE IS NORMAL) PUMP INLET VALVE EXHAUST PORT -- 6E-33 Figure 6E-33 Carburetor Fuel Bowl 33. Install float and pivot rod making sure rod is seated in casting.
6E- 58 1973 OPEL SERVICE MANUAL Figure 6E-34 Leaf Spring Installed 1 6E-36 Figure 6E-36 Checking Vent Valve Adjustment 39. Check compression of vent valve lower spring. It should be compressed l/4 inch with throttle valve completely closed. See Figure 6E-36.
CARBURETOR AND THROTTLE LINKAGE 6E- 59 Figure 6E-37 Carburetor Specifications.
6F- 60 1973 OPEL SERVICE MANUAL EMISSION CONTROL SYSTEMS ALL MODELS CONTENTS Subject DESCRIPTION AND OPERATION: Description and Operation of O.E.C.S. . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Gas Recirculation System . . . . . . . . . . .
EMISSION CONTROL SYSTEMS 6F- 61 I 1. HEAT STOVE 2. CONNECTING HOSE. 3. VACUUM DIAPHRAGM 4. VALVE (El-METAL SPRING) 5. VACUUM HOSES 6. AIR CLEANER HOUSING 7. CARBURETOR BF-2 Figure 6F-2 Heated Air System the lower edge of the stove passes across the manifold surface, picking up heat.
6F. 62 1973 OPEL SERVICE MANUAL bleed into the vacuum line, allowing more manifold vacuum to reach the vacuum motor. Whenever there is nine inches or more of vacuum in the vacuum motor, the diaphragm spring is compressed, the door is opened. When the engine is not running, the diaphragm spring will always hold the door closed.
EMISSION CONTROL SYSTEMS 6F- 63 2. With the engine “OFF”, observe damper door position through snorkel opening. If position of snor- kel makes observation difficult “se the aid of a mir- ror. At this point damper door should be in such a position that the heat stove passage is covered (snor- kel passage open).
6F. 64 1973 OPEL SERVICE MANUAL Figure 6F-5 Replacing Vacuum Motor Assembly 2. Lift vacuum motor, cocking it to one side to un- hook motor linkage at the control door. 3. Install in reverse sequence. R And R Air Cleaner Sensor 1. Remove sensor retaining clips by prying.
TUNE-UP ALL MODELS CONTENTS Subject DESCRIPTION AND OPERATION: Purpose of a Tune-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: Engine Tune-Up Mechanical Operations .
6G- 66 1973 OPEL SERVICE MANUAL 6. Check compression of each cylinder. Repeat compression check and record highest reading ob- tained on each cylinder during the two pressure checks. The recorded compression pressures are to be con- sidered normal if the lowest reading cylinder is more than 75 percent of the highest reading cylinder.
2. If inspection of contact points indicates excessive burning, pitting or wear, check condenser and re- place if necessary. 3. Inspect all connections and wires in the primary ignition circuit. Correct any abnormal conditions found. Carburetor 1. Clean fuel strainer in fuel pump.
6G- 68 1973 OPEL SERVICE MANUAL SPECIFICATIONS TUNE-UP SPECIFICATIONS AND ADJUSTMENTS Voltage Regulator Voltage Regulator Setting in Volts at 2500 Engine RPM . . . . . . . . . . . . . . . . . . . . . . 14+ .5 Ignition Coil Ignition Coil Current Draw, Amperes at 12.
GROUP 7 TRANSMISSION 7A I Clutch . . . . . . . . . . . . . . . . . . . . . . . . . 7A- 1 7B I Manual Transmission 1 76-12 1 7c I Automatic Transmission 1 7C-36 1 I I I.
.
CLUTCH 7A. 1 CLUTCH CONTENTS Subject DESCRIPTION AND OPERATION: Clutch and Clutch Pedal Mechanisms . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS: Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7A- 2 1973 OPEL SERVICE MANUAL DIAGNOSIS CLUTCH TROUBLE DIAGNOSIS Condition Possible Cause Correction Fails to release (pedal 1. Improper cable 1. Adjust cable. pressed to floor - shift adjustment. lever does not move freely in and out of “Reverse” gear.
CLUTCH 7A- 3 Possible Cause Correction Rattling - Transmission Click 1. Yoke loose on ball stud in bearing groove. 1. Check ball stud and retaining spring and replace if necessary. 2. Oil in driven plate damper. 2. Replace driven plate. 3. Driven plate damper spring failure.
7A- 4 1973 dPEL SERVICE MANUAL Condition Possible Cause Correction Heat-blued driven plate and pressure plate assembly. 1. Improper pedal 1. Replace only driven plate, and adjustment. adjust clutch pedal and cable. Grab and chatter with oil present on clutch assembly.
CLUTCH ?A- 5 MAJOR REPAIR CLUTCH REMOVAL AND INSTALLATION Remove Clutch 1. Remove transmission. Refer to Manual Transmis- sion for removal procedure. 2. Remove bolts from engine support brackets, both sides. Let brackets hang by front bolts. 3. Remove flywheel cover pan.
7A- 6 1973 OPEL SERVICE MANUAL 1. FIywheeI and Pressure Plate Examine friction surfaces of flywheel and pressure plate for scoring or roughness. Slight roughness may be smoothed with fine emery cloth, but if surface is deeply scored or grooved the part should be re- placed.
Installation 1. FLYWHEEL 2. CLUTCH ASSEMBLY 3. ASSEMBLY MARKS 4. CLUTCH ALIGNING ARBOR J-22934 7A-5 1. Slide control cable ball end through eye in clutch housing. Connect to lever and (on GT) install return spring. 2. Replace washers and rubber grommet, slide cable through retainer on dash panel, and connect to clutch pedal.
7A- 8 1973 OPEL SERVICE MANUAL “ 314” TO ,l 17 16 1. E-RING 12. CLUTCH PEDAL FREE TRAVEL- 2. WASHER 3/4” TO 1 l/4” 3. RUBBER GROMMET 13. RETURN SPRING 4. WASHER 14. RELEASE LEVER 5. SLEEVE 15. RUBBER BELLOWS 6. DASH PANEL 16. BALL STUD LOCK NUT 7.
CLUTCH lA- 9 1. 2. 3. 4. 8. - 9. - 11. BRACKET 1. “E” RING 12. CABLE 2. WASHER 13. RELEASE LEVER 3. RUBBER GROMMET 14. BALL STUD 4. CLUTCH OPERATING DAMPER 15. CLUTCH HOUSING 5. GROMMET 16. BALL STUD LOCK NUT 6. WASHER 17. RUBBER BELLOWS 7. “E” RING 18.
7A- 10 1973 OPEL SERVICE MANUAL Arrangement Of Clutch 1 Clutch release lever 14 Clutch ossy. bolt, lockwasher 2 Slot in lever for control cable boll 15 Hollow space under felt ring filled end with mol.
Figure 7A-9 Exploded View of Clutch Pedal and Housing.
7B- 12 1973 OPEL SERVICE MANUAL MANUAL TRANSM ISSION CONTENTS Subject DESCRIPTION AND OPERATION: Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSMISSION 78.13 POWER FLOW IST & 2ND GEAR SLIDING GEAR r2yDmSPEED GEAR 1ST SPEED GEAR ‘E REVERSE - IDLER GEAR COUNTERSHAFT GEAR +/ UNIT - IST SPEED GEAR ~LCOUNTERSHAFT GE A R UNIT COUNTERSHAFT GEAR UNIT f-t 3RD SPEED GEAR REVERSE SPEED GEAR COUNTERSHAFT GEAR UNIT - 2ND SPEED GEAR POWER FLOW.
7B- 14 1973 OPEL SERVICE MANUAL POWER FLOW - 1st SPEED MAI N DRIVE GEAR ( INPUT ) COUNTERSHAFT GEAR UNIT 1st SPEED GEAR 1 st SPEED GEAR 1st AND 2nd GEAR SLIDING GEAR 1st AND 2nd SP EE D SLIDING GE AR .
MANUAL TRANSMISSION 76.15 POWER FLOW. 2nd SPEED MAIN DRIVE GEAR (INPUT) COUNTERSHAFT GEAR UNIT 2nd SPEED GEAR 2nd SPEED GEAR 1st AND 2nd GEAR SLIDING GEAR 1st AND 2nd SPEED SLIDING GEAR GUIDE UNIT COUNTERSHAFT GEAR UNIT DRIVE GEAR 2nd SPEED GEAR 1st AND 2nd GEAR SLIDING GEAR Ist AND 2nd SPEED SLIDING GEAR GUIDE UI MAINSHAFT (OUTPUT) 76 Figure 78.
78. 16 1973 OPEL SERVICE MANUAL POWER FLOW - 3rd SPEED MAIN DRIVE GEAR (INPUT) COUNTERSHAFT GEAR UNIT 3rd SPEED GEAR 3rd SPEED GEAR GEAR SHIFTER SLEEVE GEAR SHIFTER SLEEVE CARRIER COUNTERSHAFT GEAR UNIT GEAR DRIVE 3rd SPEED GEAR GEAR SHIFTER SLEEVE GEAR SHIFTER SLEEVE CARRIER MAIN SHAFT (OUTPUT) 78-4 Figure 78.
MANUAL TRANSMISSION 78.17 POWER FLOW - 4th SPEED MAIN DRIVE GEAR (INPUT) GEAR SHIFTER SLEEVE GEAR SHIFTER SLEEVE CARRIER GEAR SHIFTER SLEEVE GEAR SHIFTER SLEEVE CARRIER MAIN SHAFT (OUTPUT) 7E5 Figure 78.
78.18 1973 OPEL SERVICE MANUAL POWER FLOW - REVERSE SPEED MAIN DRIVE GEAR (INPUT) COUNTERSHAFT GEAR UNIT DRIVE GEAR COUNTERSHAFT GEAR UNIT REVERSE SPEED GEAR REVERSE IDLER GEAR REVERSE IDLER GEAR Is+ .
MANUAL TRANSMISSION 76.19 DIAGNOSIS MANUAL TRANSMISSION DIAGNOSIS Condition Possible Cause Noisy in Forward Speeds 1) Low lubricant level. 2) Incorrect lubricant. 3) Transmission misaligned or loose. 4) Front main bearing worn or damaged. 5) Mainshaft bearing worn or damaged.
76.20 1973 OPEL SERVICE MANUAL GEARSHIF INTERMEDIATE SHAFT, . SHIFT FINGER1 SELECTOR LEVER JT “B’ 78-7 Figure’7B.7 Reverse Gearshift Blocker Adjustment Figure 78-B 3. Unhook tension spring of gearshift lever and, after removal of retaining washer, push pivot pin out of intermediate shift lever.
MANUAL TRANSMISSION 78.21 78-12 Figure 78-l 2 Figure 78.13 2. Knock off gearshift lever button and loosen threaded pin for Bowden control wire attachment. See Figure 7B-12. 3. Drive spiral pin and clamping sleeve out of shift finger tube and stop sleeve.
78.22 1973 OPEL SERVICE MANUAL 3. Install new bellows. Adhere to distance A - 8.07”. See Figure 7B-I 1. 4. Heat up new gearshift lever knob in boiling water to 176 degrees F. and push it onto gearshift lever tube. Adhere to distance A .3”, see Figure 7B-15.
MANUAL TRANSMISSION 70.23 5. Attach clutch cable. 6. Perform clutch lash adjustment. See Clutch, Sec- tions A and B for adjustment procedure. 7. After overhaul of transmission, refill with 2- l/2 pints of SAE 80 or SO-90 multi-purpose gear Iubri- cant.
78.24 1973 OPEL SERVICE MANUAL Removing Shifter Shaft 1. Remove cotter pins that secure each end of shifter shaft. See Figure 7B-20. 7&20 Figure 78.20 Cotter Pin Locations on Shifter Shaft 2. Remove shifter shaft with washer and spring washer at each end.
MANUAL TRANSMISSION 78.25 4. With Special Tool J-2291 1 inserted, take counter- shaft gear unit out of transmission case. Remove both thrust washers. Removing Selector Shaft and Intermediate Levers 1. Drive out reverse intermediate lever bedding bolt and remove reverie speed shifter intermediate lever.
78.26 1973 OPEL SERVICE MANUAL 4. Remove both first and second speed shifter yoke and shifter shaft cam. Removing Main Drive Gear and Mainshaft Assembly 1. From front of transmission, pull main drive gear and needle bearing out of transmission. (May be necessary to rock main drive gear.
MANUAL TRANSMISSION 78-27 SYNCHRONIZER SPAZER RING f&31 Figure 78.31 3. Remow snap ring from in front of clutch hub. See Figure 7B-32. SPEED DRIVE Figure 78.33 Removing Snap Ring Behind Speedometer Drive Gear CLUTCH HUB Figure 7%.32 Removing Snap Ring In Front of Clutch Hub 4.
iB- 28 1973 OPEL SERVICE MANUAL 1 ST SPEED GI NEEDLE BEARING- / CLUTCH SLEEc?iE, -. SNAP RING _.. ..~~ ~- KEY SPRING ,a-37 Figure 70-37 Figure 7B-39 Pressing Off Small Clutch Hub 7. With Special Tool J-21684, Press Plate, located below third speed gear, press out gear shifter sleeve carrier.
MANUAL TRANSMISSION 78.29 5. Using external snap ring pliers, secure gear shifter sleeve carrier on mainshaft with snap ring. See Fig- ure 7B-40. 6. From rear of mainshaft, slide second speed gear onto mainshaft. Gear must turn freely on mainshaft. See Figure 7B-41.
78.30 1973 OPEL SERVICE MANUAL SHOULDER OR SHIFTE .44 Figure 78-46 Installing Reverse Shifter Fork Figure 78.44 Mainshaft Assembly Secured Into Rear Bearing Retainer by Snap Ring 16.
MANUAL TRANSMISSION 70.31 COUNTER SHAFT GEAR THRUST WASHER Figure 76.48 Installing Spacer Ring and Needle Bearing Onto Mainshaft fourth speed yoke should be positioned with rounded notch at shaft hole portion of yoke toward rear. See Figure 78. 47. 3.
Figure 78-5 1 Position of Third, Fourth, and Reverse Intermediate Lever on Selector Shaft 1ST. 2ND Ilr Figure 78.52 Position of First and Second Intermediate Lever on Selector Shaft 3. Install spiral pins to secure both intermediate lev- ers to the selector shaft.
MANUAL TRANSMISSION 70-33 Installing Gearshift Interlock Ball and Gearshift Thrust Spring 1. Install gearshift interlock ball into top transmis- sion bore and then install gearshift thrust spring. Installing Transmission Case Cover 1. Install case cover gasket, cover, and tighten screws.
79.34 1973 OPEL SERVICE MANUAL 1.9 Engine Transmission Figure 78-57 Exploded View of Manual Transmission.
tiANUAL TRANSMISSION 78.35 1’ Case, Transmission 2 Gasket, Trans. Case to Clutch Housing 3 Cap, Ventilator 4 Gear, W/Bushings, ReverSe Idler 5 Shaft, Reverse Idler Gear 6 Cluster Gear, Countershaft 7 Washer, Trans. Counter Gear Thrust 8 Roller. Trans.
7C- 36 1973 OPEL SERVICE MANUAL CONTENTS Subject DESCRIPTION AND OPERATION: Description of the Opel Three-Speed Automatic , Transmission .................................................................... Principles of Operation .....................
AUTOMATIC TRANSMISSION 7c- 37 Disassembly, Inspection and Reassembly of Reaction Sun Gear and Drum .................................... Disassembly, Inspection and Reassembly of Governor Body ...........................................................
Figure 7C-1 Quadrant In Park Position -Opel 1900 and Manta 7C- 38 1973 OPEL SERVICE MANUAL R - Reverse enables the vehicle to be operated in a reverse direction. N - Neutral position enables the engine to be started and operated without driving the vehicle.
AUTOMATIC TRANSMISSION 7c- 39 TURBINE STATOR ( DRIVEN MEMBER) fREACTION MEMBER) CON;ERTER COVER P;MP (D RIVING MEMBER) 7c.3 Figure 7C-3 Torque Converter Assembly energy of the oil to the turbine. See Figure 7C-1. The driven member, or turbine is splined to the transmis- sion input shaft to transmit turbine torque to the transmission gear train.
7C- 40 1973 OPEL SERVICE MANUAL ENERGIZING SPRINGS UTER RACE (CAM) ROLLER CLUTCH STATOR LOCKS UP STATOR COUNTER CLOCKWISE FORCES ON CAM, LOCK OVERRUNS ROLLERS TO INNER RACE CLOCKWISE FORCES ON CAM CAUSE STATOR ASSEMBLY x.
AUTOMATIC TRANSMISSION 7c- 41 Figure 7C-6 Oil Flow With Stator Active gear set and utilizes two sets of planetary pinions in one planet carrier, two sun gears and one ring gear. See Figure 7C-8. The short planetary pinions are in constant mesh with both the input (front) sun gear and the long planetary pinions.
7C. 42 1973 OPEL SERVICE MANUAL PLANETARY CARRIER 7c.to Figure 712-10 First Gear Figure 7C-7 Planetary Gears LONG PINION HORT PINION PLANETARY CARRIER 7C8 Figure 7C-8 Ravigneaux Planetary Gears cariier assembly and output shaft in a clockwise di- rection.
AUTOMATIC TRANSMISSION 7c- 43 LONG PINION INPUT SUN G PLANETARY CARRIER Figure 7C-12 Third Gear LONG PINION ORT PINION INPUT SUN PLANETARY CARRIER 7c.13 Figure 7C-13 Reverse Three Speed automatic transmission has three disc clutches, a band and a sprag (overrunning) clutch.
causes the sprags to wedge and prevent rotation in one direction, and to allow free rotation in the oppo- site direction. 7C. 44 1973 OPEL SERVICE MANUAL The clutch is released by exhausting the oil from behind the piston. The release springs push the pis- ton to the released position, thereby removing the force from the plates.
AUTOMATIC TRANSMISSION 7c- 45 Figure 7C-20 Converter. Converter Housing And oil Pump INPUT SHAFT AND THIRD CLUTCH DRUM Figure 7C-21 Input Shaft And 3rd Clutch Drum.
712.46 1973 OPEL SERVICE MANUAL ___-.. _~--- ..- -_. -. - THIRD CLUTCH ASSEMBLY 7D22 Figure 7C-22 Third Clutch Drum, Piston and Springs, Clutch Plates, Input Sun Gear. Sprag Race And Retainer Assembly The stator shaft is an integral part of the transmis- sion oil pump and supports the stator assembly at the inner race of the roller clutch assembly.
AUTOMATIC TRANSMISSION 7c- 47 SECOND CtUTC 7cz3 Figure 7C.23 Second Clutch Drum. Piston, Springs, Clutch Plates, Spacer And Ring Gear REVERSE CLUTCH ASSEMBLY SECOND CLUTCH DRUM SECOND CLUTCH REVERSE CLUTCH ASSEMBLY DRUM Figure 7C-24 Oil Pump.
7C- 48 1973 OPEL SERVICE MANUAL INPUT SUN RING GEAR ASSY. GEAR PLANETARY CARRIER ASSY. REACTION SUN tow GEAR 8 DRUM BAND Figure 7C-25 Planetary Gears The planetary pinion shafts which support the plan.
AUTOMATIC TRANSMISSION 7c- 49 Figure 7C-26 Governor Assembly And Speedometer Drive Gear the sump. The oil is carried past the crescent section of the pump, beyond which the gear teeth begin to come together, pressurizing the oil as it is squeezed from between the gear teeth.
712.50 1973 OPEL SERVICE MANUAL 3. Detent pressure regulator valve. 4. 1 - 2 Accumulator valve. 5. Governor. B. Selector valves (manually and hydraulically con- trolled). I. Manual valve. 2. Detent valve. 3. 1 - 2 Shift valve. 4. 2 - 3 Shift valve. 5.
AUTOMATIC TRANSMISSION 7c-51 VACUUM MODULATOR 7c31 Figure 7C-31 Vacuum Modulator and Modulator Valve decrease as car speed increases. For this reason, gov- ernor pressure (which is a function of car speed) is directed to the area between the two different diame- ter spools at the outboard end of the valve.
7C- 52 1973 OPEL SERVICE MANUAL CCUMULATOR DRIVE: - - 7633 Figure 7C-33 1 - 2 Accumulator Valve The ports and spools operate as previously described. However, for increased engine torque, it is necessary to increase the accumulator pressure. This is accom- plished by introducing modulator pressure to the small end of the 1-2 accumulator valve.
AUTOMATIC TRANSMISSION lC- 53 Manual Valve The manual valve is mechanically connected to the shift lever. Its function is to direct hydraulic pressure to the various circuits to establish the base hydraulic range of the transmission. Line pressure is fed to the manual valve.
7C- 54 1973 OPEL SERVICE MANUAL Figure 7C-38 1 2 Shift Valve To prevent a “hunting” condition of the shift valve, modulator pressure supply to the second spool of control valve is cut off as the shift valve opens line pressure to the second clutch.
AUTOMATIC TRANSMISSION 7c- 55 valve will be held in downshifted, or second gear, condition regardless of car speed. Manual Low and Reverse Control Valve As described in the text on “Mechanical Operation”, the third clutch is applied in manual “Low” and in “Reverse” to prevent a free wheeling condition.
7C- 56 1973 OPEL SERVICE MANUAL MODULATOR Figure 7C-42 Low Speed Downshift Timing Valve During a “coast” condition, the vacuum is high and the modulator pressure is zero. The spring holds the timing valve in a bottomed position and the servo release pressure is exhausted through a restricting orifice, thus delaying the apply of the servo.
AUTOMATIC TRANSMISSION 7c-57 ACCUMULATOR Figure 7C-46 1-2 Accumulator l-2 Accumulator In order to obtain a smooth 1-2 upshift, it is neces- sary to control the rate of pressure build-up in the second clutch. This is accomplished by introducing a hydraulic modulator in the clutch circuit.
7c. 58 1973 OPEL SERVICE MANUAL a. NEUTRAL & PARK - ENGINE RUNNING Neutral - Engine Running Reverse Clutch. Released Second Clutch. Released Sprag - Locked Third Clutch - Released Low Band . .Released In neutral, the low band and all clutches are released.
AUTOMATIC TRANSMISSION 7c- 59 b. DRIVE RANGE . FIRST GEAR Orive Range . First Gear Reverse Clutch Released Second Clutch. Released Sprag Locked In Drive Range. First Gear, the low band is applied and all clutches are released. Figure 7C-49 Drive Range First Gear Third Clutch.
7C- 60 1973 OPEL SERVICE MANUAL c. DRIVE RANGE. SECONO GEAR Orive Range . Second Gear Reverse Clutch - Released Second Clutch -Applied Sprag - Overrunning In Drive Range.
AUTOMATIC TRANSMISSION 7C- 61 d. DRIVE RANGE - THIRD GEAR Drive Range - Third Gear Reverse Clutch - Released Second Clutch. Applied Sprag . Locked Third Clutch -Applied Low Band - Released In Drive Range - Third Gear, the low band is released and both the second and third clutches are applied.
Third Clutch -Applied Low Band. Released.
AUTOMATIC TRANSMISSION ?C- 63.
712.64 1973 OPEL SERVICE MANUAL HYDRAULIC OPERATION ‘I r n.
a. Operation of Controls in Neutral Engine Running Reverse Clutch Released Third Clutch Released Second Clutch Released Sprag Locked Low Band Released Whenever the engine is running with the selector lever in Neutral, oil is pulled from the sump into the oil pump and is dispensed from the pump under preure.
7C- 66 1973 OPEL SERVICE MANUAL.
.
7C- 68 1973 OPEL SERVICE MANUAL II II I- --.
c. Operation of Controls in Drive Range Second Gear Reverse Clutch Released Third Clutch Released Second Clutch Applied Low Band Applied Sprag Over Running As the vehicle increws speed. the govwnor allow more drive oil 10 pass through, and this increased pressure, acting on the end of the 1 2 shift vahre.
7C- 70 1973 OPEL SERVICE MANUAL d.
d. Operation of Controls in Drive Range Third Geat Reverse Clutch Released Third Clutch-Applied Second Clutchs Applied Low Band Released Sprag Locked As vehicle speed increases. the governor allows more oil to pass through to act against the wring at the 2 3 shift valve.
7C- 72 1973 OPEL SERVICE MANUAL.
e. Operation of Controls in Second Range Second Gear Reverse Clutch Re eased Third Clutch Released Seconds Clutch Applied Low Band Applied Sprag Over Running The selector lever is moved to the Intermediate position an the quadrant. the manual valve is positioned to allow drive oil and Intermediate oil to pan through the valve.
7C- 74 1973 OPEL SERVICE MANUAL.
f. Operation of Controls in Low Range First Gea Reverse Clutch Released Third Clutch Applied Second Clutch Released Low Band Applied Sprag Locked When the selector lever is moved to the low position on the quadrant. the manualvalve is positioned to allow drive oil, intermediate oil and low oil to pass through the valve.
712.76 1973 OPEL SERVICE MANUAL.
9. Operation of Controls in Reverse Reverse Clutch -Applied Second Clutch Released Sprag Locked Third Clutch. Applied Low Band. Released When the selector leer is moved to the Reverse position on the quadrant, the manual valve ispositioned to allow Revert oil to pars through the manual valve into the Reverse oil passage.
a 1973 OPEL SERVICE MANUAL.
h. Operation of Controlr during Detent Downshift Valves in Second Gear Position Reverse Clutch Released Second Clutch Applied Sprag Over Running Third Clutch Released Low Band Applied With the selector in the Drive position. detent downshifts ore possible by fully depressing the accelerator pedal.
7C- 80 1973 OPEL SERVICE MANUAL.
DIAGNOSIS SEQUENCE 1. Check and correct oil level. Refer to Specifications for checking and refill procedures. 2. Check and correct vacuum line and fittings. 3. Check and correct manual linkage. 4. Road test car using all selective ranges, noting when discrepancies in operation occur.
7C- 82 1973 OPEL S ERVICE MANUAL AUTOMATIC TRANSMISSION TROUBLE DIAGNOSIS CHART Condition CEllE.e Concerns Transmission Oil 1. Low oil level. a) Oil coming out of oil tiller tube. b) External oil leak. c) Failed vacuum modulator. 2. Oil coming out of oil filler tube.
AUTOMATIC TRANSMISSION 7C- 83 Condition Cause Starting 1. No starting in any drive range. a) Low oil level. b) Clogged suction screen. c) Manual valve linkage or inner trans- mission selector lever disconnected. d) Input shaft broken. e) Pressure regulator valve stuck in open position.
7C. 84 1973 OPEL SERVICE MANUAL Condition Cause 8. No starting in “R” range (proper driving in all other ranges). a) Reverse clutch failure. 9. Drive in selector lever position “N”. a) Inadequate selector lever linkage. b) Planetary gear set broken.
AlITOMATIC TRANSMISSION 7C- 85 Condition CtSlSl? 8. After full throttle upshifting transmission shifts immediately into lower gear upon easing off accelerator pedal. a) Detent valve stuck in open position, b) Detent cable stuck. c) Modulator vacuum line interrupted.
7C- 88 1973 OPEL SERVICE MANUAL Condition 6. Abrupt 3-2 coast downshift. Cause a) Low speed downshift timing valve stuck open. 7. Flare on high speed forced a) Low oil pressure. downshift. b) Band adjustment loose 8. Flare on low speed forced downshift.
AUTOMATIC TRANSMISSION 7C- 87 HYDRAULIC PRESSURE CHECK SHIFT POINTS SPECIFICATIONS HYDRAULIC PRESSURE CHECKS NOTE: ON REPLACING PLUG, TOROUE TO 6.7 LEFT. D 65 4. After pressure gage and hose is install&, replace rear crossmember s 65 and side bolts and proceed with pressure checking procedure.
7C- 88 1973 OPEL SERVICE MANUAL CONVERTER OUT / 2ND CLUTCH a !EI 1 CONVERTER i OUT x PRIMING VALVE BORE REVERSE CLUTCH :. -q MODULATOR - EXHAUST REVERSE CLUTCH INTERMEDIATE 2ND CLUTCH 3RD CLUTCH BOO.
AUTOMATIC TRANSMISSION 7C- 89 DRIVE SERVO LINE REVERSE I ,NTERMEDlATE T SERVO APPLY MODULATOR OR Figure 7C75 Valve Body Top.
7C. 90 1973 OPEL SERVICE MANUAL SHIFT BOOST SUCTION REVERSE , UNE MO/DULATOR SERVO RELEASE LOW SERVO , APPLY -REGULATOR DRIVE RNOR 7076 Figure 7C-76 Case Bottom.
AUTOMATIC TRANSMISSION 7C- 91 MAINTENANCE AND ADJUSTMENTS DETENT CABLE REPLACEMENT AND ADJUSTMENT The reliability of the detent bowden control cable is greatly dependent upon the proper adjustment of the wire whenever installation is being made.
7C- 92 1973 OPEL SERVICE MANUAL Figure 7C-84 Figure 7C-85 5. Unhook detent cable from detent valve. See Figure 7c-87. 6. Pry detent cable pipe out of retainers. 7. Unscrew upper and lower adjuster nuts and remove detent cable (on Manta models, loosen lock nut and screw adjuster out of bulkhead).
AUTOMATIC TRANSMISSION 7C- 93 (on Manta models, turn adjuster) until ball end of cable rests firmly against lever. 2. At this point, measure length of exposed detent inner cable. Depress accelerator pedal fu/fy, and again measure inner cable. If correctly adjusted, de- tent cable should move approximately 3/S inch.
7C. 94 1973 OPEL SERVICE MANUAL 7. Drive out retaining pin and shaft and remove se- lector detent. See Figure 7C-93. Figure 7C-93 Figure 7C-94 - Exploded View of Selector Lever 8. To replace bowden cable in selector lever, knock off selector handle, remove screws from clamping piece and pull knob.
AUTOMATIC TRANSMISSION 7C- 95 12. Place suitable jack under transmission and remove transmission support bolts. 13. Lower transmission enough to remove detent cable and modulator vacuum line. 14. Remove speedometer cable. 15. Remove selector lever. 16.
7C- 96 1973 OPEL SERVICE MANUAL Figure 7C-96 10. Detach rear engine support from transmission crossmember. See Figure 7C-97. Figure 7C-98 Figure 7C-97 11. Support transmission below oil pan with a suita- ble jack. 12. Unscrew transmission crossmember from side members.
AUTOMATIC TRANSMISSION JC- 97 Figure 7C-101 Figure 7C-103 Figure 7C-102 19. Pry detent cable and oil cooler pipes out of retain- ers on transmission oil pan. 20. Unscrew speedometer cable and pull it out of speedometer driven gear housing. 21. On both engine sides unscrew engine support brackets from torque converter housing.
7C- 98 1973 OPEL SERVICE MANUAL Figure 7C-105 Figure 7C-106 Installation GT 1. Assemble transmission to suitable jack and raise into position. Rotate converter to permit coupling with flywheel in original relationship. Remove hold- ing fixture. 2. Install tiller tube and converter housing to engine bolts.
AUTOMATIC TRANSMISSION 7C- 99 Converter Housing Oil Seal With transmission on portable jack and converter removed, converter housing oil seal may be removed without disassembling transmission using tool J- 23129, and slide hammer J-7004. 2. Using tool J-23129 remove oil seal with slide ham- mer.
7C-100 1973 OPEL SERVICE MANUAL Figure 7C-1 12 Figure 7C-1 13 6. Remove the two check balls located in the oil passages in the transmission case. See Figure 7C-114. Location of these check balls must be noted so that they are installed correctly. Removal of Servo Piston This operation can be performed with transmission in vehicle 1.
AUTOMATIC TRANSMISSION 7C-101 Figure 7C-1 16 -117 Figure 7C-118 GT Models Figure 7C-1 17 GT Models that one case services both models and is machined to accept selector lever on either side with the unused hole being plugged. 1. Remove retaining ring From parking actuator rod to selector inner lever.
7C-102 1973 OPEL SERVICE MANUAL Figure 7C-120 Figure 7C-122 Figure 7C-12 1 2. Remove modulator valve and sleeve from trans- mission case. Removal of Detent Valve Assembly This operation can be performed with transmission in vehicle 1. Remove spring pin by pulling upward with pliers.
AUTOMATIC TRANSMISSION 712-103 3. Remove extension housing and gasket. See Figure 7C- 124. Figure 7C-124 4. Remove parking paw1 actuator rod from transmis- sion case. Removal of Speedometer Drive Gear, Governor Body and Governor Hub 1. Depress speedometer drive gear retaining clip and remove speedometer drive gear by sliding off output shaft.
7C-104 1973 OPEL SERVICE MANUAL bolts which are the outer bolts in the housing. See Figure 7C-129. Figure 7C-129 3. Remove converter housing with oil pump, reverse and second clutch assemblies. Do not lose selective thrust washer. See Figure 7C-130. Second clutch as- sembly may remain in case.
AUTOMATIC TRANSMISSION 7C-105 Figure 7C-133 thrust bearing and race from case by pulling straight out. See Figure 7C-134. Figure 7C-135 Figure 7C-134 4. Remove needle thrust bearing and race from rear of case. See Figure 7C-135. 5. Remove low band by slightly compressing band and pulling straight out.
7C-106 1973 OPEL SERVICE MANUAL Figure 7C-138 !L REVERSE ZH )N OIL PUMP t 7c-138 2. Remove selective washer from oil pump shaft. See Figure 7C-138. 3. Remove the oil pump outer oil seal and discard. See Figure 7C-139. Figure 7’2.139 4. Remove the five bolts holding the converter hous- ing to the oil pump.
J-8092 CONVERTER Figure 7C-142 10. Install new converter housing oil seal using tool J-21359. See Figure 7C-143. 12. Mark relative location of oil pump gears and remove oil pump gears. See Figure 7C-144. AUTOMATIC TRANSMISSION 712.107 Figure 7C-144 13.
712.108 1973 OPEL SERVICE MANUAL CHSJ 3 5 1. RETAINING PIN 7 2. PRESSURE REGULATOR BOOST VALVE SLEEVE 3. PRESSURE REGVLATOR BOOST VALVE 4. PRESSURE REGULATOR VALVE SPRING SEAT 5. PRESSURE REGULATOR VALVE SPRING 6. PRESSURE REGULATOR VALVE 7. OIL PUMP BODY 8.
AUTOMATIC TRANSMISSION 7C-109 Figure 7C-149 21. Using a drift on tap, press out oil pump bushing with arbor press. Use rag or cloth to protect oil pump face. 22. Install new oil pump hub bushing with arbor press using tool J-23130-1. See Figure 7C-149.
7C-110 1973 OPEL SERVICE MANUAL H SEAL REVERSE CLUTCH Figure 7C-151 Figure 7C-153 Figure 7C-152 30. Install new oil seals on reverse clutch piston. See Figure 7C-153. 31. Install reverse clutch piston onto rear face of oil pump using liberal amount of transmission fluid.
AUTOMATIC TRANSMISSION 7C-111 OIL PUMP /’ ASSEMBLY A SPklNG I(ETAINER SNAP RING PLIERS h 7C146 Figure 7C.155 37. Turn oil pump and reverse clutch assembly so that oil pump face is facing up. 38. Install oil pump gears using the location mark made before disassembly.
7C-112 1973 OPEL SERVICE MANUAL SECOND CLUTCH SPACER ----I Figure 7C-159 5. Remove second clutch steel and composition plates. The plates should be kept in the same se- quence as they were installed in the clutch. See Fig- ure 7C- 160. Figure 7C-160 6.
AUTOMATIC TRANSMISSION 7C-113 12. Inspect the piston return springs. Evidence of extreme heat or burning in the area of the clutch may have caused the springs to take a heat set and would justify replacement of the springs. Figure 7C-163 13. Inspect second clutch hub bushing for scoring or wear.
7C-114 1973 OPEL SERVICE MANUAL 4. Cracking 5. Charring 6. Chips or metal particles imbedded in lining If a composition drive plates exhibits any of the above conditions, replacement is required. B. Wipe steel plates dry and check for heat discolora- tion.
AUTOMATIC TRANSMISSION 7C-115 INPUT SPRAG RACE 8 RETAINER ASSEMBLY / GEAR CLUTCH HUB Figure 7C-169 3. Push sprag assembly and retaining rings from sprag race and retainer. See Figure 7C-170. Figure 7C.17 I 7. Remove snap ring using snap ring pliers such as J- 8059.
7C.116 1973 OPEL SERVICE MANUAL DRUM THIRD CLUTCH PISTON 70174 Figure 7C-174 damaged, replace piston. Install new lip seal on pis- ton. See Figure 7C-175. CHECK THI Figure 7C-175 12. Install new oil lip seal on input shaft inside of third clutch drum.
AUTOMATIC TRANSMISSION 7C-117 WIRE CRIMPED INTO COPPER TUBING Figure 7C-178 19. Inspect condition of the third clutch composition and steel plates. Do not diagnose a composition drive plate by color, A. Dry composition plates with compressed air and inspect the composition surface for: 1.
712.119 1973 OPEL SERVICE MANUAL 26. Align third clutch composition plates and install third clutch hub to index with the third clutch plate splines. Input sprag, race, and retainer assembly must also spline into third clutch drum. See Figure 7c-181. .
driver and remove secondary valve spring retainer. See Figure 7C-187. S ,ECONDARY ’ VALVE SPRING / SECONDARY VALVE REACTION SUN GEAR DRUM #ii INER Figure 7C-185 7G186 Figure 7C-186 Disassembly. Inspection and Reassembly of Governor Body 1. Depress secondary valve spring with small screw $%OLL PIN Figure 7C-187 2.
7C-120 1973 OPEL SERVICE MANUAL 4. Inspect the secondary valve spring for distortion or breakage. 5. Clean in solvent, air clean, and blow out all oil passages. Inspect all oil passages, valve bores for nicks, burrs or varnish in governor body. Replace if necessary.
AUTOMATIC TRANSMISSION 7C-121 Fig 7C-192 Figure 7C-194 6. Inspect cushion spring, adjusting bolt, and piston sleeve for damage. Inspect piston for damage and piston ring for side wear, replace if necessary. 7. Reassemble servo piston, reversing disassembly procedure.
7C-122 1973 OPEL SERVICE MANUAL 1. SERVO PISTON RETURN SPRING 7. SERVO PISTON 2. SERVO PISTON APPLY ROD 8. SERVO PISTON RETAINING RING 3. SERVO PISTON ADJUSTING SLEEVE 9. SERVO PISTON ADJUSTING BOLT 4. SERVO PISTON CUSHION SPRING SEAT 10. SERVO PISTON ADJUSTING BOLT NUT 5.
7. Remove accumulator piston, oil ring, and spring. See Figure 7C-200. ACCUMULATOR PISTON Figure 7C-200 AUTOMATIC TRANSMISSION 7C-123 8. Inspect accumulator oil ring for damage or edge wear and piston for damage. Replace if necessary. For steps 9 through 21 refer to Figure 7C-201.
7C.124 1973 OPEL SERVICE MANUAL 14. Remove the downshift timing valve plug retain- ing pin and remove downshift timing valve plug. Remove the low speed downshift timing valve and spring. 15. Remove the manual low and r&erse control valve retaining pin.
AUTOMATIC TRANSMISSION 7C-125 1. CASE VENT 4.3RD CLUTCH 7. SUCTION 2. CONVERTER OUT 5MODULATOR 8. LINE / 3.2ND CLUTCH 6. BOOST 9. REVERSE Figure 7C-202 Case Front View Oil Passage Identification 7. !nspect reaction sun gear drum bushing sleeve inside case at rear for scoring.
7C-126 1973 OPEL SERVICE MANUAL 1 3 5 7 9 11 n-205 1. CLUTCH ASSEMBLY THRUST WASHER 2. 2ND CLUTCH ASSEMBLY TO 3RD CLUTCH ASSEMBLY BRONZE THRUST WASHER 3. 2ND CLUTCH ASSEMBLY TO 3RD CLUTCH ASSEMBLY STEEL THRUST WASHER 4. INPUT SHAFT TO SUN GEAR THRUST WASHER 5.
AUTOMATIC TRANSMISSION ?C-127 INPUT SHAFT Figure 7C-208 1. Place needle thrust bearing race on rear of case around the case bushing. Secure with petroleum jelly (unmedicated). 2. Place needle thrust bearing on race. See Figure 7C- 209. Secure with petroleum jelly (unmedicated).
7C-128 1973 OPEL SERVICE MANUAL 2. Insert third clutch drum and input shaft through top of second clutch drum seating third clutch drum splines into the second clutch plate splines.
AUTOMATIC TRANSMISSION 7C-129 4. Install reverse clutch cushion plate (wave washer) 2. Insert guide pin into oil pump for alignment of into case. converter housing and lower housing onto pump. Determining Selective Washer Size 1. Place gauging tool J-23085 on case flange and against input shaft.
7C-130 1973 OPEL SERVICE MANUAL Figure 7C-2 17 into case. See Figure 7C-218. Use liberal amount of transmission fluid on oil seal rings. GOVERNOR HUB Figure 7C-2 18 3. Install snap ring over output shaft using snap ring pliers such as J-8059. See Figure 7C-219.
AUTOMATIC TRANSMISSION 7C-131 4. Bolt extension housing to rear of case. Torque to 20-30 Ibs. ft. See Figure 7C-221. Figure 7C-22 1 Installation of Speedometer Driven Gear 1. Install speedometer driven gear and housing into extension housing. See Figure 7C-222.
7C-132 1973 OPEL SERVICE MANUAL Figure 7C-226 Figure 7C.224 Figure 7C-225 4. Using 3/16” hex head wrench on servo adjusting bolt, adjust servo apply rod by tightening adjusting bolt to 40 lbs. in. Back off bolt five (5) turns. exact/u. See Figure 7C-226.
AUTOMATIC TRANSMISSION 7C-133 8 / Figure 7C-228 Figure 7C-229 6. Install small end of manual valve link “A” into selector lever and install valve body and transfer plate assembly over guide pins. See Figure 7C-23 1. 7. Install selector lever roller spring and retainer.
7C-134 1973 OPEL SERVICE MANUAL Figure 7C-232 Torque Converter 4. Rotate converter to check for free movement. 1. Place transmission on portable jack 2. Slide torque converter over stator shaft and input shaft. 3. Be sure that converter pump hub keyway is seated into oil pump drive lugs and the distance “A” is .
AUTOMATIC TRANSMISSION 7C-135 becomes necessary to check the fluid level, the trans- mission may be checked at room temperature (70 degrees F.) as follows: 1. With manual control lever in Park position start engine. DO NOT RACE ENGINE. Move manual control lever through each range.
7C-136 1973 OPEL SERVICE MANUAL should be secured to keep the front wheels in a straight-ahead position. sand,. mud, or snow, move the selector lever from “D” to “R” in a repeat pattern while simultaneously applying moderate pressure to the accelerator.
AUTOMATIC TRANSMISSION X-137 F. OPEL AUTOMATIC TRANSMISSION LINKAGE ADJUSTMENT P 1. REMOVE LOCK CLIP -‘R l 2. PL ACE SELECTOR LEVE R IN “r’ 0~ “1” POSITION 2 3. PLACE TRANSMISSION SHIFT LEVER IN “L” OR “1” POSITION 4. ADJUST CONTROL ROD (ALLOWING IT TO FIT OVER PIN IN LOWER SELECTOR LEVER FREELY) 5.
7C.138 1973 OPEL SERVICE MANUAL 4 5 I Figure 7C-234 Special Tools. Automatic Transmission 7C223.
AUTOMATIC TRANSMISSION 75139 SPECIAL TOOLS J-8763-01 :: J-21369 3. J-8400-1 4. J-3289-20 5. J-23130-3 6. J-8092 7. J-21359 8. J-21426 9. J-23129 10. J-7004 11. J-2590-12 12. J-21420-1 13. J-23130-7 14. J-23075 15. J-23 130-S 16. J-231306 17. J-23130-1 18.
I 4 I . 7C.140 .1973 OPEL SERVICE MANUAL J-7004-1 SLIDE HAMMER J-2291 3 MAIN SHAFT ASSEMBLY TOOL J-22929 SPEEDOMETER DRIVEN GEAR REMOVER AND INSTALLER J-22922 J-22926 TRANSMISSION CASE EXTENSION SPEED.
HOOD, FENDERS, AND GRILLE GROUP 8 I I Section I I Page No. 1 8A 1 Grille’. 1 814-2 ( Hood Fenders, and.
8A-2 1973 OPEL SERVICE MANUAL HOOD, FENDERS, AND GRILLE CONTENTS Subject DESCRIPTION AND OPERATION: GT Headlamp Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS GT Headlamp Mechanism .
HOOD, FENDERS, AND GRILLE 8A- 3 2. Adjust headlamps to lock or unlock simultane- ously by adjusting lock nut (B). See Figure EA-1. 3. Adjust headlamp assembly in opening as follows: a. To align front of assembly vertically or horizon- tally, loosen bolts indicated (A) in Figure 8A- 2.
8A.4 1973 OPEL SERVICE MANUAL Figure SA-5 Location of Fender Attaching Bolts 9. Fit new fender and apply a sealing compound, as required, to joint. See Figure SA-6. Figure 8A-6 Sealing Location 10. Coat fender inside with a dampening compound. REMOVAL AND INSTALLATION OF HEADLAMP COVERING (OPEL 1900.
HOOD, FENDERS, AND GRILLE BA- 5 2. Remove headlamp assembly and remove multiple plug from wire set. 3. Disconnect Bowden control wire(B). Loosen link- age at the clamp screw (A) and disconnect linkage in direction of arrows. See Figure SA-9. Figure EA.
8A-6 1973 OPEL SERVICE MANUAL 9. On installation make sure that the gaps between headlamp housing in closed position and headlamp opening is equal all round and housing is flush in its height with the body. REMOVAL AND INSTALLATION OF HEADLAMP CABLE ASSEMBLY Removal 1.
HOOD, FENDERS, AND GRILLE 8A- 7 2. Remove two plastic caps and phillips screws from outer end of grille extension. 3. Remove grille extension, Installation 1. Install grille extension and secure with Phillips screws and two (2) plastic caps. 2. Install hex head screw and washer holding grille extension to baffle plate.
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GROUP 9 ACCESSORIES Section Title Page No. HEATER 9A GT, 9A- 2 Opel 1900-Manta. 9A- 10 AIR CONDITIONING Refrigerant Components 9B- 17 9B Air Conditioner System Opel 1900~Manta. 9B- 90 Air Conditioner System GT. OB- 97 RADIO 9c GT.............. 9c-105 Opel 1900~Manta.
9A-2 1973 OPEL SERVICE MANUAL HEATER SYSTEM - GT CONTENTS Subject DESCRIPTION AND OPERATION: Flow-Through Ventilation System ................................ Heater System Description ............................................ Heater System Operation .
HEATER SYSTEM. GT 9A- 3 Figure 9A-‘2 Heater Assembly-Rear View The heater-defroster air door directs the air to the floor outlets, defroster outlets, or apportions the air flow to both outlets depending on the position of the door.
9A-4 1973 OPEL SERVICE MANUAL Figure 9A-4 Heater Control Blower Switch - This switch actuates blower motor to low or high blower speed. HEATER SYSTEM OPERATION To operate heater proceed as follows: 1. Position air inlet, heater-defroster control as desired.
HEATER SYSTEM - GT 9A- 5 MAJOR REPAIR REMOVAL AND INSTALLATION INSTRUMENT PANEL FRESH AIR OUTLET Removal 1. Remove instrument panel cover assembly. Refer to Group 1. 2. Snap grille out of outlet. 3. Remove knob from lever and remove outlet. Installation 1.
9A-6 1973 OPEL SERVICE MANUAL b. Remove retaining screw in headlamp lever handle and remove handle. c. Console cover is held in place by four push button type studs, unsnap studs by prying cover up and work cover upwards over shift lever and rubber shift lever boot.
HEATER SYSTEM - GT 9A. 7 13. Remove all screws from instrument panel pad- ding and remove it from instrument panel. Arrow in Figure 9A-14 show location at left side of dash panel and windshield. Screws are located in same areas on right side. Figure 9A-1 1 Removing Instrument Cluster Figure 9A-14 Instrument Panel Padding Screws 14.
9A-8 1973 OPEL SERVICE MANUAL Installation 1. Install heater blower and case assembly, securing with one (1) bolt at the top and two (2) nuts from the bottom. See Figure 9A-15. 2. Install instrument panel padding and connect heater and defroster duct hoses, making sure hoses are properly positioned and connected.
HEATER SYSTEM. GT 9A- 9 REMOVAL AND INSTALLATION HEATER VALVE Removal 1. Remove lower radiator hose and drain and collect coolant. 2. Disconnect control cable. 3. Loosen heater hose clamps and remove valve from hoses. See Figure 9A-17. SPECIFICATIONS Engine Recommended Coolant .
SA-10 1973 OPEL SERVICE MANUAL HEATER SYSTEM OPEL 1900 - MANTA CONTENTS Subject DESCRIPTION AND OPERATION: Heater System . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER SYSTEM. OPEL 1900. MANTA 9A- 11 air is attained, as the water does not cool down in the second part of the core. A Water Outlet B Water Inlet The center lever actuates the two-stage blower mo- tor.
9A-i2 1973 OPEL SERVICE MANUAL Check that air doors and water temperature control valve are operating properly. Check for plugged heater core-backflush heater core as necessary. TROUBLE Inadequate defrosting action. CAUSE AND CORRECTION Examine heater-defroster door for proper operation.
Figure SA-35 Heater Core Installation 1. Apply sealing compound between heater housing and dash panel. 2. Install heater core into heater housing and attach water hoses. See Figure 9A-35. 3. Instaii heater housing to dash panel. S,ee Figure 9A-44. 4. Install bowden control wire to heater valve.
9A-14 1973 OPEL SERVICE MANUAL upper attaching screw through opening for heater control housing and lower attaching screw below instrument panel. See Figure 9A.-38. 5. On right side, viewed in driving direction, install air distributor housing attaching screws.
HEATER SYSTEM. OPEL 1900. MANTA 9A- 15 Figure 9A-4 1 Bowden Wire Attachment Figure SA-42 Control Wire to Distribution? Door Attachment A - Yellow Wire B - Grey Wire C - Brown Wire 6. Remove heater control housing. Installation 1. Install heater control housing, 2.
9A-16 1973 OPEL SERVICE MANUAL Figure 9A-44 Shroud Cover Attachments Figure 9A-46 Heater Motor Attaching Screws Figure 9A-45 Heater Motor Wires Installation Figure 9A-47 Sealing Shroud 1. Install heater motor, attaching with three (3) screws. See Figure 9A-46.
REFRIGERANT COMPONENTS ALL MODELS CONTENTS Subject DESCRIPTION AND OPERATION: Fundamental Principles of Refrigeration .................. Description of Air Conditioning Components .......... DIAGNOSIS: General Information .............................
98.18 1973 OPEL SERVICE MANUAL DESCRIPTION AND OPERATION FUNDAMENTAL PRINCIPLES OF REFRIGERATION We all know what air conditioning does for us, but very few understand how or why it works. An air conditioner is functionally very similar to a refrigera- tor, so let’s take a look at refrigeration.
REFRIGERANT COMPONENTS ALL MODELS 9s. 19 Figure 98.3 Effect of One B.T.U. on One Pc’und of water teristics of heat if we think of heat as a sort of color- ing dye. If we add one drop of red dye to a glass of water, it will turn slightly pink. Another drop will make the water more reddish in color (Fig.
98-20 1973 OPEL SERVICE MANUAL If we were to put a thermometer in the cold drain water, we would see the temperature gradually creep upwards. That is to be expected because heat is flow- ing into the cold water making it warmer. Before long the water would be as warm as the stored foods.
REFRIGERANT COMPONENTS ALL MODELS SE- 21 about heat instead of refrigeration. But in doing so, we have learned how a simple ice-box works. It’s because the magic of latent heat of fusion gives ice the ability to soak up quantities of heat without get- ting any warmer.
9B-22 1973 OPEL SERVICE MANUAL We can change a vapor back into a liquid by chilling it, or do the same thing with pressure. When we condense a vapor we will find that the heat removed just exactly equals the amount of heat that was neces- sary to make the substance vaporize in the first place.
REFRIGERANT COMPONENTS ALL MODELS 96.23 Figure 96-l 3 Basic Refrigerant Circuit we get the heat-laden vapor outside, we can com- press it with a pump. With enough pressure, we can squeeze the heat out of “cold” vapor even in a warm room. An ordinary.
9B-24 1973 OPEL SERVICE MANUAL Figure 9B-15 Compressor Assembly - GT Shown Figure 3B-16 Condenser Assembly condenser. The refrigerant vapor gives up its heat, which is quickly and easily radiated into the sur- rounding air through the large finned surfaces of the condenser.
REFRIGERANT COMPONENTS ALL MODELS 9B- 25 96.15 Figure 95.17 Float Type Flow Valve enough to close the valve and stop the flow of refrig- erant liquid. For the sake of simplicity, we have described the float and valve action as being in a sort of definite wide open or tight shut condition.
98-26 1973 OPEL SERVICE MANUAL greater than the opposing pressure in the power ele- ment. Therefore, the valve remains closed. When the compressor is started, it will reduce the pressure and temperature of the refrigerant in the cooling coil to a point where the vapor pressure in the power ele- ment becomes the stronger.
REFRIGERANT COMPONENTS ALL MODELS 99.27 that line, they still hadn’t gotten anywhere. So, they started from scratch and juggled molecules around to make an entirely new refrigerant. Eventually they succeeded by remodeling the molecules in carbon tetrachloride.
9B-28 1973 OPEL SERVICE MANUAL Thus, from the standpoint of comfort, complete air conditioning should control the relative humidity of the air as well as its temperature. By reducing the humidity, we sometimes can be just as “cool” in a higher room temperature than other- wise would be comfortable.
REFRIGERANT COMPONENTS ALL MODELS 99.29 1 REFRIGERANT LEAVES COMPRESSOR AS A HIGH PRESSURE-HIGH TEMPERATURE VAPOR REFRIGERANT RETURNS TO COMPRESSOR AS LOW PRESSURE VAPOR EXPANSION VALVE 5 HEAT REMOVED.
9B-30 1973 OPEL SERVICE MANUAL refrigerant penetrates to every nook and cranny of the unit. Among the many desirable properties of R-12, is its stability under operating conditions. However, while more stable than the other refrigerants under the same conditions, it, too, can be caused to form harm- ful acids which will eventually fail the system.
REFRIGERANT COMPONENTS ALL MODELS 9B- 31 When adding oil, the container should be exception- ally clean and dry due to the fact that the refrigera- tion oil in the container is as moisture-free as it is possible to make it. Therefore, it will quickly absorb any moisture with which it comes in contact.
98-32 1973 OPEL SERVICE MANUAL inserting it in the connection. Another precaution - inspect the fitting for burrs which can cut the “0” ring. Restrictions Restrictions may be due to powdered desiccant or dirt and foreign matter. This may result in starved evaporator and loss of cooling, or a seized compres- SOT.
REFRIGERANT COMPONENTS ALL MODELS 99- 33 That the attraction of the drying material for mois- ture is so powerful that if the receiver is left open, moisture will be drawn in from the outside air.
98-34 1973 OPEL 3ERVlCE MANUAL 9B-23 Figure 98.26 Compressor Front and Rear Heads and circulated through the system via a 3/16 inch diameter oil passage through the shaft center and also four 5/64 inch diameter holes drilled perpen- dicular to the shaft.
REFRIGERANT COMPONENTS ALL MODELS 9s. 35 THRUST UNIT SHOES ARE USED CONTROLS PISTON TO GIVE HEAD CLEARANCE .0005 TO .OOlO TOTALCLEARANCE THRUST UNIT CONTROLS RUNNING CLEARANCE .0005 TO .0015 9B-25 Figure 98-28 Compressor Needle Thrust Bearings and into the scraper grooves and allow oil to drain back into the reservoir.
98-36 1973 OPEL SERVICE MANUAL SPACER 17 RETAINER RING c Q CLUTCH COIL 8 HOUSING ARING TO HEAD TAINER RING SHAFT NUT CLUTCH DRIVEN PLATE BEARING TO PULLEY PULLEY BEARIN RETAINER RING COIL 8 HOUSING CLUTCH DRIVE PLAT IRETAINER RING AND PULLEY ASSEMBLY Figure 98-32 Magnetic Clutch and Pulley Assembly is tack-welded to the inside of the shell.
REFRIGERANT COMPONENTS ALL MODELS 99.37 in front of the radiator so that it receives a high volume of air flow. Air passing over the condenser absorbs the heat from the high pressure gas and causes the refrigerant to condense into a high pres- sure liquid.
9B-38 1973 OPEL SERVICE MANUAL expand and return to the original gaseous state. To accomplish this transformation it begins to boil. The boiling action of the refrigerant demands heat. To satisfy the demand for heat, the air passing over the core gives up heat to the evaporator and is subse- quently cooled.
REFRIGERANT COMPONENTS ALL MODELS 96-39 In all instances where the indications of refrigerant shortage continues, additional refrigerant should be added in l/4 lb. increments until the sight glass is clear. An additional charge of l/4 lb. should be ad- ded as a reserve.
98.40 1973 OPEL SERVICE MANUAL 2. Interconnect manifold and gage set (J-5725-01), gage charging lines (J-5418) and gage adapters (J- 5420) to air conditioning system as shown in Figure 9B-40. 3. Place transmission in “Park” for automatics and in neutral for manuals.
REFRIGERANT COMPONENTS ALL MODELS 9s. 41 BIower Operating Normal Check for the following: Restriction or leakage in air ducts, A/C outlets not opening. 2. Do not carry cylinder in passenger compartment of car. 3. Do not subject cylinder to high temperatures.
98-42 1973 OPEL SERVICE MANUAL SCHRADER VALVE ADAPTER J-5420 1 CO MPRESSOR (TOP VIEW) [ /--DISCHARGE LINE I LOW PRESSURE GAUGE MANIFOLD AND -GAUGE SET J-5725-01 rGAUGE LINES (5) J-5418 99-31 Figure 98.
REFRIGERANT COMPONENTS ALL MODELS 9B- 43 4. Start the vacuum pump and slowly open low and high pressure sides of manifold gauge set to avoid forcing oil out of refrigeration system and pump, Pressure is now being reduced on both sides of the refrigeration system.
9B-44 1973 OPEL SERVICE MANUAL Do not turn refrigerant drum upside down, as this would allow liquid refrigerant to enter compressor which may cause damage. 4. If line at center gauge fitting has not been purged of air, loosen line at center fitting on gauge set and crack valve on refrigerant drum to blow air from line.
REFRIGERANT COMPONENTS ALL MODELS 9t3- 45 B. If system is charged using J-6272-02, close the valve of opener after all cans are empty. Release the locking lever and discard the three (3) empty cans.
98-46 1973 OPEL SERVICE MANUAL shut off vacuum pump. Open refrigerant control valve and allow some refrigerant to enter system. Locate and repair all leaks. 7. After evacuating for 15 minutes, add l/2 lb. of refrigerant to system. Purge this l/2 lb. and reevacu- ate for 15 minutes.
REFRIGERANT COMPONENTS ALL MODELS 9a- 47 B. Connect center flexible line of gauge set to the fitting on the valve. C. Start engine, turn temperature control knob to full cold position, set blower switch to Max Hi. Operate engine for 10 minutes at 2000 RPM to stabilize sys- tem.
98-48 1973 OPEL SERVICE MANUAL Condition 3. Compressor being replaced with a ser- vice replacement compressor major oil loss evident. Amount of Oil Drained From Compressor a. More than 4 oz. Amount of 525 Oil to Install In Compressor a. Same amount as drained from compressor being replaced.
REFRlGEdANT COMPONENTS ALL MODELS 96-49 Figure 96.50 Sheet Metal Cover Removed 5. Unplug compressor clutch electrical plug, and remove idler pulley bracket assembly and ground wire. See Figure 9B-5 1. Radiator hose is removed for photographic reasons only.
96-50 1973 OPEL SERVICE MANUAL I Figure 98.53 Compressor Installation Opel 1900 Manta I 2. Disconnect refrigerant lines to both ends of re- ceiver-dehydrator and tape closed open ends of re- frigerant lines, and also the open ends ofthe inlet and outlel pipes of the receiver-dehydrator.
REFRIGERANT COMPONENTS ALL MODELS SB- 51 3. Remove two (2) screws securing receiver-dehy- drator within support bracket and lift out receiver- dehydrator.
96-52 1973 OPEL SERVICE MANUAL REMOVAL AND INSTALLATION OF EVAPORATOR AND EXPANSION VALVE. OPEL 1900 - MANTA Removal 1. Remove negative battery cable from battery. 2. Remove left side of distributor duct, and in line fuse. See Figure 9B-61. 3. Remove glove box.
REFRIGERANT COMPONENTS ALL MODELS 9B- 53 7. Remove two (2) upper evaporator attaching nuts. See Figures 9B-66 and 9B-67. 8. Remove two (2) attaching case mounting bracket to instrument panel screws.
96-54 1973 OPEL SERVICE MANUAL valve. The filter screen at the inlet port may be re- placed. Remove screen by threading a lo-32 NF screw into old filter screen. With a washer and a nut on the screw arranged to work as a puller screw, hold the body of the screw and turn the nut.
REFRIGERANT COMPONENTS ALL MODELS 99.55 pipes and tape closed the open ends of refrigerant lines, and also the open ends of the inlet and outlet pipes of the condenser. 10. Remove two (2) top retaining screws. Figure 9,S-73 Condenser Retaining Screws - Opel 1900 - Manta 11.
98-56 1973 OPEL SERVICE MANUAL oil cooler lines to lower radiator tank. It is essential that no dirt enters the oil lines. When tightening oil lines hold connectors on lower radiator tank with pliers to avoid leakages. Ensure that no dirt enters oil cooler.
REFRIGERANT COMPONENTS ALL MODELS 9B- 57 SUPPORT BRACE (LARGE) Figure 98-84 Compressor Installation GT.
98-58 1973 OPEL SERVICE MANUAL 2. Discharge system. Refer to DISCHARGING SYSTEM. 3. While system is discharging remove air cleaner and loosen idler pulley and bracket assembly. See Figure 98-80. 4. Remove bolt holding compressor adapter fitting into rear head.
REFRIGERANT COMPONENTS ALL MODELS 9s. 59 2. If the receiver-dehydrator has been exposed to the atmosphere for any amount of time, (more than 5 minutes), the receiver-dehydrator should be re- placed, since the life of the dessicant is probably expended.
9B-60 1973 OPEL SERVICE MANUAL EVAPORATOR EVAPORATOR DRAIN HOSE DRAIN HOSE Figure 96-91 Drain Hose GT Figure 98.92 Evaporator Mounting Bracket Bolts Driver Side GT 9. Lift off the mounting bracket and remove the evaporator assembly from the car. 10. Remove the resistor assembly.
REFRIGERANT COMPONENTS ALL MODELS 96.61 CAPILLARY T”BE Figure 98.95 Evaporator and Expansion Valve Assembly GT valve from refrigerant lines, and tape closed open ends of lines and inlet and outlet ports of expansion valve. Installation 5. Install resistor assembly.
98-62 1973 OPEL SERVICE MANUAL Figure 98.99 Refrigerant Hoses Retainer Grommet - Under Car - GT 8. From under car install four (4) nuts securing evaporator mounting bracket to floor. See Figures 9B- 92 and 9B-93. Figure 98.100 Refrigerant Hoses - Under Car GT 9.
REFRIGERANT COMPONENTS ALL MODELS SB-63 2. Install condenser into car and secure with 4 at- taching screws. See Figure 9B-101. 3. Untape discharge line and pipe and install using new o-rings lubricated with No. 525 viscosity oil. Figure 99.102 Condenser - Receiver - Dehydrator O-Rings.
9B-64 1973 OPEL SERVICE MANUAL 4. Using No. 21 Truarc pliers (J-5403) take out retainer ring from hub of clutch drive plate (see Fig- ure 9B-106). Lift our spacer. Figure 95.106 Removing or Installing Retainer Ring in Clutch Drive Plate 5. If compressor has an absorbent sleeve in the neck, pry out the sleeve retainer and remove the sleeve.
REFRIGERANT COMPONENTS ALL MODELS 96-66 Figure 98.109 Removing or Installing Shaft Seal SEAL SEAT - Figure 98-l 10 Removing Seal Seat O-Ring assembly engages the flats on the shaft and is seated in place. Disengage the tool by pressing downward and twisting tool counterclockwise.
9B-66 1973 OPEL SERVICE MANUAL LEAK TEST FIXTURE Js - s -- -Y623 COMPRESSOR ADAPTERS J-5420 USE LINE ONLY DURING - COMPRESSOR SEAL TEST -4 - It-’ rDISCHARGE LINE - LOW PRESSURE HIGt GAGE 4 PRESSUR.
REFRIGERANT COMPONENTS ALL MODELS 9B- 67 Figure 9B-1 13 Positioning Clutch Drive Plate on Shaft PLATE ON UNTlL THERE IS APPROXIMATELY 3/32”- . l m l GAP BETWEEN SURFACE OF PLAT Figure 98-1 14 Installing Clutch Drive Plate drive plate should be approximately l/32 to l/16 inch (see Figure 9B-115).
98-68 1973 OPEL SERVICE MANUAL J-9395: Figure 9B-1 17 Removing Pulley Assembly Figure 9B-1 10 Removing Pulley Bearing Retainer 26 truarc pliers (J-6435), and lift out coil and housing assembly. Reassembly 1. Reassemble coil and housing assembly reverse of disassembly.
REFRIGERANT COMPONENTS ALL MODELS 96.69 J-9481 J-8092 / BEARING Disassembly of Rear Head, Oil Pump, Rear Discharge Valve Plate, and Rear Suction Valve Reed Disc If compressor is not going to be disassembled any further than removal of rear head, oil pump, rear discharge valve plate, or rear suction valve reed disc, omit Steps “1, 2 and 4”.
9B-70 1973 OPEL SERVICE MANUAL SUCTION SCREEN TEFLON I ut 98-98 Figure 96-l 24 Rear Head Removal 8. Take out and discard shell to head “0” ring. 9. Carefully pry out rear discharge valve plate and rear suction valve reed disc with screwdrivers (see Figures 9B-125 and 9B-126).
REI :RIGERANT COMPONENTS ALL MODELS 9s. 71 / Figure 9%128 Removing Internal Cylinder Assembly Figure 9B-130 Removing Front Head If sealing surfaces of front head (see Figure 9B- 13 1) are damaged, replace front head. There is no Teflon on front head sealing surface.
96-72 1973 OPEL SERVICE MANUAL RUBBER MALLET Figure 98-133 Separating Cylinder Halves parts tray (J-9402) the following: number “1, 2 and 3” pistons, piston drive balls, and (if service pistons) piston rings.
REFRIGERANT COMPONENTS ALL MODELS 9B- 73 F Figure 9B-137 Shaft and Front Needle Thrust B E in Cylinder Half I1 :igure 98.138 Installing Piston Into Cylinder Half Service Piston Sliown 3. Generously coat with clean petroleum jelly two “zero” thrust races, and a new needle thrust bearing.
98.74 1973 OPEL SERVICE MANUAL (a) Using a feeler gage, select a leaf or combination of leaves which result in satisfactory “feel” when inserted between rear piston drive ball and wash plate (see Figures 9B-141 and 9B-142).
REFRIGERANT COMPONENTS ALL MODELS 9B- 75 Shoe Disc Table SERVICE ID. NO. PART NO. STAMPED 6557000 6556175 6556180 6556185 6556190 6556195 6556200 6556205 6556210 6556215 6556220 EXAMPLE SHOE DISC 0 (“ZSXO” Shoe Disc) 17 l/2 18% 19 19 l/2 202&2 21 21 l/2 22 Piston’ 1st 2nd 3rd No.
9B-76 1973 OPEL SERVICE MANUAL race. If, for example a feeler gage reading of 0.009 inch results, a thrust race with a number “9”, stamped on it should be selected. Thrust Race Table SERVICE ID NO. THICK- PART NO. ON RACE NESS 6556000 0 .0920 6556050 5 .
REFRIGERANT COMPONENTS ALL MODELS 99.77 In order to tit the piston onto the wash plate and into the cylinder bore, the wash plate must be raised approximately l/2 inch, the front needle thrust bear- ing and races must be held up against the hub of the wash plate, and the service piston rings must be squeezed together (see Figure 9B-147).
98-78 1973 OPEL SERVICE MANUAL der assembly and align with dowel pins, suction poit and discharge port (see Figure 9B-153). 2. Assemble front discharge valve plate to front of cylinder assembly and align with dowel pins. 3. Coat sealing surfaces on front head (see Figure 9B- 154) with No.
REFRIGERANT COMPONENTS ALL MODELS 9B- 79 HELL TO HEAD O-RING (BE SURE INSIDE SHELL GRASP FRON Figure SB-156 Installing Front Head and Cylinder Assembly in Shell Figure 96-155 Shell To Front Head O-Rin.
96-80 1973 OPEL SERVICE MANUAL LINE UP LOCA PINS AND HO Figure SB-158 Installing Rear Head “0” rings into suction and discharge ports of rear head. 9. Reassemble shaft seal onto front of shaft and wash plate assembly. Do not reassemble clutch drive plate at this time.
REFRIGERANT COMPONENTS ALL MODELS 9B- 81 ADAPTERS 91 I I -.n” 1 -“II I II I DISCHARGE 11 1 COMPRESSOR USE LINE ONLY DURING COMPRESSOR- SEAL T&T GAGE I J-541 6 MANIFOLD AND GAGE SET J-5725-01 REFRIGERANl CYLINDER 99.
r 98-82 1973 OPEL SERVICE MANUAL SPECIFICATIONS Tightening Specifications Part Location Nut Drive Plate Nut to Compressor Shaft .............................. Nut Rear Head to Shell ................................................................ Ca P Schrader Service Valve .
REFRIGERANT COMPONENTS ALL MODELS 9B- 83 FUNCTIONAL TEST - OPEL 1900. MANTA Temp. of Air Entering Cond. Engine RPM Camp. Head Pressure* Suction Press.’ Discharge Air Temperature* *When compressor clutch disengages, FUNCTIIONAL TEST - GT Temp. of Air Entering Cond.
9B-84 1973 OPEL SERVICE MANUAL t COMPRESSOR CONDENSER EVAPORATOR q H.P. VAPOR q H.P. LIQUID q 1.p. LIQUID q L.P. VAPOR q H.P.T.X.V. POWER ELEMENT Figure 96-l 61 Cycle of Operation.
REFRIGERANT COMPONENTS ALL MODELS SB- 85 1 2 3 4 5 6 7 a 9 10 11 12 13 14 15 lb 17 18 19 _ 20 21 22 23 24 25 26 27 2a 29 30 31 32 33 34 35 3b I. Rear Head 13. Coil and Housing Assemblv 2. Rear Head to Shell “0” Ring 3. Rear Discharge Valve Plate 14.
REFRIGERANT COMPONENTS ALL MODELS 9B- 87 SUCTION ,011 INLET T”BE REAR CYLINDER ’ REAR NEEDtE”q. PRESSURE RELIEF VALVE THRUST BEARlNG / IT DISCHARGE VALVE PLATE f FRONT HEAD ,-SEAL SEAT O-RING I ,-SHAFT SEAL ~&SHELL TO HEAD O-RING I,I PORT FRONT CYLINDE<.
98-88 1973 OPEL SERVICE MANUAL Figure gB-165 Special Tools.
AIR CONDITIONER SYSTEM -OPEL 1900 - MANTA SB- 89 c J 6084 J 14OVS J 5428.03 , J 23390 J 23600 BELT IENSION GAUGE J 6212.01 #4 MlJLTI.OPtNtR . 4 CAN RtFRIGtRANT OPENER J 23400 tlKlRONIC LEAK DETECTOR J 23575 COMPLHE MANIFOLD ASSfYBLY J 6034 LEAK WtClOR J 5418-03 VACUUM PUMP ! ?!!~O~!~~~.
System controls are the AIR knob controlling the three speed blower motor switch and the TEMP knob which controls the setting of the thermostatic switch.
AIR CONDITIONER SYSTEM -OPEL 1900 - MANTA 9B- 91 FAN DOES NOT RUN Correct electrical fault. FAN RUNS - Check air velocity. NOT OK Clean evaporator inlets. Clean evaporator core. Clean evaporator outlets. OK Check refrigeration (refer to Refrigeration Diagnosis Guide).
98-92 1973 OPEL SERVICE MANUAL MAJOR REPAIR REMOVAL AND INSTALLATION OF BLOWER SWITCH Removal I. Remove the face plate retaining screws and remove the face plate assembly. See Figure 9B-172. Figure SE-172 Face Plate Retaining Screws and controts 2. Remove the blower switch retaining screws and remove switch.
AIR CONDITIONER SYSTEM. OPEL 1900. MANTA 9B- 93 2. Remove the left side of distributor duct, and the in-line fuse. See Figure 9B-174. 98.139 Figure SB-174 Location of Distributor Duct (Left Side) Retaining Screws Figure SB-175 Removing Left Side Distributor Duct 3.
98.94 1973 OPEL SERVICE MANUAL 7. Remove 2 upper evaporator attaching nuts. See Figures 9B-178 and 9B-181. Figure 98-181 Location of Upper Evaporator Attaching Bolt (Right Side) 8. Remove 2 attaching case mpunting bracket to instrument panel screws. See Figure 9B-182.
AIR CONDITIONER SYSTEM -OPEL 1900 - MANTA 9B- 95 Figure 96.185 Evaporator Inlet and Outlet Pipes and O-Rings 7. Connect the 2 drain hoses underneath evapora- tor. 8. Install evaporator inlet and outlet pipes retainer and rubber grommet. See Figure 9B-178.
98.96 1973 OPEL SERVICE MANUAL r DARK BLUE LIGHT BLUE STRIPE CUTOUT 111 111 DARK GREEN DARK GREEN , , I , , BATTERYl L J flu- +tL-2+- -7- - RESISTOR A EXlSilNG ‘I WIRE I I I FUSE BLOCK *, *, - I ./ SWITCH r ti ‘WIRE fI fI 1- I A A I i$+.- lAC~,‘XESW WIRE I I T T EVAPO.
AIR CONDITIONER SYSTEM - GT 96. 97 AIR CONDITIONER SYSTEM GT CONTENTS Subject : DESCRIPTION AND OPERATION: General Description of System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation of Controls . . . . . , . . . . . . .
98.98 1973 OPEL SERVICE MANUAL DIAGNOSIS TROUBLE DIAGNOSIS GUIDE Insufficient Cooling CHECK AIR FLOW FAN DOES NOT RUN - Correct electrical fault. FAN RUNS - Check air velocity. NOT OK - Clean evaporator inlets. Clean evaporator core. Clean evaporator outlets.
5. If the low side pressure was less than the pre- scribed pressure at the end of each cooling cycle, turn the adjusting screw a partial turn clockwise. See Fig- ure 9B-192. AIR CONDITIONER SYSTEM - GT 9B- 99 CONNECTOR Figure 98.192 Adjusting Thermostatic Switch 6.
gB-100 1973 OPEL SERVICE MANUAL 2. Remove the retaining screws from the duct as- sembly. See Figure 9B-190. 3. Lift up duct assembly and note the position of the air sensing capillary so that it can be reinstalled in the same location as when removed.
Figure 98-197 Electrical Connections Installation 1. In611 the resistor assembly and two (2) attach- ing screws. See Figure 9B-198. Figure ?B-198 Resistor Assembly Attaching Screws 2. Install the electrical plug connector. 3. In&l the evaporator cover and attaching screws.
98-102 1973 OPEL SERVICE MANUAL 2. Discharge system. Refer to DISCHARGING SYSTEM in Refrigerant Components Section. 3. While system is discharging remove the luggage tray attaching screws and lift out tray. See Figure 9B-200. 4. Remove all evaporator cover screws and remove cover.
AIR CONDITIONER SYSTEM. GT 9s. 103 Figure 98.206 Evaporator Mounting Bracket Bolts Passenger Side 8. Remove inlet and outlet pipes from evaporator and tape closed the refrigerant lines and also the open ends of the inlet and outlet pipes of the evapora- tor.
98-104 1973 OPEL SERVICE MANUAL the el&trical connector side of the motor to the right side of the bracket. 2. Assemble the fan housing case halves and attach the cover plate. 3. Install the resistor assembly. 4. Install the evaporator assembly into the car and install mounting bracket.
RADIO. GT 9c- 105 RADIO GT CONTENTS Subject DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: Radio Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE AND ADJUSTMENTS: Antenna Trimmer Adjustment .
9C-106 1973 OPEL SERVICE MANUAL c. Adjust trimmer screw for maximum volume. d. If antenna trimmer does not have a definite peak, check for defective antenna by substitution. 2. Check that the speaker connection is plugged in SXUdY. 3. If the radio is still weak, remove the receiver and speaker assembly for repair.
RADIO - GT 9c. 107 mer screw and rotate screw until maximum volume is achieved. MAJOR REPAIR REMOVING AND INSTALLING RADIO Removal 1. Disc&ect battery. 2. Remove access trim plug from right side of con- sole. See Figure 9C-1. Figure 9C-3 Location of Access Trim Cover 3.
9C-108 1973 OPEL SERVICE MANUAL 11. Grasp instrument cluster and pull straight back, being careful of wires, etc. See Figure 9C-7. Figure 9C-7 Removing Instrument Cluster 12. Disconnect radio harness plug and antenna lead- in cable from back of radio.
RADIO - OPEL 1900 - MANTA 9c- 109 RADIO OPEL 1900 - MANTA CONTENTS Subject DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: Radio Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9C-110 197j 6PEi SERVICE MANUAL c. Adjust trimmei screw for maximum volume, d. If antenna trir&ner does not have a definite peak, check for defective ant&ma by substitution. 2. Check that the speaker connection is plugged in securely. 3. If the radio is still weak, remove the receiver and speaker assembly for repair.
MAJOR REPAIR RADIO - OPEL 1900 - MANTA 9c- 111 REMOVING AND INSTALLING RADIO Removal ~ 1. Rem&e control knobs and ornamental cover plate. See Figure 9C- 15. 2. Unscrew two (2) hex. nuts behind and remove ornamental cover plate. 3. Unscrew support bracket from back of radio hous- ing and air distribution housing.
.
Subject Page Number Subject Page Number A Air Conditioning Refrigerant Components ................. 98.17 Opel 1900 & Manta-In Car Components ..... 9B-90 GT.ln Car Components .................. 98-97 Alignment Opel 1900 & Manta ...............
Subject Page Numbel Subject Page Number 4.Speed Manual I .. Clutch Detent Cable Adjustment : Differential Directional Signal Switch Repair Opel 1900 & Manta Repair GT : Disassembly of 4.Speed Manual Transmission Distributor Function of Valves and Hydraulic Control Units Opel 3.
Subject Page Number Subject Page Number o,,e, 1900 & Manta ..................... 1H-59 GT .................................. lH-63 intake Manifold, 1.9L Engine .......... : ..... 6A-12 R Radiator J Radiator All Models .,. Radio 66-32 Joint, Ball adder.
Subject Page Number 1 Throttle Linkage Adjustment ........ ,: ....... 6E-51 Timing Chain Cover ....................... 6A-23 Timing Chain and Sprocket ......... ': ....... 6A-23 Tires ................................... 36-55 Inflation ..........
Credits Opel enthusiasts worldwide would like to thank General Motors Corporation for granting permission to reproduce electronically the contents of the 1973 Opel Shop Manual.
An important point after buying a device Opel 1900 GT (1973) (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Opel 1900 GT (1973) yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Opel 1900 GT (1973) - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Opel 1900 GT (1973) you will learn all the available features of the product, as well as information on its operation. The information that you get Opel 1900 GT (1973) will certainly help you make a decision on the purchase.
If you already are a holder of Opel 1900 GT (1973), but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Opel 1900 GT (1973).
However, one of the most important roles played by the user manual is to help in solving problems with Opel 1900 GT (1973). Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Opel 1900 GT (1973) along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
