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Table of Contents

   Summary of Contents for Opel 1900 1973

  • Page 2: Important Safety Notice

    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. Some of these service operations require the use of tools specially designed for the purpose.
  • Page 4 STEERING This manual contains service information R E A R A X L E 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 B R A K E S easily.
  • Page 5 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. Each wow is rubdivided as follows:...
  • Page 6: Opel Service Manual

    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. Every GROUP contains one or more SECTIONS. Each SECTION deals with a specific version of a component or system.
  • Page 8 GROUP 0 Section Title Page General Information OA-1 GENERAL Vehicle Lifting Points INFORMATION Maintenance and Lubrication. OC-5...
  • Page 10 Attached to the protective key cover of Opel 1900 and Manta keys, is a tab on which the profile and cutting code letters and numbers are imprinted. Record the key cutting code letters and...
  • Page 11 MODEL DESIGNATIONS OL15 OPEL 1900 3DR WAGON MANTA 2 DR SPT. CPE. MANTA 2DR RALLYE SPT. CPE. MANTA LUXUS 2DR SPT. CPE. VEHICLE IDENTIFICATION 1 2 3 4 5 6 GM Model Designation Engine Code Model Year Assembly Plant G E N E R A L S P E C I F I C A T I O N S...
  • Page 12 GENERAL INFORMATION OA-3 MODELS EXTERIOR PAINT 5 7 5 7 Name Name 5 1 5 1 5 3 5 3 Alpine Alpine White White Strato Blue Blue Glacier Blue Glacier Blue Jade Mist Jade Mist Flame Red Flame Red Antique Antique Bronze Bronze...
  • Page 13 GT (ONLY) AT TRACK-BAR ALL OPEL ATTACHMENT TO AXLE. II II NOTE: SUPPORTS MUST BE POSITIONED Figure OB<l Vehicle Lifting Points CAUTION: Failure to follow the procedure If it is necessary to use any liftink device other thin may result in unsatisfactory...
  • Page 14: Lubrication And Maintenance

    LUBRICATION MAINTENANCE LUBRICATION AND MAINTENANCE O P E L 1900 M A N T A G T System F i g u r e O C - 1 1 9 7 3 L u b r i c a t i o n C h a r t...
  • Page 15 CC-6 1973 OPEL SERVICE ‘MANUAL LUBRICATION AND GENERAL MAINTENANCE *Engine Oil EMISSION CONTROL MAINTENANCE I Air Cleaner E,eme”t Figure OC-2 1973 Maintenance Schedule...
  • Page 16 OC-6. Engine Oil Filter Replace at the first oil change and every other oil change thereafter using Part No. 7965051 or equiva- Adjust clutch when necessary as indicated by the lent. clutch warning lamp on Opel 1900 and Manta or...
  • Page 17 1973 OPEL SERVICE MANUAL Clutch Pedal Floor-Pan - Figure OC-7 GT Clutch Lash drain, flush, and refill the cooline svstem with a new Figure OC-5 Brake Master Cylinder coolant so&ion of permanent anti-freeze and water for protection-of -20°F. D-6 NOT REMOVE...
  • Page 18 LUBRICATION AND MAINTENANCE OC-9 4. Remove dipstick and wipe clean. haust fumes to seep into the trunk or passenger compartment. Dust or water in the trunk may be an indication of a problem in one of these areas. Any 5. Reinsert dipstick untip cap seats. defects should corrected immediately.
  • Page 19 CC-10 1973 OPEL SERVICE MANUAL wiper blades. Check amount and direction of fluid tempting to start the engine. The starter should oper- ate only in the Park (“P”) or Neutral (“N”) sprayed by washers during use., positions. E. Defrosters - Check performance by moving con- trols to “DEF”...
  • Page 20 Correct mixtures for emission compliance and idle quality have been preset by Opel. Plastic idle mixture limiters have Headlights been installed on the idle mixture screw, idle air screw, and throttle stop screw to preclude unauthor- Check for proper aim.
  • Page 21 OC-12 1973 OPEL SERVICE MANUAL i Fuel Cap, Fuel Lines and Fuel Tank Exhaust Gas Recirculation Systep Inspect the fuel tank, cap and lines for damage which Check system operation at 12 &onth/12,000 mile could cause leakage. Inspect fuel cap for correct seal- intervals.
  • Page 22 GROUP 1 Page No. Title Section Battery and Cables ..Starting System ... . Ignition System , Charging System 1 D-28 Washers and Wipers ., 1 E-37 ELECTRICAL 1 F-45...
  • Page 23 Delco-General batteries. In order that Opel owners shall have the protection and benefit of Batteries used for display purposes or standing in this warranty, it is necessary for the dealer or car...
  • Page 24 BATTERY AND CABLES - ALL MODELS lost as the result of charging and discharging, and it put into service. This type of battery will retain its must be replaced before the electrolyte level falls to “charged” condition indefinitely if protected from moisture.
  • Page 25 6. Iflights stay bright but no cranking action occurs gravity corrected to 80 degrees F.’ shows more than when cranking motor solenoid switch is closed, it a thirty point (.030) drop from the initial tilling with indicates an open circuit in cranking motor, switch, electrolyte, or if one or more cells’gas violently after or control circuit.
  • Page 26 Clean and tighten cable terminals (sub- justed to avoid internal damage to battery. age drop Still exceeds 2/10 volt, replace cable with a genuine Buick-Opel cable to insure ample capacity. ADJUSTMENTS AND MINOR SERVICE Undercharge Failure of Battery PERIODIC BATTERY INSPECTION AND SERVICE...
  • Page 27 1973 OPEL SERVICE MANUAL resistance is found by voltage test, disconnect the Do not overfill, as electrolyte may be sprayed out by cable for thorough cleaning of terminals. When gassing or may overtlow due to heat expansion dur: removing a corroded cable terminal from battery ing charging.
  • Page 28 BATTERY AND CABLES - ALL MODELS 421 Test F$ocedure age of the battery, should be further tested by the Hydrometer Test. 1. Visual Inspection - The first step in testing the Energizer br 12-V& Battery should be a visual in- HYDROMETER TEST OF BATTERY spection which very often will save time, labor and expense in determining the condition.
  • Page 29 C O R R E C T I O N washed off immediately with soda solution. FUSIBLE LINKS All 1973 Opel Models have fusible links located be- tween the starting motor post and the generator regulator. These links are the weakest point in the...
  • Page 30 BATTERY AND CABLES - ALL MODELS plus 61 terminal of the voltage regulator and protects BATTERY REMOVAL AND INSTALLATION the circuit to the generator telltale light. Removal BATTERY RECHARGING 1. Disconnect battery cables (remove negative cable There are two separate methods of recharging batter- ies which giffer basically in the rate of charge.
  • Page 31: Trouble Diagnosis

    1 B- 10 1973 OPEL SERVICE #MANUAL ALL MODEILS CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Starting System Description ......... .
  • Page 32 STARTING SYSTEM 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. Charge battery. on, cranking motor locks up or dra’gs. 2. Battery defective. 1.
  • Page 33 Condition Correction Voltage drop. 1. Check wiring and wiring connections. 5. Overrun&g clutch slips. 1. Replace overrunning clutch. The cranking motor keeps 1. Ignition {witch does not motor cable from battery. Inspect on rotating after ignition cut off or solenoid switch sticks.
  • Page 34 STARTING SYSTEM 3. Remove end frame from field frame and pull both 4. Connect test equipment and, with transmission in insulating tubes out of field frame. neutral, turn engine over until voltage stabilizes. Note read.ings. To prevent brushes from coming out when remov- ing the field frame, place a 29 millimeter socket over 5.
  • Page 35 6. Check armature for an open circuit on a growler. 6. Remove shift lever shaft and: lift armature aid Considerable variation in readings between in- shift lever assembly. dividual commutator bars would indicate an open circuit. 7. Drive back retaining ring on armature shaft. See Figure lB-5.
  • Page 36 STARTING SYSTEM 2. Check brushes. Replace brushes, if worn down to 2. Unscrew the four (4) pole shoe attaching bolts and take field coils out of field frame. See Figure lB-9. brushes. 3. To ensure proper installation of the pole shoes, align shoes exactly parallel with the armature shaft 3.
  • Page 37 8. Making sure that brush holder is aligned at right 2. Slide pinion stop retainer down over shaft with recessed side outward. angles to the field frame, rivet brush holder to field frame. See Figure lB-14. 3. Place a new snap ring on drive end of shaft and hold it in place with a hard block.
  • Page 38 STARTING SYSTEM 12. Check starter on bench before installing. 7. Seal area between solenoid and frame. See Figure Starter Installation 8. With brushes and spring in housings held in place with a 29 @llimeter socket, slide frame assembly in position. 2.
  • Page 39 1 C- 18 1973 OPEL SERVICE MANUAL Page No. Subject DESCRIPTION AND OPERATION: Ignition System ..............Ignition Switc,h ..............Ignition Coil ................Distributor ......I..........DIAGNOSIS: (Not Available) MAINTENANCE AND ADJUSTMENTS: 1 c-20 Contact Point Replacement ..........Dwell Angle Adjustment : ..........
  • Page 40 IGNITION SYSTEM power stroke. The air-fuel charges are, however, not The ignition key must be released as soon as engine starts. The switch then burned instantly, so it is necessary to advance the spark in relation to the piston top dead center as returns aujomatically to the on position.
  • Page 41 1973 OPEL SERVICE MANUAL 4. Tighten breaker point set screw, then recheck There is also a plastic hood slipped over the distrivu- dwell. added protection against moisture from the outside. See Figure lC-2. 5. Install rotor and cap.~Start engine and recheck dwell.
  • Page 42 IGNITION SYSTEM resistance type. These secondary ignition wires 4. Rota&distributor counterclockwise slightly until reduce television and radio interference. contact pbints just start to open. This must be done very carefully or engine will not start. 2. Wipe ignition wires with a cloth moistened with solvent and wipe dry.
  • Page 43 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 1. Remove spark plugs. If electrodes are badly worn, volts). discard plugs. If inner or outer porcelain is cracked or broken, discard plugs.
  • Page 44 I G N I T I O N S Y S T E M until cutout in distributor shaft (or rotor tip) points 9. Install:spark plugs using a 13/16 deep socket, an extension and a torque wrench. Tighten to 22-29 to notch in distributor housing.
  • Page 45 1 C- 24 1973 OPEL SERVliTE MANUAL 5. For cleaning, partly pull distributor shaft together 2. Push retaining ring out of groove in distribitor with centrifugal advance mechanism out of distribu- shaft. See Figure lC-10. tor housing. Do not disassemble advance mech- anism.
  • Page 46 IGNITION SYSTEM 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.
  • Page 47 1973 OPEL SERVICE MANUAL / SPECIFICATIONS IGNITION COIL K12 V ............... Ignition Coil Number Ignition Coil Current Draw, Amperes at 12.5 Volts Engine Stopped ... :......Engine Idling ........................DISTRIBUTOR JFU4 Distributor Type Number: ....................Total Advance (Centrifugal and Vacuum), Engine Degrees at 3600 R.P.M.
  • Page 48 IGNITION SYSTEM Figure 1 C-l 3 Distributor Exploded...
  • Page 49 M A N U A L Page No. DESCRIPTION 4ND OPERATION‘: Alternator ......i ..........1 D-28 R e g u l a t o r .
  • Page 50 CHARGING SYSTEM The diodes in the alternator, since they act like one- way check valves, make a cutout relay unnecessary; battery current can flow only as far as the diodes, but The regulator contains only one unit - a double con- cannot discharge through the alternator.
  • Page 51 1973 OPEL SERVICE MANUAL 1 D- 30 cover and adjust voltage regulator armature spring 6. Make sure all electrical accessories are turned (lff. tension to obtain a middle reading of 14.0 volts. If Start engine with battery post adapter switch closed;...
  • Page 52 CHARGING SYSTEM Alternator Disassembly 1. Remove nut and alternator pulley. See Figure 2. Mark ‘drive end frame, stator and rear end frame to ensurd correct installation of parts on reassembly. Remove drive end frame. See Figure lD-7. Figure lD-9 Removing Drive End Frame Bearing Figure /l 1D-7 Removing Drive End Frame and Rotor Assembly 3.
  • Page 53 1 D- 32 1973 OPEL SERVICE MANUAL 12. Unsolder brushes, if they are worn to a length of this, hold connecting wire in flat-nosed pliers to pre: vent from flowing between wire strands, oth- solder erwise the wire strands will become rigid and the brushes unserviceable.
  • Page 54 CHARGING SYSTEM 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. Ohmmeter should read between .26 and .29 ohms. See Figure lD-20. Figure lD-17 Checking Rotor for Ground 301 D20 Figure 1 D-20 Checking Stator for Short 17.
  • Page 55 1 D- 34 1973 OPEL SERVICE MANUAL 2. Using Tool J-23526, press diode from support. See one direction, but should not light at all in the otlier Figure lD-23. direction. Diodes in each set of three should p&s current and block current in the ‘same directions As the others in the set.
  • Page 56 CHARGING SYSTEM Figure lD-25 Installing Diode 7. Instail rotor together with drive end frame into sembly +-ire aligned. 8. Insta!l pulley and fan. Tighten nut to 30 lb.ft. Figure 1 D-26 Alternator Installation 9. Test benerator on test bench, if available. If not, install alternator on car and test.
  • Page 57 1 D- 36 1973 OPEL SERVICE MANUAL Figure 1 D-27 Alternator - Exploded View...
  • Page 58 WINDSHIELD WIPERS WIPERS ALL MODELS CONTENTS Page No. Subject DESCRIPTION AND OPERATION: 1 E-37 Windshield Wiper Motor ..........DIAGNOSIS: 1 E-37 Windshield Wiper .
  • Page 59 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?- lead from battery to terminal No. 53 wiper motor.
  • Page 60 WINDSHIELD WIPERS 4. Remove center deflector panel. Remove left de- flector panel together with wiper motor and com- plete wiper linkage. See Figure lE-7. Figure lE-7 - Removing Left Panel, Motor and Linkage 5. Remove nut and lockwasher from wiper motor Figure Removing Wiper...
  • Page 61 1 E- 40 1973 OPEL SERVICE MANUAL 2. Remoyz transmission housing together with arma- Disassembly ture from motor housing. See Figure lE-10. It may be necessary to hold armature in transmission hous- 1. Remove two (2) motor housing attaching screw$ ing with a screw driver.
  • Page 62 WINDSHIELD WIPERS 3. Apply a small amount of grease to ball cavity of driven gear and insert ball. See Figure lE-15. Figure lE-15 Insert Ball into Driven Gear 4. Install transmission housing cover. See Figure lE- 1 6 . Figure iE-14 Remove Negative Brush Retaining Cleaning apd Inspection of Parts With the ekception of electrical parts and bushings,...
  • Page 63 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 Figure 1 E-l 8 Adjusting Armature End Play drain hole on housing is facing downward when mb- tor assembly is installed in car.
  • Page 64 WINDSHIELD WIPERS SPECIFICATIONS 12 VDC 13 VDC Current Draw (Amps) , Low Speed ..__...__..__..,_,,..,,,.,,,,..,....,,..............1 . 5 2 . 2 Low Speed ___.,._,,,..,,,........,,..,,..,,,.,,,,....,,,......, High Speed ..___.._......................Commutator Diameter __....,,,,............‘Brush Spring Pressure 6.35 to 8.47 oz.
  • Page 65 1 E- 44 1973 OPEL SERVICE MANUAL ATTACHING SCREWS 16. NEGATIVE BRUSH TRANSMISSION COVER 17. ATTACHING SCREW HEX. NUT 18. RETAiNING PLATE 19. POSlilVE BRUSH THREADED 20. WIRE’ GASKET 21. THRUST SPRING 22. RUBBFR MOUNTS BALL 23. ARMATURE DRIVEN GEAR 24.
  • Page 66 DESCRIPTION OF LIGHTING SYSTEM Pulling the knob out all the way turns the headlights The three-baition light switch on Opel 1900 and Manta corjtrols the headlights, taillights, parking The instrument panel lights come on when the head- lights, side marker lights, instrument panel lights, and the lic&se plate light.
  • Page 67 MAJOR REPAIR Courtesy Light HEADLIGHT SWITCH - OPEL 1900. MANTA The courtesy light illuminates the interior of the Car when any door is opened. The courtesy light can also Removal be turned on with all doors closed by tilting the l&s.
  • Page 68 LIGHTING SYSTEMS 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. See Figure lF-3. Figure 1 F-l Removing Headlight Switch 3.
  • Page 69 M A N U A L 3. Disassemble headlight assembly from retaini+g ring. See Figure lF-4. 1. Apply sealer to housing 2. Connect wiring harness. 3. Replace housing in body with two (2) retaining screws. Replace lamp lens. REAR STOP, TAIL, DIRECTIONAL SIGNAL, OR BACK-UP LAMP HOUSING Removal 1.
  • Page 70 LIGHTING SYSTEMS 2. III luggage compartment, unscrew three (3) hous- 2. Take Le:s off housing. See Figure lF-7. ing attaching nuts. See Figure lF-9. 3. Remove housing. Installation; 1. Install le$ in housing. 2. Replace +. Model 54 ; 2. Remove kear quarter trim pad. 3.
  • Page 71 1 F- 50 1973 OPEL SERVlCE,MANUAL 2. Pull wires off flat plugs. See Figure lF-12. 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 lens.
  • Page 72 LIGHTING SYSTEMS 2. Install Switch to door jam. LIGHTS. GT Housing 1. Remove lamp lens. 2. Remove lamp housing. 3. Discon$ect electrical wires. See Figure lF-13. wires. 2. Install famp housing and lens. Removal df Front Directional Signal Lamp 1. Remove lamp lens. Figure lF-15 Removing Headlamp Shield 2.
  • Page 73 1 F- 52 1973 OPEL SERVICE’MANUAL Remove lamp housing. 3. Disconnect electrical wires. See Figure lF-100.’ Figure lF-18 Side Marker Light Location 5. Remove lamp housing. See Figure lF-19. Figure 1 F-l 7 Rear Directional Signal. Stop and Tail’ Installation 1.
  • Page 74 LIGHTING SYSTEMS Removal of Headlamp Switch Removal if Back-Up Lamp 1. Completely remove left headlamp and headlamp 1. Remode back-up lens. housing. 2. Remove switch from base plate. See Figure lF-21. 3. Discodnect electrical wires. See Figure lF-20 Figure 1 F-2 1 Light Switch Positions Interior djght Removal Installation...
  • Page 75 The horn button is located in the center part of the steering wheel. The horn is actuated by pushing Figure lG-1 Directional Signal Position for Headlamp down on the ends of both spokes on Opel 1900 and Operation Manta’s or on the center horn button on the Rallye.
  • Page 76 SIGNAL SYSTEMS MAJOR REPAIR Removing Installing Directional Signal Switch Proceed as outlined in Group 3, Section E. HORN REMOVAL 1. Remove grille (GT only). Remove horn attaching bolt. bracket 3. Disconnect wires and remove horn. HAZARD; WARNING FLASHER Installation The hazard warning flasher is operated by the button on the toi, of the steering column.
  • Page 77 FUSE AMPS. PROTECTED OPEL 1900 & ‘MANTA (51,53,54,57,57R) LEFT PARkING LIGHT, LEFTTAIL LIGHT, LEFTSIDE MARKER LIGHTS RIGHT PApKING LIGHT, RIGH TAIL LIGHT, RIGHT SIDE MARKER LIGHTS, INSTRUMENT PANEL LIGHTS, SHIFT GUADRANT LIGHTS, LICENSE PLATE LIGHT, FOG LIGHTS (RALLYE ONLY) IGNITION IKEY WARNIN BUZZER, TRUNK LIGHT, HAZARD WARNING FLA,SHER, COURTESY LIGHT, CLOCK BACKUP L’IGHTS, BLOWER MOTOR, CIGAR LIGHTER;...
  • Page 78: Instrument Panel

    Subject DESCRIPTION AND OPERATION: Instrument Panel - Opel 1900 - Manta ..... . 1 H-58 Instrument Panel - G T ............
  • Page 79 1 H- 58 1973 OPEL SERVICE MANUAL L I G H T S W I T C H IRALLYEi HEADLIGHT HIGH BEAM INDICATOR -HAZARD WARNING FLASHER INDICATOR SYSTEM WARN,NG WINDSHIELD WIPER SWlTCH -1 LFUEL CONTROL SWITCH 1 HEATED REAR GLASS CHARGING INDICATOR LlGHT HEATER’...
  • Page 80 Removal of Instrument Cluster Housing Assembly. The Heiter Blower Switch is a three position switch. By depressing the lower half of the switch to the first Opel 1900 Manta stop, th& blower will operate at low speed. When Before starting any instrument panel repair, always at high ipeed.
  • Page 81 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.
  • Page 82 Installation 1. Connect wiring to switch. 2. Snap switch back into panel. 3. Replace instrument cluster trim plate. Removing Instrument Cluster Bulbs - Opel 1900. Manta 1. Remove instrument cluster assembly. 2. Replace bulbs from back ofcluster. See Figure lH- 4.
  • Page 83 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 to remove tear bolts. See Figure lH-13.
  • Page 84 INSTRUMENT PANEL 3. Connect speedometer cable. 4. Raise steering column into position and install hex head bolt% Be sure to install ground wire. Tighten hex head bolts to 14 lb.ft. 5. Tighten tear lock bolts until hex head of bolt is torn off.
  • Page 85 Installation Removal of Cigar Lighter GT 1. Install cigar lighter base. 1. Remove instrument housing. 2. Install hex nut on back of lighter base. 2. Disconnect electrical wire. 3. Connect wire to lighter. 3. Remove hex nut on back of cigar lighter base’.’ 4.
  • Page 86 System - Opel 1900 - Manta ........
  • Page 87 Condition Possible Cause Correction Gas gauge does not read 1. Tank unit misadjusted full when tank tilled between connector and ground (disconnect from unit). If dash unit reads full within one pointer width. Remove gas tank unit from tank, install connector, ground unit and adjust tab to obtairi full reading on dash.
  • Page 88 GAUGES 1 I- 67 Correction Possible Cause 1. Follow corrective action as Car &s out of gas with 1. Tank unit misadjusted gauge indicating fuel in stated above (obtain empty tank. 1 reading on dash) 1. See corrective action above. 2.
  • Page 89 1 I- 68 1973 OPEL SERVICE MANUAL 2. Pull voltage stabilizer of back of printed circhit. See Figure 11-l. Figure 1 l-3 - Speedometer Attaching Screws 2. Install six (6) screws holding instrument cluster Figure 11-l -Voltage Stabilizer lens in housing.
  • Page 90 GAUGES 1 I- 69 Installation 3. Replace instrument housing. 1. Replace gauge with attaching nuts on panel. Hook up wires to gauges. 3. With holding screws, attach gauge cluster to in- 2. Remov; six screws and remove both instrument strument panel. cluster le+ See Figure 11-2.
  • Page 91 Removal of Speedometer Removing Oil Pressure Sending Upit 1. Remove instrument housing. from sending Fit. Disconnect wire 2 . Remove speedometer. See Figure 11-9 1. 2. Unscrew oil pressure sending u?it from block. St& Figure 11-7. Installation 1 . Install speedometer. 2 .
  • Page 92 GAUGES 2. Remove electrical clock. 3. Disconnect electrical wires. See Figure 11-I I. Installation 1. Install clock and connect wires. 2. Install instrument cluster housing. Removal of Ammeter and Oil Pressure Gauge 2. Remove ammeter and oil pressure gauge. 3. Disconnect electrical wires. See Figure 11-12. Figure 1 IL10 Rear View of Temperature Indicator and Fuel Gauge Dash Unit 1.
  • Page 93 ................Manta 1 J-82 Indicator Lights and Gauges . Rallye ......1 J-83 Dome Light and Buzzer - Opel 1900 - Manta ..1 J-84 Dome Light, Buzzer and Clock - GT ......1 J-85 ............ Headlamps - Opel 1900 1 J-86 ....
  • Page 94 Page No. Seat Belt Warning System (Automatic Transmission) . GT ............lJ- 99 Heated Rear Glass . Opel 1900 . Manta ....15-100 Heated Rear Glass . G T ..........*, lJ-101 Opel 1900 Color Schematic ......... lJ-103 ..........1 J-105 Manta Color Schematic GT Color Schematic ............
  • Page 95 Figure 13-1 Windshield Wiper and Horn - Opel 1900 - Manta...
  • Page 96 WIRING DIAGRAMS Figure lJ-2 Windshield Wiper and Horn - Rallye...
  • Page 97 1 J. 76 1973 OPEL SERVICE IMANUAL Figure lJ-3 Wind$hield Wiper and Horn - Gl...
  • Page 98 WIRING DIAGRAMS Figure 1 J-4 Turn Signal and Hazard Flasher . Opel 1900 - Manta...
  • Page 99 Figure lJ-5 Turn Signal and Hazard Flasher - GT...
  • Page 100 WIRING DIAGRAMS Figure lJ-6 Oil. Fuel. Temp. Tach, Stop and Brake Warning Light. GT...
  • Page 102 WIRING DIAGRAMS Figure 1 J-8 Blower and Lighter - GT...
  • Page 103 1973 OPEL SERVICE MANUAL...
  • Page 104 WIRING DIAGRAMS Figure 1 J-10 Indicator Lights and Gauges - Ratlye...
  • Page 105 DOME LIGHT & S W I T C H 14 RED - TO STEERING COLUMN CONN. 12 RED FROM BATTERY- -12 RED S T E E R I N G TRUNK LIGHT? COLUMN CONNECTOR BUZZER IGNITION SWITCH K E Y I N “ O F F ” & “ L O C K ”...
  • Page 107 1 J- 86 1973 OPEL SERVICE MANUAL Figure 1 J-l 3; Headlamps - Opel 1900...
  • Page 108 WIRING DIAGRAMS Figure lJ-14 Headlamps Manta...
  • Page 109 1 J- 88 1973 OPEL SERVICE MANUAL...
  • Page 110 301516...
  • Page 112 WIRING DIAGRAMS Figure lJ-18 Right Parking, Tail and Instrument Panel Lighting -Opel Manta...
  • Page 113 1 J- 92 1973 OPEL SERVICE> MANUAL Figure 1~19 Starting, lgniiion and Charging Opel 1900 Manta...
  • Page 114 WIRING DIAGRAMS Figure Starting, Ignition Charging...
  • Page 115 1 J- 94 1973 OPEL SERVICE MANUAL Figure lJ-21 Instrument Panel GT...
  • Page 116 WIRING DIAGRAMS Figure lJ-22 A/C Generator and Regulator -All Models...
  • Page 117 301523...
  • Page 118 WIRING DIAGRAMS Figure 1 J-24 Seat Belt Warning System (Automatic Transmission) Opel 1900 Manta...
  • Page 120 WIRING DIAGRAMS Figure lJ-26 Seat Belt Warning System (Automatic Transmissionl...
  • Page 121 1973 OPEL SERVICES MANUAL Figure 1 J-27 Heated Rear Glass - Opel 1900 - Manta...
  • Page 122 WIRING DIAGRAMS 1 J-101...
  • Page 123 1 J-102 1973 OPEL 9ER”IC; MANUAL...
  • Page 124 GROUP 2 Page No. Section Title General Information Frame and Body Mountings ....Windows and Window Moldings Doors _........ Rear Compartment Lid BUMPERS Roof and Sun Roof Seats, Interior Trim and...
  • Page 125 1973 OPEL SERVICE MANUAL GENERAL INFORlVlATION CONTENTS Subject Page No. DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: Paint Maintenance ............
  • Page 126 GENERAL INFORMATION on blood stains since they will set the stain, thereby ded with rubber, and volatile cleaners are generally making its removal practically impossible. solvents for rubber. The application of too much Do not use cleaner may destroy these rubber pads. Rub the stain with a clean cloth saturated with cold volatile cleaners on vinyl coated fabrics.
  • Page 127 1973 OPEL SERVICE MANUAL 9. Shoe Polish and Dressings. On types of shoe fabric to dry thoroughly; then rub lightly with a dressing which contain starch or dextrine or some clean cloth dipped in a volatile cleaner. This is the water soluble vehicle, allow the polish to dry;...
  • Page 128 GENERAL INFORMATION SPECIAL BODY TOOLS J-21828 & J-21549...
  • Page 129 1973 OPEL SERVICE MANUAL OPEL 1900, MANTA AND GT FRAME AND BODY MOUNTINGS CONTENTS Subject Page No. DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: (Not Applicable) SPECIFICATIONS: Frame and Body Mounting Specifications ....
  • Page 130 FRAME AND BODY MOUNTINGS GT FRAME MEASUREMENTS From centerline of lower ball joint stud to centerline of front lower arm bushing. Outside of left frame horn to outside of right frame horn. Centerline of front crossmember right attaching bolt holes to centerline of front crossmember left attaching bolt holes.
  • Page 131 1973 OPEL SERVICE MANUAL Figure 28-3 Opel 1900 Manta Frame Details 1900 - MANTA 1900 - MANTA FRAME MEASUREMENTS 1 O-9/ 16” Mating surface of frame rail to horizontal line from center of front crossmember to frame support bolt hole.
  • Page 132 WINDOWS AND WINDOW MOLDINGS WINDOWS AND WINDOW MOLDINGS CONTENTS Subject Page No. DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Removal and Installation Windshield Reveal Molding ........Windshield and Back Window .
  • Page 133 1973 OPEL SERVICE MANUAL 4. Place new windshield on glass holding fixture and REMOVAL AND INSTALLATION OF WINDSHIELD tit new rubber channel. See Figure 2C-4. OR BACK WINDOW-WINDSHIELD SHOWN 5. Insert a thick string into large sealing lip of rubber channel so that both ends are crossed at bottom cen- 1.
  • Page 134 WINDOWS WINDOW MOLDINGS 3. Remove and install door inside handle. 8. With a sealer gun, apply window sealing com- pound between outside of windshield and rubber 4. Remove and install door belt reveal molding. channel. See Figure 2C-8. 5. Scribe position of window lifter guide rail screws. 6.
  • Page 135 See Figure 2C-10. window. See Figure 2C-13. REMOVAL AND INSTALLATION OF REAR QUARTER WINDOW OPEL 1900. MANTA 1. Unscrew rear quarter window Iqck. See Figure Figure 2C-13 Drilling Off Quarter Window Lock Pin REMOVAL AND INSTALLATION OF HINGED...
  • Page 136 DOORS CONTENTS Subject Page No. DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Front Door - Removal and Installation ............Door Lock Striker Window Regulator Handle .......... Trim Pad ................Door Handle . Inside ............Reveal Molding ..............
  • Page 137 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 5. Remove door trim pad.
  • Page 138 3. Unhook con&cting rod out of support and the water deflector foil is inserted in lower door slot. hook into new support and door lock. See Figure 2D-6. Reverse procedure for installation. 4. Screw support onto door inner panel so that it can be shifted in both holes.
  • Page 139 1973 OPEL SERVICE MANUAL 10. Remove window lifter through opening in inner 2. Remove door lock knob. door panel upper part. See Figure 2D-11. 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.
  • Page 140 DOORS Figure 2D-14 Engaging Actuating Lever Figure ZD-12 Guide Rail Bolt 3. Install guide rail through access hole and install bolt and rail bolt. See Figure 2D-12. 4. Install inside door handle. 5. Install door lock knob. 6. Install door trim pad.
  • Page 141 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.
  • Page 142 10. Remove door weatherstrip, using a clip remover. See Figure 2D20. 12. Drive out upper and lower door hinge sleeve and remove door, using Tool J-21688. See Figure 2D-21. Figure ZD-19 Installing Weatherstrip Figure ZD-21 Removing Hinge Pin 3. Remove door inside handle. 13.
  • Page 143 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. Figure 2D-25 Cable and Pully Location 4. Position sash window so that cable retainer can be unscrewed through access hole.
  • Page 144 DOORS HINGE TRIM PANEL1 Figure ZD-28 Removing Tailgate Hinge Trim Panel 4. Release and remove torque rods. See Figure 2D- LEFT ~- RIGHT Figure ZD-27 Cables Wound On Regulators Figure ZD-29 Tailgate Torque Rods Installation - Right Door 5. Remove bolts securing tailgate hinges to roof panel and lift out tailgate hinges.
  • Page 145 1973 OPEL SERVICE MANUAL REAR COMPARTMENT LID CONTENTS Subject Page No. DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Removal and Installation Weatherstrip ..............
  • Page 146 REAR COMPARTMENT inch deep socket, and remove it, together with inter- mediate ring. See Figure 2E-4. Figure ZE-5 Lock Cylinder Rod Location 3. Remove rubber bumpers, lamp, lid lock, and lock cylinder. See Figure 2E-6. Installation 1. Install lock cylinder nut, together with intermedi- ate ring, and fasten with a 13/16 inch deep socket.
  • Page 147 1973 OPEL SERVICE MANUAL ROOF AND SUN ROOF CONTENTS Subject Page No. DIAGNOSIS: Sun Roof Diagnosis ............
  • Page 148 ROOF AND SUN ROOF Condition Correction Sun roof lifts up on one Lifter wedge welded to under- Remove sun roof panel and bend side only. lifter wedge so that it squarely hits side of sun roof panel does not run up ramp welded in ramp.
  • Page 149 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-2 Sun Roof Front Guide rail and should have a clearance of no more than 0.02...
  • Page 150 ROOF AND SUN ROOF the case, take off crank handle and cable crank 3. Hold lifter pin adjusting screw down and tighten (see Figure 2F-4) and physically reposition lifters to lifter pin nut. be approximately 90 degrees to guide rails and to contact guide stops.
  • Page 151 1973 OPEL SERVICE MANUAL d should have a clearance of no guides to height adjustment rings, loosen second screw (see Figure 2F-6), and swing guides away from guide rail. 3. Reconnect riar lifter guides onto sun roof panel NOTE: When swinging front guides inboard, be brackets and reposition tension spring as shown in Figure 2F-3.
  • Page 152 ROOF AND SUN ROOF Installing Velvet Strip and Weatherstrip On Rear Installation of Sun Roof Frame of Sun Roof Panel 1. Slide sun roof frame into lower slot of guide rails, position fully rearward and reattach guide rails to 1. Using nitrile vinyl trim adhesive (3M Vinyl Trim roof.
  • Page 153 1973 OPEL SERVICE MANUAL 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.
  • Page 154 ROOF AND SUN ROOF REMOVAL AND INSTALLATION OF FRONT AND 2. Press off snap ring holding drive pinion in place REAR WATER DRAINAGE HOSES and remove drive pinion (see Figure 2F-10). Installation Removal of Front Water Drainage Hose 1. Install drive pinion reverse of removal. NOTE: If drive pinion is to be replaced, also replace drainage pipe taken out.
  • Page 155 1973 OPEL SERVICE MANUAL 2. Pry out plastic fasteners securing cardboard parcel 3. Carefully detach a portion of headlining around shelf in position and remove shelf. window corner post involved. 3. Remove rear quarter trim pad. 4. Detach water drain hose from sun roof hose iit- ting.
  • Page 156 SEATS, INTERIOR TRIM AND HEADLINING SEATS, INTERIOR TRIM AND HEADLINING CONTENTS Page No. Subject DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Removal and Installation Front Seat ............... . Rear Seat .
  • Page 157 1973 OPEL SERVICE MANUAL a 13/16 inch deep socket, and remove. See Figure Figure ZG-4 Seat to Underbody Hook Figure ZG-6 Removing Glove Compartment Lock 2. Install new glove compartment lid lock. REMOVAL AND INSTALLATION OF FRONT SIDE PANEL TRIM PAD to the instrument panel cover.
  • Page 158 SEATS, INTERIOR TRIM AND HEADLINING 1st listing wire - No marking, wire is thinner than 2. Push off side panel trim pad. Trim pad is held in other wires position by a retaining button. 2nd listing wire - Red REMOVAL AND INSTALLATION OF HEADLINING 3rd listing wire - Blue Removal...
  • Page 159 1973 OPEL SERVICE MANUAL 3. Install and align the remaining five listing wires. should be used to smooth cemented portions down If required, caulk retainers of 2nd and 5th listing of headlining. wires so that wires run in a straight line transversally under the roof.
  • Page 160 SEATS, INTERIOR TRIM AND HEADLINING REMOVAL AND INSTALLATION OF REAR SIDE 8. If wagon, install front window and quarter win- dows. It other than wagon, install front and rear PANEL TRIM PAD windows. 9. Install coat hooks, assist straps, interior lamp, sun visors, and rear view mirror.
  • Page 161 ‘AND OPERATION PROTECTIVE MOLDINGS All 1973 Opel bumpers are equipped with rubber protective moldings as standard equipment. The moldings are easily removed by removing the attach- ing nuts located on the inboard side of the bumper. Figure ZH-2 Bumper Attaching Screws MAJOR REPAIR 2.
  • Page 162 BUMPERS REMOVAL AND INSTALLATION OF FRONT REMOVAL AND INSTALLATION OF FRONT BUMPER ASSEMBLY (GT) BUMPER ASSEMBLY (GT) Removal 1. Remove grille. 1. Remove grille. 2. Disconnect bumper at points shown in Figure 2. Disconnect bumper at points shown in Figure and remove bumper.
  • Page 163 1973 OPEL SERVICE MANUAL 2. Remove bumper attaching nuts accessible through 2. Install grille. lamp opening. See Figure 2H-7. REMOVAL AND INSTALLATION OF REAR Installation BUMPER ASSEMBLY (GT) Install bumper and secure with attaching nuts Removal accessible through lamp opening. See Figure 2H-7.
  • Page 164 INSTALLATION INSTRUCTIONS 1969 - 73 OPEL GT TRAILER HITCH LESS BALL GROUP 7.068 S T E P 1 . REMOVE ONE RIGHT HAND AND ONE LEFT HAND TAIL LAMP ASSEMBLY, STEP 2. P L A C E T I E B A R (C) U N D E R T H E R E A R B O D Y...
  • Page 165 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.
  • Page 166 MAXIMUM GROSS WEIGHT 1000 LBS. MAXIMUM TONGUE WEIGHT 100 LBS. MOST STATES PROHIBIT OBSTRUCTION OF LICENSE PLATES. BALL SHOULD BE REMOVED WHEN NOT IN USE IF IT OBSTRUCTS A CLEAR VIEW. Figure ZH-10 Opel 1900 - Manta - Less Wagon -Trailer Hitch lnsfallafion...
  • Page 168 GROUP 3 Section Title Page No Front Suspension ..Steering Linkages SUSPENSION Front End Alignment Steering Gear .._..STEERING Steering Column 1900 - Manta ,._________... GT ........Rear Suspension .
  • Page 169: Front Suspension

    1973 OPEL SERVICE MANUAL FRONT SUSPENSION CONTENTS Subject Page No. DESCRIPTION AND OPERATION: Suspension Description ........... .
  • Page 170 GT Front Suspension (Disc Brakes) the upper and lower control arm are not in parallel (anti- dive). The lower control arm is connected to the steering knuckle with a ball joint. Figure 3A-3 Cross Member Marking Figure Front Suspension - Opel 1900 Manta...
  • Page 171 Removal GT 1. Prior to raising front end of car, apply parking Removal Opel 1900 - Manta brake and block rear wheels. 1. Prior to raising front end of car, apply parking 2. Raise front end of car with a jack. It is recom- brake and block rear wheels.
  • Page 172 FRONT SUSPENSION Figure 3A-6 GT Steering Mast Joint Figure 3A-9 Removing Guard Plate 2. Install Hooks J-23697 before jacking up car to assure proper loading of suspension bushings and 7. Suspend engine with a suitable engine lifter, simi- mounts. See Figure 3A-7. lar to the one shown in Figure 3A-9.
  • Page 173 9. Inr;tall mast guide sleeve stop bolt. Always install new lock plate. See Figure 3A-7. 10. Remove front support stands and lower vehicle. Installation Opel 1900 - Manta 1. With jack, lift up front suspension assembly so that the individual attaching points coincide. At the same time, insert lower steering mast into pinion flange.
  • Page 174: Wheel Nuts

    The lower ball joints are checked for wear by using Checking Gauge J-23402 for the GT, and using CAUTION: Fasteners are important attachingparts in Checking Gauge J-23745 for the Opel 1900 - Manta. that they could afEct the pertkmance of vital com- See Figure 3A-15.
  • Page 175 1973 OPEL SERVICE MANUAL HOUSING Figure 3A-16 Spring Compressa Figure 3A-14 Lower Ball Joint attachment bolt and swing shock absorber out of the 6. Remove castle nut from ball joint stud. Prior to the removal of the lower ball joint from the control arm, note the position of the locating notch, shown in Figure 3A-17, in the rim of the ball joint housing.
  • Page 176 2. Install dust cap on lower ball joint and fill with 8. Press ball stud out of lower control arm. chassis lubricant. Attach dust cap retainer. Removal Opel 1900 - Manta 3. Press ball joint into steering knuckle. Use J- 9519-3 as installer...
  • Page 177 Do not use a re- placement part or lesser quality or substitute design. Torque values must be used as specified during reas- Figure 3A-18 Lower Ball Joint Notch Opel 1900 - sembly to assure proper retention of these parts. M a n t a...
  • Page 178 FRONT SUSPENSION UPPER CONTROL ARM SHAFT INNER SLEEVE OUTER SLEEVE RUBBER DAMPENIN GUIDE SLEEVE ABSORBER SUPPOR SHOCK ABSORBER SUPPORT ON FRONT SUSPENSION CROSS MEMBER TOOTHED WASHER UPPER CONTROL ARM RUBBER BUSHINGS PLATE WASHER Figure 3A-19 Upper Control Arm Shaft and Bushings placement part of lesser quality or substitute design.
  • Page 179 1973 OPEL SERVICE MANUAL Figure 3A-20 Lower Control Arln Attachment jack so that spring and lower control arm assembly 10. Loosen nut that retains lower control to front is removed from the front cross member and steering cross member. knuckle.
  • Page 180 30 lb.ft. from steering knuckle. 9. Install nuts on upper shock absorber attaching Removal Opel 1900. Manta studs. Tighten nuts until a distance from top of nut to stud is approximately l/2 inch. 1. Raise car and support with stands.
  • Page 181 7. Install caliper on steering knuckle and torque bolts to 72 lb.ft. See Figure 3A-21. 8. Install wheel and torque wheel nuts to 65 lb.ft. Installation Opel 1900 - Manta Fasteners are important attachingparts in CAUTION: that they could affit the performance of vital com- ponents and systems, and/or could result in ma&...
  • Page 182 SHOCK ABSORBER REMOVAL AND mets when replacing a shock absorber. INSTALLATION 2. Install the lower grommet retainer and grommets Removal Opel 1900. Manta on shock absorber. Compress shock absorber and place in position. 1. Raise car and support with stands.
  • Page 183 9. Slowly lower hoist to release spring tension. Removal (Opel 1900 - Manta) 10. Swing lower control arm downwards and remove front spring. 1. Prior to raising car, install upper control arm hooks J-23697.
  • Page 184 43 lb.ft. For proper location of the marking lugs, see Figure 5. Attach stabilizer bar to cross member to body support. Installation (Opel 1900. Manta) 6. Install shock absorber and torque lower attaching nut and bolt to 30 lb.ft.
  • Page 185 Steering Gear Housing to Front Suspension Crossmember (1900 - Manta) ........Stabilizer Bar to Lower Control Arm (Opel 1900 - Manta) ............Tie Rod Clamp Bolts (GTJ ............ Castle Nut, Tie Rod to Steering A r m ......Upper Control Arm Shaft to Shock Absorber Support and Upper Control Arm (GT) ..........
  • Page 186: Steering Linkage

    The ball joints of the tie rods do not require service. Tie rods on the Opel l&O and Manta are connected to both rack ends by means of a axial joint. Two rubber bellows between the axial joint and steering...
  • Page 187 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.
  • Page 188 4. Attach rubber bellows to axial joint using hose OUTER TIE ROD 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 RETAINER RING rod ball stud from tie rod.
  • Page 189 FRONT END ALIGNMENT CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Front Wheel Alignment ......“......DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: Inspection Before Checking Front Wheel Alignment Adjusting Caster .
  • Page 190 To decrease caster ADJUSTING CASTER (OPEL 1900. MANTA) place one thick washer at the front of the control arm shaft and one thin washer at the rear.
  • Page 191 Figure 3C-3 Upper Control Arm Shaft and Bushings FRONT OF CAR Figure 3C-5 Caster Adjustment Washer Location - Opel 1900 - Manta several washers in one place. The washers B installed in production have a larger outer diameter than the washer A.
  • Page 192 The bellows must not be twisted and wire Torque to 29 ft. lbs. on GT and 44 ft.lbs. on Opel ends must show towards steering gear adjusting screw opening.
  • Page 193 With camber known to be within specitied limits, theoretical king pin inclination should check to 8.5 degrees for Opel 1900 - Manta, and 6 degrees for GT. If camber is incorrect beyond limits of adjustment and theoretical king pin inclination is correct, or nearly so, a bent steering knuckle is indicated.
  • Page 194 It is laterally guided by the sintered bronze shell in the adjusting screw opening, and in the short The Opel 1900 - Manta and GT steering gear is the gear housing neck by the rack guide bushing. See rack and pinion type. The steering gear pinion shaft, Figure 3D-3.
  • Page 195 1973 OPEL SERVICE MANUAL FLEXIBLE COUPLING S H A F T . NEEDLE BEARING BUSHING O-RING SEAL Figure 3D-2 Steering Gear Assembly - End View RACK GUIDE Figure 3D-3 Steering Gear Assembly Front View until a resistance is felt. By threading in adjusting...
  • Page 196 Figure 3D-6 Steering Gear Assembly Attaching Bolts Removal (Opel 1900. Manta) Figure 3D-4 Stop Bolt 1. Remove splash shield from lower deflector pa: and both side members. See Figure 3D-7.
  • Page 197 1973 OPEL SERVICE MANUAL 5. Reinstall stop bolt into steering column. 6. Full turn steering wheel both right and left. If any resistance is noticeable, it will be necessary to remove the sleering column and correct the cause. CAUTION: Fasteners are important attachingparts in...
  • Page 198 6. From steering gear housing remove “0” rings from retainer and pinion bushing. Also take out thrust washer. See Figure 3D-17. Disassembly (Opel 1900. Manta) Figure 3D-1 1 - Removing Axial Joint 1. Carefully clamp steering gear assembly in soft jaw vise.
  • Page 199 Check that bellows is not twisted and will compress and expand properly. IN FLEXIBLE COUPLING PARALLEL OR Reassembly (Opel 1900 - Manta) 1. Clamp steering gear housing in a soft jaw vise and Figure 3D-14 Installing Pinion Shaft reassemble new “0” rings onto retainer and pinion shaft bushing.
  • Page 200 STEERING GEAR ASSEMBLY 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 2.
  • Page 201 1973 OPEL SERVICE MANUAL LOCK PLATE 7, FLEXIBLE COUPLING -/ PINION SHAFI BOLT RUBBER BOOT RETAINER RACK GUIDE BUSHING RACK ADJUSTER SCREW RUBBER BUSHING LOCK NUT BOLT \ Figure 3D-17 Steering Gear Assembly Exploded View...
  • Page 202: Table Of Contents

    OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY 3E.35 OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Description and Operation of Directional Signal Lever ................. .
  • Page 203: Description And Operation Of Horn

    The horn is actuated by pushing on steering mast jacket assembly, especially if removed, the ends of the spokes for the Opel 1900 - Manta and has in contrast with the standard steering to be given by pushing on the center horn button on 57R, 57L, a difierent treatment.
  • Page 204: Assembly

    OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY Figure 3E-7 - Steering Mast Jacket Attachment Figure 3E-5 Steering Column Assembly With Gear replacement of steering column or steering ignition 4. Pull off signal switch, as well as steering and igni- lock parts.
  • Page 205: Removal And Installation Of Steering Wheel

    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. Torque values must be used as specified during reas- sembly to assure proper retention of these parts.
  • Page 206 OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY 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). 2. Pull off signal switch and steering and ignition lock wire set.
  • Page 207 (2) projection on electrical switch fits into recess on lock housing. 2. On the Opel 1900 - Manta, insert lock cylinder in the P l* position into housing. Install lower half of signal switch housing.
  • Page 208 OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY SPECIFICATIONS Steering Column Tightening Specifications Location Part Steering Wheel Retaining (1900 - Manta) .._.._...,,..Steering Column Flexible Coupling (1900 - Manta) ._., N u t Slide Off Base Attaching (1 900 - Manta) ._..,,,,,,.._,,,,,..
  • Page 209 1973 OPEL SERVICE MANUAL GT STEERING COLUMN ASSEMBLY CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Description of Steering Column ........
  • Page 210 GT STEERING COLUMN ASSEMBLY UPPER STEERING C O L U M N A S S E M B L Y - \ U P P E R U N I V E R S A L J O I N T - STEERING - C E N T E R S T E E R I N G...
  • Page 211 1973 OPEL SERVICE’MANUAL Figure 3E-17 Steering Column Bracket installed in a car it is no more susceptible to damage joints to allow ~for the offset between the steering column and the gear assembly. through usage than an ordinary column; however, when the column is removed, special care must be taken in handling this assembly.
  • Page 212 GT STEERING COLUMN ASSEMBLY 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.
  • Page 213 1973 OPEL SERVICE MANUAL Attachments Figure 3E-19 Steering Column 3. Install new tear bolts and tighten until hex head of bolt is tom off. Fasteners are important attaching parts CAUTION: in that they could affect the performance of vital 4. Reconnect ignition and direction signal wire sets.
  • Page 214 GT STEERING COLUMN ASSEMBLY tion signal switch lever into oblong opening in cover 2. Disconnect ignition (white) wire set plug. and push steering lock into housing and remove cover. See Figure 3E-37. 3. Remove steering lock retaining screw. See Figure Figure 3E-22 Figure 3E-20 Steering Lock Retaining Screw 4.
  • Page 215: Switch

    1973 OPEL SERVICE MANUAL 6. Install direction signal switch lever. 7. Install ignition lock cylinder. See previous para- graph in this section. REMOVAL AND INSTALLATION OF UPPER STEERING BEARING AND/OR DIRECTION SIGNAL SWITCH 1. Remove ignition switch and steering lock, see previous paragraph in this section.
  • Page 216 GT STEERING COLUMN ASSEMBLY 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. 3.
  • Page 217 L O C A T I O N TORQUE P A R T Steering Wheel Upper Universal Joint - Lower Clamp Upper Universal Joint - Hex Head Bolt Lower Universal Joint Bolt...
  • Page 218: Rear Suspension

    2. Extend shock absorber and position in car. Attach and also to the underbody through rubber bushings at lower end first, torque nut to 15 lb.ft. on the GT, in the central joint support bracket. and torque to 47 lb.ft. on the Opel 1900 - Manta.
  • Page 219 4. Attach shock absorbers and tighten retaining nuts 2. Properly install upper damper rings on springs. to 15 Ib.ft. For the GT and 47 lb.ft. for the Opel 1900 Fasteners are important attaching parts in CAUTION: that they could affect the performance...
  • Page 220 REAR SUSPENSION Installation Remove jack stands. 1. Work stabilizer rod into position and loosely at- LOWER CONTROL ARM REPLACEMENT tach stabilizer to underbody retainers. Removal 2. Connect stabilizer rod to shackles. This operation can be performed with the vehicle 3. With the vehicle standing on its wheels or the rear standing at curb height or elevated.
  • Page 221 1973 OPEL SERVICE MANUAL DAMPER RING TRACK ROD COIL SPRING SHOCK ABSORBER LOWER RUBBER ’ DAMPER RING REAR AX;E ASSEMBLY COIL SPRING SEAT STABILIZER ROD LOWER CONTROLA R M Figure 3F.5 Exploded View Rear Suspension...
  • Page 222: Wheels And Tires

    WHEELS AND TIRES WHEELS AND TIRES CONTENTS Subject Page No. DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: Car Roughness and Vibration ........Abnormal Tire Wear .
  • Page 223 1973 OPEL SERVICE MANUAL tires that cause vibration as follows: parking brake cable. Spin the other wheel using the same procedure. By spinning the wheels, the offending tire will cause Unbalance vibration that may be felt by touching the bumper or fender.
  • Page 224 Tire grinding is .very effective in eliminating tire complaints due to excessive tire runout. Grinding can be accomplished on or off the car. Grinding is ASSEMBLY CAUSING REPOSITION TIRE/WHEEL approved by Opel, if done as recommended by the VIBRATIONS MOUNTING BY 1 80° equipment manufacturer...
  • Page 225 1873 OPEL SERVICE MANUAL should be deflated and the tire repositioned (indexed) Tire Wear Irregularities 180 degrees from original location. An additional cause of vibrations may sometimes be 5. After repositioning, rebalance tire/wheel assembly tire wear irregularities. These can also produce noise (static and dynamic preferred).
  • Page 226 WHEELS AND TIRES TREAD CONTAil WITH ROAD TREAD CON& I UNDERINFLAlIONI T R E A D C O N T A C T WITH ROAD P R O P E R I N F L A T I O N U N D E R I N F L A T I O N O V E R I N F L A T I O N CENTER OF TREAD WOI...
  • Page 227 1973 OPEL SERVICE MANUAL severe or careless driver. Rapid acceleration and de- Canter or Overinflation Tread Wear celeration, severe application of brakes, taking turns Excessive wheel camber, either positive or negative, at excessive speed, high-speed driving, and striking causes the tire to run at such an angle to the road...
  • Page 228 WHEELS AND TIRES Cornering Tread Wear car driven mostly at highway speeds without recom- mended tire rotation. Factors which promote cup- The modern independently-sprung automobile al- ping include underinflation, incorrect toe-in setting lows the driver to negotiate turns at a high rate of or camber setting, and steady highway speeds on speed with a greater feeling of safety.
  • Page 229 Leak test wheel and tire assembly and if satisfactory, reduce to recommended pressure. SPECIFICATIONS General Specifications Wheels Opel 1900 - Manta and GT ,._..,,,._....,...,,......~,,,....Tires 165-13 GT ..__.._....,...,,..,,,...,,..,..,..,,...,,..,....,,,..... 165-13 Tire Size and Pressures (Pounds Per Square Inch...
  • Page 230 WHEELS AND TIRES would require inflation pressures above the maximum allowable, speed must be limited to 75 miles per hour. 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.
  • Page 232: Propeller Shaft

    GROUP 4 Title Page No. PROPELLER SHAFT Propeller Shaft and Central Joint ....AND DIFFERENTIAL Rear Axle ....
  • Page 233 1973 OPEL SERVICE MANUAL PROPELLER SHAFT AND CENTRAL JOINT CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Propeller Shaft and Central Joint ....... .
  • Page 234 2. Disconnect parking brake cable equalizer from turn spring from brake rod. rod. 4. On the Opel 1900 and Manta, unhook exhaust 3. On the Opel 1900 and Manta, unhook parking system and let it down. brake cable from floor panel.
  • Page 235 1973 OPEL SERVICE MANUAL TORQUE TUB; Figure 4A-3 Removing Pinion Flange Figure 4A-5 Disassembling Central Joint bracket to support cushion bolts and pull central joint support from torque tube. See Figure 4A-5; Assembly of Central Joint Fasteners in the following steps are impor- CAUTION: tant attaching parts in that they could ah&t the...
  • Page 236 PROPELLER SHAFT AND CENTRAL JOINT 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.
  • Page 237 1 9 7 3 O P E L S E R V I C E M A N U A L SPECIFICATIONS PROPELLER SHAFT AND CENTRAL JOINT SPECIFICATIONS Tightening Specifications ~ Use a reliable to’rque wrench. Specifications are for clean and lightly-oiled threads.
  • Page 238: Rear Axle

    During installation, varying the shim thickness from side to The Opel rear axle is a semi-floating type that carries side also determines the ring gear to pinion backlash. car weight through the axle shafts by way of ball...
  • Page 239 1973 OPEL SERVICE MANUAL DIAGNOSIS DIFFERENTIAL TROUBLE DIAGNOSIS Possible Cause Condition 1. a) Road noise. 1. Noise is the same in b) Tire noise. “Drive” or “Coast”. c) Front wheel bearing noise. d) Front or rear U-joint angle too great.
  • Page 240 REAR AXLE MAJOR REPAIR 7. Disconnect universal joint from pinion flange and support or tie propeller shaft out of way after mark- ing mating areas. If propeller shaft is removed, install REMOVAL AND INSTALLATION OF REAR AXLE plug in rear of transmission to prevent loss of lubri- ASSEMBLY cant.
  • Page 241 7. Torque lower control arm to Axle housing bolts to performance of vital components and systems, and- 18 Ib.ft. on the GT and 22 lb.ft. dn the Opel 1900 and /or could result in major repair expense. They must Manta.
  • Page 242 REAR AXLE 4. Check axle shafts end play as follows: a. Using a depth gauge, measure depth of rear axle bearing seat in axle housing (backing plate and gas- kets in place). See Figure 4B-4. b. Measure width of bearing outer race. The differ- ence between the two measurements indicates the required thickness of the shims.
  • Page 243 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.
  • Page 244 2. Using Special Tool J-22932 hold barrel spline and 4. Remove drive pinion by tapping rearward with a remove pinion preload nut. See Figure 4B-8. soft faced hammer. 3. With the aid of Special Tool J-22937 remove barrel 5. Remove rear pinion bearing using Special Tool J- 22912.
  • Page 245 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. 3. To determine the correct pinion depth setting use the following procedures: a. Assemble gauge plate J-21691-4, rear pinion bear-...
  • Page 246 J-781 B INSTALLER UNDERLINED J-8092 Figure 48.18 Installing Rear Pinion Bearing Outer Figure 46-16 - Pinion Gear Reference Number Install rear pinion bearing onto the pinion using NOTE: The digit “1’: when written in German, resembles installer J-21022. See Figure 4B-19. the digit “7, However, the digit “7: when written in German, always...
  • Page 247 1973 OPEL SERVICE MANUAL Assembly and Installation of Differential Case. protruding to install the pinion preload nut. Do not use Installer J-22938 to adjust pinion preload. Opel 1900 and Manta See Figure 4B-20. 1. Install side gears without thrust washers or shims.
  • Page 248 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.
  • Page 249 1973 OPEL SERVICE MANUAL 1 I. In.stall side bearings using installer J-22919 and drive handle J-8092. Support opposite side of case on pilot J-2241-1 1 to prevent bearing damage. See Fig- ure 4B-27. 12. Determine differential side bearing preload and backlash as follows: a.
  • Page 250 REAR AXLE FEELER DIFFERENTIAL DIAL INDICATOR Figure 48.29 Removing Differential Case and End Play using installer J-22919, driver handle J-8092 and pi- 16. Install torque tube assembly. lot J-2241-11. 17. Install axle shafts. 13. Position case assembly and outer races in the carrier.
  • Page 251 1973 OPEL SERVICE MANUAL imum permissible runout is X03”. If runout is greater than specified, make certain that dirt or burrs are not holding the ring gear in a cocked position on the case and that the bolts are evenly torqued.
  • Page 252 REAR AXLE FEELER DIFFERENTIAL DIAL INDICATOR SIDE BEARINGS Figure 48.34 Removing Differential Case and End Play 8. Determine differential side bearing preload and d. Adjust feeler gauge thickness from side to side backlash as follows: until ring gear backlash is 004” to ,008” (.005” is desired).
  • Page 253 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 IN.
  • Page 254 Pinion Depth Setting Number of Notches in Circumference Thickness In. Flattened on One Side Clearance Between Differential Side Gears and Case Max. ,000” on the Opel 1900 and the GT using the following selective shims: Number of Notches Thickness In. in Circumference 1900 Max.
  • Page 255 Stabilizer Rod to Body ............Bolt Track Rod to Rear Axle (Opal 1900 & Manta) ....N u t Track Rod to Side Member (Opel 1900 & Manta) ..N u t 10 MM Bolt Nut ........................8 MM Bolt Nut ........................
  • Page 256 DIFFERENTIAL COVER AND SIDE BEARING CAP COVER GASKET DRIVE PINION REAR PINION BEARING , DIFFERENTIAL CASE SIDE GEAR PINION GEAR THRUST WASHER AXLE SHAFT PRELOAD BEARING RETAINER FLAT WASHER TORQUE TUBE Figure 48-37 Exploded View Rear Axle Assembly...
  • Page 257 MM Inches MM Inches MM Inches MM Inches MM Inches MM Inches 1.00 1.0236 1.0630 1.1024 1.1417 1.1811 Figure 48-38 Conversion Table - Millimeter to Inch Equivalent...
  • Page 258 REAR AXLE J - 7 8 1 8 J-21691-6 J - 2 2 9 3 8 J - 2 2 9 3 5 J - 2 2 9 3 7 J - 2 2 5 8 8 J - 2 2 9 3 6 J-24093 J - 8 8 7 2 J-2241-1 I...
  • Page 260 GROUP 5 Section Title Page No. Brake Booster and Master Cylinder BRAKES Disc Brakes .._.__.._____ Drum Brakes ... . .
  • Page 261 A check valve is mounted on the primary circuit which supplies fluid to the rear Figure 5A-1 Brake Booster Attachment (Opel 1900 brakes. This keeps a slight static pressure in the rear and Manta) brake system.
  • Page 262 POWER BRAKE BOOSTER AND MASTER CYLINDER Figure 5A-2 Exploded View Master Cylinder (Opel 1900 and Manta) held in position a retaining plate. The front brake hose between the intake manifold and the brake circuit is connected to the brake fluid container by a...
  • Page 263 1973 OPEL SERVICE MANUAL Figure 5A-4 Brake Pedal and Master Cylinder Attachment (GT) 2 VALVE SEAT HOUSING Figure 5A-5 Vacuum Control Valve DIAGNOSIS POWER BRAKE UNIT TROUBLE DIAGNOSIS Correction C o n d i t i o n Possible Cause 1.
  • Page 264 POWER BRAKE BOOSTER AND MASTER CYLINDER P o s s i b l e C a u s e C o r r e c t i o n C o n d i t i o n Grabby Brakes (Apparent Off- 1.
  • Page 265 4. Install new filter and air silencer. On the GT, the cylinder brake booster assembly. On the Opel 1900 smooth side of the filter must face towards the inside. and Manta, remove the nut and bolt attaching clevis The radial slots in filter and deadener must be stag- on the pedal.
  • Page 266 14 Ib.ft. on the GT and 12 lb.ft. on the Opel 1900 and Manta. If lapping scores and rust spots are still noticeable, replace brake master cylinder assembly. 2. Position assembly into brake booster bracket and,...
  • Page 267 Add or subtract washers between bracket and switch to obtain proper adjustment. 5. Road test car for proper brake performance. MASTER CYLINDER OVERHAUL. OPEL 1900 AND MANTA 1. Remove master cylinder from brake booster by disconnecting brake pipes and removing two self-...
  • Page 268 Brake Booster Size ......................2.06 to 1 Brake Boost Ratio - (GT) ..................2.64 to 1 Brake Boost Ratio - (Opel 1900 and Manta) ............Name Torque Master Cylinder to Brake Booster (GT) .__.._.._.._..Master Cylinder to Brake Booster (Opel 1900 and...
  • Page 269: Disc Brakes

    DISC BRAKES CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Description ................Operation .
  • Page 270 DISC BRAKES 2. RUBBER FLUID SEALS 3. HOLLOW PISTONS Figure 58.21 Left Front Disc Brake - Emloded View the piston circumference by its inherent tension. See The adjustment of the pads is effected by the pistons Figure 5B-21. Both pistons are hollow. The open end which push the friction pads ahead towards the of each piston faces the brake disc.
  • Page 271: Disc Brake Trouble Diagnosis

    1973 OPEL SERVICE MANUAL FRICTION BRAKE RUBBER FLUID SEAL BRAKE DISC CALIPER PISTON RUNNING CLEARAN BETWEEN FRICTION PAD AND BRAKE DISC B = BRAKE OFF THE PISTON IS RETRACTED BY THE AMOUNT OF A = BRAKE ON RUBBER FLUID SEAL DEFLECTION.
  • Page 272 DISC BRAKES Condition Correction Possible Cause 2. Front end out of line. 2. Check and align to manufac- turer’s specifications. 3. Unmatched tires on same 3. Tires with approximately the same amount of tread should be axle. used on the same axle. 4.
  • Page 273 1973 OPEL SERVICE MANUAL C o n d i t i o n P o s s i b l e C a u s e C o r r e c t i o n 2. Partial system failure.
  • Page 274: Maintenance And Adjustments

    DISC BRAKES Condition Possible Cause Correction Check and lubricate, if 2. Binding brake pedal necessary. mechanism. 3. Clean and lubricate. 3. Corroded caliper assembly. MAINTENANCE AND ADJUSTMENTS Checking Disc Brake Friction Pads for Wear Whenever a disc brake equipped car is in for periodic DISC BRAKE MAINTENANCE service, while the car is raised, the friction pads in both brake calipers should be checked for wear by...
  • Page 275 OPEL SERVICE MANUAL Figure 56-26 Removing Installing Rubber Seal Figure 56-24 Removing Dowel Pins Clamp Ring (d) Attach brake caliper to steering knuckle and Prior to installation of torque bolts to 72 Ib.ft. caliper, make sure contacting surfaces of both caliper and steering knuckle are perfectly clean and free of any burrs.
  • Page 276: Checking Brake Disc For Lateral Runout

    DISC BRAKES assembly and true disc in a suitable disc turning a tine cut file. Do not use any solvent except dena- lathe, following manufacturer’s instructions. The tured alcohol. Do not use a metaIJic scraper too/. depth of cut on each side of disc should be just deep enough to get a true flat surface.
  • Page 277 1973 OPEL SERVICE MANUAL Figure 58.28 Brake Caliper to Steering Knuckle Figure 58.30 Removing Brake Disc to Hub Bolts Attaching Bolts 4. Pull brake disc from wheel hub. Do not drive if off. Install in reverse sequence, paying attention to the wheel.
  • Page 278: Removing And Installing Brake Disc Shield

    DISC BRAKES CAUTION: Fasteners in Steps 7 and 9 are important placed with one of the same part number or with an part if repJacement becomes necessary. Do not use a replacement part or Jesser quaJity or substitute design. Torque vaJues must be used as specified during reassembJy to assure proper reten- tion of these parts.
  • Page 279 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 58-35 Removing Rubber Fluid Seal From...
  • Page 280: Specifications

    Replacement ........................Disc Brake Master Cylinder Bore ..................Disc Brake Caliper Cylinder Bore - GT ................1.770 Disc Brake Caliper Cylinder Bore Opel 1900 and Manta ..........1.890 Disc Brake Shoe Adjustment ................Self-Adjusting Torque Specifications Use a reliable torque wrench to tighten the parts listed, to insure proper tightness without straining or distorting parts.
  • Page 281: Drum Brakes

    1973 OPEL SERVICE MANUAL DRUM BRAKES CONTENTS Subject Page No. DESCRIPTION AND OPERATION: Description of Brake Mechanism .......
  • Page 282 13. TRANSMITTAL LEVER the exception of the additional transmittal lever at 14. MOUNTING SUPPORT the floor panel, identical with that of the Opel mod- els. The transmittal lever is attached to the propshaft 15. BOLT tunnel by means of a mounting support. See Figure 16.
  • Page 283: Operation Of Hydraulic Service Brake

    Each rear wheel cylinder contains two pistons and Figure 5C-46 Brake Light Switch - Opel 1900 and two rubber cups which are held in contact with the M a n t a...
  • Page 284 DRUM BRAKES CYLINDER HOUSING PISTON BLEEDER VALVE SC-47 Figure 5C-47 Wheel Cylinder Exploded View against the ends of the shoes. Rubber boots en- cups are of a special heat resisting rubber. The inlet port for brake fluid is located between the close both ends of the cylinder to exclude foreign pistons so that when fluid pressure is applied, matter.
  • Page 285 1973 OPEL SERVICE MANUAL...
  • Page 286: Maintenance And Adjustments

    D R U M B R A K E S 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.
  • Page 287: Hydraulic System

    1973 OPEL SERVICE MANUAL not result in proper brake action, inspect linings on both rear wheels for possible replacement. Filling Brake Master Cylinder R e s e r v o i r The master cylinder reservoir must be kept properly filled to insure adequate reserve and to prevent air from entering the hydraulic system.
  • Page 288: Major Repair

    DRUM BRAKES 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.
  • Page 289: Inspecting And Reconditioning Brake Drums

    2. Thoroughly clean brake shoes and remove all burrs around rivet holes. 3. Use Opel brake lining or equivalent. Install in place and rivet in sequence shown in Figure Z-54. Keep hands clean while handling brake lining. Do not permit oil or grease to come in contact with lining.
  • Page 290: Brake Wheel Cylinder Overhaul

    DRUM BRAKES remove grooves, and the ridges in the lining should BRAKE WHEEL CYLINDER OVERHAUL be lightly removed with a lining grinder. 1. Remove wheel, drum, and brake shoes. Be careful If brake linings are more than half worn, but do not not to get grease or dirt on brake lining.
  • Page 291: Specifications

    1973 OPEL SERVICE MANUAL Never use copper tubing because copper is subject to 2. Cut tubing to length. The correct length may be determined by measuring the old pipe using a cord fatigue cracking which would result in brake failure.
  • Page 292 GROUP 6 Section Title ‘age No. Engine Mechanical and Mounts All Models Cooling System All Models ..... . ENGINE Fuel System All Models .
  • Page 293: Description And Operation - Drum

    The 1.9 liter engine is standard equipment on all 1973 Opel 1900, Manta and GT models. This engine has non- scaling and promotes long life. All engines have a compression ratio of 7.6:1 and operates “regular”...
  • Page 294 ENGINE MECHANICAL AND MOUNTS Figure 6A-1 Side Cross Section View of Engine This engine has full skirt “Autothermic” type pistons the camshaft front bearing seat outer face in one with two horizontal slots in oil control ring groove, direction, and by the front bearing cover in the other which partly separate head and skirt to maintain direction.
  • Page 295 1973 OPEL SERVICE MANUAL Hot exhaust gases are used for heating a vaporization hand side above crankshaft sprocket, has a plunger plate located at bend of intake manifold below carbu- head with oil- proof and wear-resistant synthetic retor and communicating with its tinned underside...
  • Page 296 ENGINE MECHANICAL AND MOUNTS incorporating a gear-type pump driven by the dis- and pumps it through drilled passages in timing case tributor shaft. The pump body forms part of the to the full flow filter. From there it passes to the timing case.
  • Page 297 1973 OPEL SERVICE MANUAL DIAGNOSIS EXCESSIVE OIL CONSUMPTION C o n d i t i o n C o r r e c t i o n Tighten attaching bolts. If leaks External Oil Leaks at: Rocker Arm Covers persist, remove cover (or pan),...
  • Page 298 ENGINE MECHANICAL AND MOUNTS engine off. It makes no difference whether the engine Pour penetrating oil over the valve spring cap and is cold or is at operating temperature. Set piston of allow it to drain down the valve stem. Apply pressure the respective cylinder to upper top center on the to the one side of the valve spring and then the other, and then rotate the valve spring about l/2 turn.
  • Page 299 ASSEMBLY REMOVAL INSTALLATION Removal (Opel 1900 and Manta)’ The engine assembly on the Opel 1900 and Manta can be removed together with the transmission through the top of the engine compartment. 1. Remove hood (scribe hood hinge to hood mount- Figure 6A-7 Transmission Support Bolts .
  • Page 300 ENGINE MECHANICAL AND MOUNTS 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.
  • Page 301 1. Lower engine and transmissior assembly into car. device was made up using hardwood, bolts, and chain. 2. Install components as remov&d in steps .1 through 1. Assemble chains to engine. 19 above. Figure 6A-14 Engine Support Tool - Opel 1900 and Manta.
  • Page 302 10. Lower the front suspension assembly and remove from under car. 11. Drain engine oil and remove oil pan and gasket. Installation (Opel 1900 and Manta) Figure 6A-15 Engine Holding Fixture 1. Apply a light bead of sealer to the clean sealing surfaces of the oil pan and affix a new gasket.
  • Page 303 1973 OPEL SERVICE MANUAL 4. Connect parts removed in Steps 1 thru 8 above. INTAKE AND EXHAUST MANIFOLD REMOVAL A N D CYLINDER HEAD REMOVAL AND INSTALLATION INSTALLATION R e m o v a l R e m o v a l 1.
  • Page 304 ENGINE MECHANICAL AND MOUNTS Apply silastic sealer or equivalent to both sides of the cylinder head gasket where the gasket mates with the timing chain cover, place new cylinder head gas- ket onto cylinder block. 5. Install cylinder head. Be careful to place head squarely over guide pins.
  • Page 305 1973 OPEL SERVICE MANUAL 5. Clean carbon and gum deposits from valve guide wire brushes for removing carbon, avoid scratching bores. valve seats and valve faces. A soft wire brush such as J-8089 is suitable for this purpose. 6. Inspect valve faces and seats for pits, burned spots or other evidences of poor seating.
  • Page 306 ENGINE MECHANICAL AND MOUNTS New inlet valves must not be refaced or lapped with 10. Install cylinder head. grinding compound. The correct angle for the intake and exhaust valve head is 44 degrees. 11. Adjust valve clearance. See MAINTENANCE ADJUSTMENTS. 7.
  • Page 307 1973 OPEL SERVICE MANUAL lengthwise along the bottom center of the lower bear- Inspection of Connecting Rod Bearings and ing shell (Figure 6A-25, view A), then install cap Crankshaft Journals with shell and tighten nuts to 36 lb. ft. Do not turn crankshaft with gauge type material in bearing.
  • Page 308 ENGINE MECHANICAL AND MOUNTS The ends of she//s bearing noise, it is not necessary to replace the bear- seating and to prevent turning. must never be tiled flush with parting surface of ing. bearing cap. crankcase or 6. Loosen all crankshaft bearing cap bolts l/2 turn, and remove cap of bearing to be replaced.
  • Page 309 1973 OPEL SERVICE MANUAL pressure. If heavy pressure is required, shell was not 2. Remove flywheel. started squarely and will be distorted if force into place. 3. Punch a hole into oil seal and screw in a sheet metal screw and pull out oil seal. See Figure 6A-28.
  • Page 310 ENGINE MECHANICAL AND MOUNTS 8. Remove other rod and piston assemblies in the torque to 43 lb.ft. same manner. 9. Remove compression rings and oil rings. PISTON, RINGS AND CONNECTING RODS 10. Remove piston pin in following manner: Removal and Disassembly of Piston and Rod Assemblies a.
  • Page 311 6A. 20 1973 OPEL SERVICE MANUAL diameter at the right angle to the piston pin is greater Cylinder bores may not be the same size. Standard than the diameter parallel to the piston pin. When a replacement piston sizes are in the midpoint of the piston is checked for size, it must be measured with cylinder bore size range.
  • Page 312 ENGINE MECHANICAL AND MOUNTS 2.. Expand a telescope gage to fit the cylinder bore at cylinders, the glazed cylinder walls should be slightly right angles to the piston pin 2-l/2” from top. See dulled without increasing the bore diameter by Figure 6A-33.
  • Page 313 1973 OPEL SERVICE MANUAL b. Place tool J-23436-l in support J-6047 with small diameter bore facing upward. J-23436- 1. d. Position piston, rod, and pin guide J-23436-3. e. Line up pin on piston, and using tool J-23436-4 press pin into piston. See Figure 6A-37.
  • Page 314 Then install rubber strips in grooves in rear main bearing cap and engine front cover. Install oil pan, torquing bolts to 5 lb.ft. 14. Install (Opel 1900 and Manta) front suspension assembly. (GT) Install engine suspension cross mem- Figure 6A-39 Bolt Behind Water Pump ber.
  • Page 315 1973 OPEL SERVICE: MANUAL 5. Inspect chain tensioner for proper operation and on front side of timing chain to permit reinstallation reusability. in original position. 6. Install timing case rubber gaskets to cylinder Timing Chain Cover and Timing block. Stick on with grease as necessary. Gaskets will Chain installation somewhat overlap with oil pan gasket.
  • Page 316 ENGINE MECHANICAL AND MOUNTS Figure Installing Timing Chain Cover Oil Seal Replacing Distributor Drive Gear 1. Remove fan belt. 2. Remove fuel pump. Plug end of fuel line with a suitable stop. 3. Remove spark plug wires, distributor hold down clamp.
  • Page 317 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. 4 . C O V E R G A S K E T R E L I E F 5 .
  • Page 318 E N G I N E M E C H A N I C A L A N D M O U N T S With feeler gauge, check gear backlash. It should be 3. Remove (2) bolts holding pipe and screen assem- between .I?04 in.
  • Page 319 1973 OPEL SERVICE MANUAL Torque Part Lb.Ft. Connecting R o d Bolts ............Crankshaft Main Bearing Bolts .......... Flywheel t o Crankshaft Attaching Bolts ......Cylinder Head Attaching Bolts ..Cold 72 -Warm 58 Camshaft Sprocket Attaching Bolts ........ Generator Bracket to Cylinder Block Attaching Bolts ..............
  • Page 320 ENGINE MECHANICAL AND MOUNTS Cooling System - Type ,._...___..___..___......Liquid Cooling With Circulating Pump Filler Cap Type - Pressure _,._.,,._.,,...,,..,..,..,.,....,,......13.2-15.2 PSI Water Temperature Control ._,..__,,._.,,__.,,...,.,.,,.,,.,,.,....,,...,,,... Thermostat and Bypass Thermostat Open At ._,,.,,..,__.,..,,...,...,,..,.,,.,,............189 F. 6 Qts. Cooling System Capacity ...._...__....,,.,,.,,..,........,,....Fan Drive .,,...,,,..,,.,..,..,,..,..,,..,,,.....,..,,.,..,,....,,....
  • Page 321 SERVICE MANUAL Valve Seat and Correction Angle in Cylinder Head Intake 45” Correction .,,,.,,._.,._..___,,,.,,,,,..,,.,..,...,,..,..,,..,,..,,,..........30” Exhaust Valve Seat Angle ,,,.,,.__,.__..___.,..,,..,...,,..,..,..,..,,..,..,...,..,,,...,,......... 45” Outer Correction .,,..,,...,._.,.__..,,,..,,,................30” Valve Face Angle ,,..,,,..,.__..__.._..,,,..,,...,,..,.,..,..,..,,.,,,..,..,,,..,,,..,,,...,,........ Valve Seat Width in Cylinder Head Intake ...._..._._....,,..,..,,..,....,...,..,,,..,,..,,...,,...,,,..,....Exhaust .,..,,,..,,.___..,,..,,...,..,,,..,,...,,...,,....,,..,,..,,..,,...,.....
  • Page 322 ENGINE MECHANICAL AND MOUNTS...
  • Page 323: Cooling System

    1973 OPEL SERVICE MANUAL COOLING SYSTEM CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Cooling System and Water Pump ....... .
  • Page 324 COOLING SYSTEM remove drain plug on right.side of cylinder block. Set indicate that it meets General Motors Specification GM 1894-M. It should be recognized that this is only heater temperature control valve at full heat posi- tion. After the cooling system is drained, and plugs a temporary measure.
  • Page 325 3. Remove lower attaching and slide radiator upward and out of engine compartment. Water Pump Removal Opel radiators do not have a drain plug. Drain radia- Installation tor by first, loosening radiator cap, then remove lower hose from lower radiator tank.
  • Page 326 COOLING SYSTEM SPECIFICATIONS 1973 COOLING SYSTEM CAPACITIES Liquid Cooling With Circulating Pump Cooling System - Type ............. 13.2-15.2 PSI Filler Cap Type - Pressure _.._..__.._.._.,,.,,..,,.,,..,.,,..,,,.,,,.., .....
  • Page 327: Fuel System

    1973 OPEL SERVICE MANUAL FUEL SYSTEM ALL MODELS CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Fuel Pump ................
  • Page 328 FUEL SYSTEM must always be removed before the distributor can be flows, together with the fuel vapor, to the carburetor. Metered bores in the hose fittings of the fuel tank removed. control the air - and fuel vapor flow through the activated carbon container to the carburetor, and the EVAPORATION CONTROL...
  • Page 329 (a) Strainer must be properly seated with projections facing upward. tions, more frequent attention may be required. Figure W-4 Exploded View of Opel 1900 and Manta Fuel Tank...
  • Page 330 FUEL SYSTEM 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.
  • Page 331 1973 OPEL SERVICE MANUAL 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 Attachment at Figure Fuel Line...
  • Page 332 3. Remove fuel gauge tank unit, together with suc- tion tube and screen. Clean screen and blow out from 6. Connect battery. cover side. Flush fuel tank. SPECIFICATIONS Fuel Tank Capacity (Gallons) Opel 1900 and Manta ....................11.9 13.2 GT ............................ Electrical Fuel Gauge Type ......................
  • Page 333 1973 OPEL SERVICE MANUAL EXHAUST SYSTEMS ALL MODELS CONTENTS Page No. Subject DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: (Not Applicable) MAJOR REPAIR: Exhaust System (All Models) .., ......
  • Page 334 EXHAUST SYSTEMS Figure 6D-1 Opel 1900 and Manta Exhaust System G . T . - E X H A U S T S Y S T E M DESCRIPTION MUFFLER, FRT. W/CTR. EXHAUST PIPE, FRT. EXHAUST MUFFLER, RR. W/TAIL PIPE BUMPER, MUFFLER SUSPENSION - RR.
  • Page 335 The tension of the spring - depending on Opel GT. In the GT, the secondary throttle valve is temperature of the heater coil - decreases with rising operated by mechanical linkage from the primary temperature and the choke valve opens progressively throttle valve.
  • Page 336 CARBURETOR AND THROTTLE LINKAGE Sectional View Of 19 US Carburetor (both barrels) channels, secondary barrel) 6 Float chamber Carburetor cover 7 Idle a i r passage 3 Vent tube 8 Idle air iet 9 Idle air adjusting screw 10 Mixture adjusting screw Figure 6E-1 Sectional View of Primary and Secondary Barrels valve gradually opens...
  • Page 337 1973 O P E L S E R V I C E MANUAL Sectional View Of Carburetor 1 7 Pump lever 1 Carburetor cover 18 Diaphragm 2 Vent valve 19 D iophragm spring 3 Ball valve (pressure valve) 4 Injection tube 20 Ball valve (suction valve) 21 Float 5 Primary...
  • Page 338 The secondary valve diaphragm is operated by vacuum taken from the mixing chamber of the pri- mary barrel on the Opel 1900 and Manta only. With the primary throttle valve almost open and with en- gine speed at approximately half of the maximum...
  • Page 339 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 nozzle secondary bore just before the secondary starts feeding.
  • Page 340 CARBURETOR AND THROTTLE LINKAGE DIAGNOSIS 2. Dirt in accelerator pump circuit. 3. Defective inlet check ball. CARBURETOR 4. Defective accelerator pump pressure relief valve. Condition I Hesitation or Stall Upon Light Acceleration 5. Defective accelerator pump diaphragm. 6. Maladjusted accelerator pump linkage. Correction 1.
  • Page 341 1973 OPEL SERVICE MANUAL MAINTENANCE AND ADJUSTMENTS 4. Ad,just idle mixture screw until highest R.P.M. is obtained. Alternately adjust idle mixture screw and air speed screw until R.P.M. is obtained that is 50 IDLE SPEED ADJUSTMENT R.P.M. higher than the desired final setting. This is to be accomplished with the idle mixture screw at Idle speeds of 600 to 800 R.P.M.
  • Page 342 3200 to 3300 R.P.M. using 2 nuts on fast idle rod. spring. See Figures 6E-13 and 6E-14. Opel 19W and Manta Series The carburetor bowden control wire is properly ad- justed if, with correctly-adjusted engine idle speed, engine at operating temperature and accelerator...
  • Page 343 1973 OPEL SERVICE MANUAL Figure 6E-16 Bowden Control Wire Adjuster and Segmental Disc 4. Disconnect throttle linkage by removing lock pin and unsnapping ball socket from ball on end of throt- tle shaft. 5. Remove carburetor by removing four nuts and lockwashers.
  • Page 344 THROTTLE LINKAGE REMOVAL R e m o v a l Opel 1900 and Manta Series 1. Remove control wire from bracket and unhook it from segmental disc. See Figure 6E-16. 2. In passenger compartment, unhook wire with ball plastic bushing from accelerator pedal lever. See arrow in Figure 6E- 18.
  • Page 345 1973 OPEL SERVICE MANUAL Figure 6E-23 Removing Vacuum Case Reduction Jet Figure 6E-21 Removing Vacuum Case Lever out of carburetor housing. Nozzle is press fitted. See 5. Unscrew vacuum diaphragm cover from choke Figure 6E-24. housing. See Figure 6E-22. Figure 6E.24 Removing Accelerator Pump Discharge Figure 6E-22 Removing Vacuum Diaphragm Cover 10.
  • Page 346 CARBURETOR AND THROTTLE LINKAGE 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. See Figure 6E-25. 15.
  • Page 347 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 position, hold, and tighten lock nut. closed This is done to insure that the throttle blade will not stick closed.
  • Page 348 CARBURETOR AND THROTTLE LINKAGE ACCELERATOR PUMP PRESSURE RELIEF VALVE SEAT ALVE VENT DISCHARGE (AIR BUBBLES FROM THIS HOLE IS NORMAL) PUMP INLET VALVE EXHAUST PORT Figure 6E-33 Carburetor Fuel Bowl 36. Install new air horn gasket so that the holes in 33.
  • Page 349 GENERAL SPECIFICATIONS Compression Ratio ......................7.6 to 1 Fuel Required ........ Low Lead Fuel Tank Capacity (Gallons) 11.9 Opel 1900 and Manta...................... GT........................... 13.2 Fuel Gauge Type ......................Electrical Mechanical Fuel Pump Type ...................... Fuel Pump Drive ..................
  • Page 350 CARBURETOR AND THROTTLE LINKAGE Figure 6E-37 Carburetor Specifications...
  • Page 351: Emission Control Systems

    MAJOR REPAIR: Removal and Replacement of O.E.C.S. Units ..SPECIFICATIONS: Opel Emission Control System Specifications ..DESCRIPTION AND OPERATION containing a temperature controlled door operated by vacuum through a temperature sensor.
  • Page 352 EMISSION CONTROL SYSTEMS HEAT STOVE C O N N E C T I N G H O S E . V A C U U M D I A P H R A G M VALVE (El-METAL SPRING) V A C U U M H O S E S AIR CLEANER HOUSING CARBURETOR Figure 6F-2 Heated Air System...
  • Page 353: Exhaust Gas Recirculation System

    Whenever there All 1973 Opel 1900’s, Manta’s and GT’s is nine inches or more of vacuum in the vacuum equipped with an exhaust gas recirculation (E.G.R.) motor, the diaphragm spring is compressed, the door system.
  • Page 354: Exhaust Gas Recirculation System

    EMISSION CONTROL SYSTEMS indicated, temperature sensor is defective and must 2. With the engine “OFF”, observe damper door position through snorkel opening. If position of snor- be replaced. kel makes observation difficult “se the aid of a mir- ror. At this point damper door should be in such a EXHAUST RECIRCULATION SYSTEM...
  • Page 355: Specifications

    1973 OPEL SERVICE MANUAL Figure 6F-5 Replacing Vacuum Motor Assembly Figure 6F-6 Replacing Sensor Assembly 2. Lift vacuum motor, cocking it to one side to un- hook motor linkage at the control door. so that you can install new sensor in same position.
  • Page 356 TUNE-UP ALL MODELS CONTENTS Subject Page No. DESCRIPTION AND OPERATION: Purpose of a Tune-Up .........., ..DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: Engine Tune-Up Mechanical Operations .
  • Page 357 1973 OPEL SERVICE MANUAL Repeat 6. Check compression of each cylinder. MAXIMUM MINIMUM MINIMUM compression check and record highest reading ob- PRESSURE PRESSURE ‘RESSURE PRESSURE tained on each cylinder during the two pressure POUNDS/ checks. SQ. INCH INCH 1 3 4...
  • Page 358 any abnormal condition with sealastic or new seals 2. If inspection of contact points indicates excessive and gaskets. burning, pitting or wear, check condenser and re- place if necessary. Battery 3. Inspect all connections and wires in the primary 1. Inspect battery, battery mount and cables and ignition circuit.
  • Page 359 1973 OPEL SERVICE MANUAL SPECIFICATIONS TUNE-UP SPECIFICATIONS ADJUSTMENTS Voltage Regulator Voltage Regulator Setting in Volts at 2500 Engine RPM ..... .
  • Page 360 GROUP 7 Clutch ......TRANSMISSION Manual Transmission Automatic Transmission...
  • Page 362 Figure 7A-6. which are riveted to and extend into the eye of the yoke. Opel 1900 and Manta The clutch pressure plate is similar in design to the Buick Century pressure plate. A radially slotted dia- The pedal lever pivots on a tubular steel shaft and...
  • Page 363 1973 OPEL SERVICE MANUAL DIAGNOSIS CLUTCH TROUBLE DIAGNOSIS C o n d i t i o n Possible Cause Correction Fails to release (pedal 1. Adjust cable. pressed to floor - shift adjustment. lever does not move freely in and out of “Reverse”...
  • Page 364 CLUTCH P o s s i b l e C a u s e Correction 1. Check ball stud and retaining Rattling - Transmission 1. Yoke loose on ball stud in bearing groove. spring and replace if necessary. Click 2. Oil in driven plate 2.
  • Page 365 E-ring two grooves ahead of Figure 7A-6. washer on rubber grommet. Clutch pedal free travel is now between 3/4 and 1 l/4 inches and clutch Opel 1900 and Manta release bearing has proper clearance from pressure The clutch actuation works without clutch pedal free plate.
  • Page 366 CLUTCH 5. To remove release bearing from clutch fork, slide MAJOR REPAIR lever off ball stud against spring action. Remove ball stud lock nut and remove stud from housing. See CLUTCH REMOVAL INSTALLATION Figure 7A-2. Remove Clutch 1. Remove transmission. Refer to Manual Transmis- sion for removal procedure.
  • Page 367 1973 OPEL SERVICE MANUAL 1. FIywheeI and Pressure Plate replaced. If replacement is necessary, remove bear- ing with Tool J-21718 and Slide Hammer J-7004-1. Install new bearing using J-21706. See Figure 7A-3 Examine friction surfaces of flywheel and pressure for removal procedure and Figure 7A-4 for installa- plate for scoring or roughness.
  • Page 368 CLUTCH CONTROL CABLE REMOVAL AND INSTALLATION (SEE FIGURE 7A.6 OR 7A-7) If a new cable was installed or the cable adjustment was changed during an operation, x-adjust cable afterwards. Removal 1. Disconnect return spring and cable with ball end from release lever. Slide control cable out of eye in clutch housing.
  • Page 369 1973 OPEL SERVICE MANUAL 1 . E-RING 12. CLUTCH PEDAL FREE TRAVEL- 2 . WASHER 13. RETURN SPRING 3. RUBBER GROMMET 4. WASHER 14. RELEASE LEVER 5. SLEEVE 15. RUBBER BELLOWS 6. DASH PANEL 16. BALL STUD LOCK NUT 17. CLUTCH HOUSING 7.
  • Page 370 6. W A S H E R 17. RUBBER BELLOWS CABLE SUPPORT BRACKET 8. ADJUSTMENT SWITCH 19. NUT, CABLE SUPPORT BRACKET 9. CLUTCH PEDAL 20. DISTANCE BETWEEN RELEASE JA-7 10. RETURN SPRING LEVER AND CLUTCH HOUSING Figure JA-7 Clutch Pedal Adjustment - Opel 1900 and Manta...
  • Page 371 1973 OPEL SERVICE MANUAL Arrangement Of Clutch 14 Clutch ossy. bolt, lockwasher 1 Clutch release lever 15 Hollow space under felt ring filled Slot in lever for control cable boll with molybdenum disulfide paste 3 Assembly marks 4 Clutch assembly...
  • Page 372 Figure 7A-9 Exploded View of Clutch Pedal and Housing...
  • Page 373 1973 OPEL SERVICE MANUAL MANUAL TRANSM ISSION CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Description ................
  • Page 374: Power Flow

    M A N U A L T R A N S M I S S I O N POWER FLOW GEAR SLIDING GEAR SPEED GEAR DRIVE R E V E R S E ERSHAFT IDLER GEAR R U N I T C O U N T E R S H A F T G E A R +/ U N I T - IST S P E E D G E A R R UNIT...
  • Page 375 1973 OPEL SERVICE MANUAL POWER FLOW - 1st SPEED COUNTERSHAFT GEAR UI‘!IT DRIVE GEAR M A I DRIVE G E A R I N P U T COUNTERSHAFT GEAR UNIT 1st SPEED GEAR 1 st SPEED GEAR AND 2nd GEAR SLIDING GEAR...
  • Page 376 MANUAL TRANSMISSION POWER FLOW. 2nd SPEED COUNTERSHAFT GEAR UNIT DRIVE GEAR MAIN DRIVE GEAR (INPUT) 2nd SPEED GEAR COUNTERSHAFT GEAR UNIT 2nd SPEED GEAR 1st AND 2nd GEAR SLIDING GEAR 2nd SPEED GEAR 1st AND 2nd GEAR SLIDING GEAR MAINSHAFT (OUTPUT) 1st AND 2nd SPEED SLIDING GEAR GUIDE UNIT Figure 78.3 Second Speed...
  • Page 377 1973 OPEL SERVICE MANUAL POWER FLOW - 3rd SPEED MAIN DRIVE GEAR (INPUT) COUNTERSHAFT GEAR UNIT GEAR DRIVE 3rd SPEED GEAR COUNTERSHAFT GEAR UNIT 3rd SPEED GEAR 3rd SPEED GEAR GEAR SHIFTER SLEEVE GEAR SHIFTER SLEEVE CARRIER GEAR SHIFTER SLEEVE...
  • Page 378 MANUAL TRANSMISSION POWER FLOW - 4th SPEED GEAR SHIFTER SLEEVE MAIN DRIVE GEAR (INPUT) GEAR SHIFTER SLEEVE CARRIER GEAR SHIFTER SLEEVE MAIN SHAFT (OUTPUT) GEAR SHIFTER SLEEVE CARRIER Figure 78.5 F o u r t h S p e e d After synchronizing speeds of the main drive gear and mainshaft, the gear shifter sleeve shifts forward and locks the main drive gear to the mainshaft...
  • Page 379 1973 OPEL SERVICE MANUAL POWER FLOW - REVERSE SPEED COUNTERSHAFT GEAR UNIT DRIVE GEAR MAIN DRIVE GEAR (INPUT) REVERSE IDLER GEAR COUNTERSHAFT GEAR UNIT REVERSE SPEED GEAR REVERSE IDLER GEAR UNIT GUIDE MAINSHAFT (OUTPUT) 1st AND 2nd SPEED SLIDING GEAR GUIDE UNIT Figure 76.6...
  • Page 380: Maintenance And Adjustments

    MANUAL TRANSMISSION DIAGNOSIS MANUAL TRANSMISSION DIAGNOSIS Possible Cause C o n d i t i o n 1) Low lubricant level. Noisy in Forward Speeds 2) Incorrect lubricant. 3) Transmission misaligned or loose. 4) Front main bearing worn or damaged. 5) Mainshaft bearing worn or damaged.
  • Page 381 1973 OPEL SERVICE MANUAL GEARSHIF INTERMEDIATE SHAFT, . SHIFT FINGER1 SELECTOR LEVER JT “B’ Figure 7B-10 Figure 78-B Figure 78.1 1 3. Unhook tension spring of gearshift lever and, after removal of retaining washer, push pivot pin out of 4. After installation, check as to whether pull ring intermediate shift lever.
  • Page 382 MANUAL TRANSMISSION SPIRAL PINS Figure 78-l 2 Figure 71-14 8. Heat up new gearshift lever knob in boiling water to 176 degrees F. and push it onto lever tube. Ob- serve distance A - .3”, see Figure 7B-15. The gear- shift lever tube end is provided with transverse grooves for which reason the old button can no longer be used.
  • Page 383: Major Repair

    1973 OPEL SERVICE MANUAL 3. Install new bellows. Adhere to distance A - 8.07”. 8. Disconnect speedometer cable from transmission See Figure 7B-I 1. case extension housing. 4. Heat up new gearshift lever knob in boiling water 9. Unhook parking brake cable return spring and to 176 degrees F.
  • Page 384: Removing And Installing Speed0 Driven Gear

    MANUAL TRANSMISSION 5. Attach clutch cable. 6. Perform clutch lash adjustment. See Clutch, Sec- tions A and B for adjustment procedure. S N A P R I N G 7. After overhaul of transmission, refill with 2- l/2 pints of SAE 80 or SO-90 multi-purpose gear Iubri- cant.
  • Page 385 1973 OPEL SERVICE MANUAL Removing Transmission Case Cover Removing Shifter Shaft 1. Remove ten (10) transmission case cover bolts, 1. Remove cotter pins that secure each end of shifter cover, and gasket. shaft. See Figure 7B-20. 2. Invert transmission to drain oil.
  • Page 386 MANUAL TRANSMISSION 3. Push selector shaft out of case and remove inter- 4. With Special Tool J-2291 1 inserted, take counter- mediate levers. shaft gear unit out of transmission case. Remove both thrust washers. 4. With screwdriver, pry out selector shaft oil seals on transmission case.
  • Page 387 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.)
  • Page 388 M A N U A L T R A N S M I S S I O N SPEED DRIVE SYNCHRONIZER Figure 78.31 3. Remow snap ring from in front of clutch hub. See Figure 78.33 Removing Snap Ring Behind Speedometer Drive Gear Figure 7B-32.
  • Page 389: Transmission Reassembly

    1973 OPEL SERVICE MANUAL 1 ST SPEED GI N E E D L E B E A R I N G - CLUTCH SLEEc?iE, SNAP RING KEY SPRING Figure 7B-39 Pressing Off Small Clutch Hub Figure 70-37 7. With Special Tool J-21684, Press Plate, located 2.
  • Page 390 M A N U A L T R A N S M I S S I O N GUIDE UNIT SPRING sleeve carrier on mainshaft with snap ring. See Fig- ure 7B-40. 6. From rear of mainshaft, slide second speed gear onto mainshaft.
  • Page 391 1973 OPEL SERVICE MANUAL SHOULDER OR SHIFTE Figure 78-46 Installing Reverse Shifter Fork Figure 78.44 Mainshaft Assembly Secured Into Rear Bearing Retainer by Snap Ring 16. Place front synchronizer spring in the gear shifter sleeve carrier. Install (3) third and fourth speed shoes (short design) and gear shifter sleeve over gear shifter sleeve carrier along with synchronizer cover.
  • Page 392 M A N U A L T R A N S M I S S I O N COUNTER SHAFT GEAR T H R U S T W A S H E R Figure Countergear Thrust Washers Installed Figure Installing Spacer Ring and Needle Bearing Onto Mainshaft...
  • Page 393 1973 OPEL SERVICE MANUAL bedding bolt through reverse speed shifter intermedi- ate lever and into case. Reverse speed shifter inter- mediate lever end play on bolt should be between 2. Insert both interlock balls and then springs, and drive both interlock plugs into case holes until they bottom in interlock plug hole seats.
  • Page 394: Specifications

    MANUAL TRANSMISSION Installing Gearshift Interlock Ball 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. Installing Gearshift Linkages Figure 78.55 Pin and Bracket Securing Selector Lever to Intermediate Shaft and Bearing Retainer 1.
  • Page 395 1973 OPEL SERVICE MANUAL Engine Transmission Figure 78-57 Exploded View of Manual Transmission...
  • Page 396 TRANSMISSION Case, Transmission Bearing, Trans. Main Shaft Needle - Right Gasket, Trans. Case to Clutch Housing Gear, Speedometer Drive 3 Cap, Ventilator Washer, Speedo Drive Gear 4 Gear, W/Bushings, ReverSe Idler Ring, Speedo Drive Gear Snap 5 Shaft, Reverse Idler Gear Retainer, R.R.
  • Page 397 1973 OPEL SERVICE MANUAL CONTENTS Subject Page No. DESCRIPTION AND OPERATION: Description of the Opel Three-Speed Automatic , Transmission ..............Principles of Operation ............ Component Operation and Location ......Mechanical Operation ............Hydraulic Control Units and Valves ......DIAGNOSIS: Sequence for Trouble Diagnosis ........
  • Page 398: Description And Operation

    See Figure 7C-71. Automatic DESCRIPTION upshifts and downshifts are controlled by road speed, The Opel Three-Speed Automatic is a fully auto- engine vacuum and an accelerator pedal connection to the transmission.
  • Page 399: Principles Of Operation

    It also multiplies the torque from the engine under certain conditions of input and output speed. The torque converter used in the Opel three speed automatic transmission consists of three basic ele- ments: the pump (driving member), the turbine...
  • Page 400 AUTOMATIC TRANSMISSION TURBINE TURBINE P U M P MEMBER) DRIVEN TURBINE P U M P Figure 7C-4 Oil Flow Without Stator If the counterclockwise spinning oil were allowed to return directly to the converter pump, the oil would strike the inner section of the pump blades in a direc- tion that would hinder its rotation, cancelling out any gains in torque that have been obtained.
  • Page 401 The simplest planetary gear set consists of a center or sun gear, internal or The gear set used in the Opel Three Speed Automatic ring gear and a planetary gears called planetary pin- transmission is known as a Ravigneaux planetary...
  • Page 402 AUTOMATIC TRANSMISSION Figure 7C-6 Oil Flow With Stator Active gear set and utilizes two sets of planetary pinions in clockwise direction (when viewed from the front) one planet carrier, two sun gears and one ring gear. turning the short planet pinions counterclockwise See Figure 7C-8.
  • Page 403 1973 OPEL SERVICE MANUAL PLANETARY CARRIER Figure 712-10 First Gear Figure 7C-7 Planetary Gears LONG PINION LONG PINION HORT PINION PLANETARY CARRIER Figure 7C-1 1 Second Gear Figure 7C-8 Ravigneaux Planetary Gears In reverse, the ring gear is held and the input (front) sun gear is driven in a clockwise direction.
  • Page 404 A U T O M A T I C T R A N S M I S S I O N method of apply in an automatic transmission is a hydraulic piston. LONG PINION One set of plates is lined with friction material and the other plates are steel.
  • Page 405: Component Operation And Location

    !See Figure 7C-19. The band is connected to the case (stationary anchor) and is ope- rated by a servo piston. One band is used in the Opel S P R Three: Speed Automatic Transmission and holds the reaction sun gear...
  • Page 406: Automatic Transmission

    AUTOMATIC TRANSMISSION Figure 7C-20 Converter. Converter Housing And oil Pump INPUT SHAFT AND THIRD CLUTCH DRUM Figure 7C-21 Input Shaft And 3rd Clutch Drum...
  • Page 407 1973 OPEL SERVICE MANUAL T H I R D C L U T C H A S S E M B L Y Figure 7C-22 Third Clutch Drum, Piston and Springs, Clutch Plates, Input Sun Gear. Sprag Race And Retainer Assembly...
  • Page 408 AUTOMATIC TRANSMISSION SECOND CtUTC 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 D R U M Figure 7C-24 Oil Pump. Reverse Clutch Piston, Springs, Clutch Plates and Second Clutch Drum...
  • Page 409: Mechanical Operation

    The following information describes how engine located in the sump. See Figure 7C-29. Since the torque is transmitted through the Opel Three Speed pump drive gear is keyed to the converter pump hub, automatic transmission for each selected position on it turns whenever the engine is operating and turns the quadrant.
  • Page 410 AUTOMATIC TRANSMISSION Figure 7C-26 Governor Assembly And Speedometer Drive Gear 1. Main pressure regulator valve. the sump. The oil is carried past the crescent section of the pump, beyond which the gear teeth begin to squeezed come together, pressurizing the oil as it is 2.
  • Page 411 1973 OPEL SERVICE MANUAL 3. Detent pressure regulator valve. 4. 1 - 2 Accumulator valve. 5. Governor. B. Selector valves (manually and hydraulically con- trolled). 2. Detent valve. 3. 1 - 2 Shift valve. 4. 2 - 3 Shift valve.
  • Page 412 AUTOMATIC TRANSMISSION Modulator pressure is then directed to: Pressure regulator boost valve. 2 - 3-Shift control valve by way of the 3 - 2 control valve. Detent Valve. Low Speed Downshift Timing Valve. Detent Pressure Regulator Valve VACUUM MODULATOR The regulating action of the Detent Pressure Regula- tor Valve is essentially the same as for the Modulator Valve, except that it regulates a constant pressure.
  • Page 413 1973 OPEL SERVICE MANUAL that is a function of output shaft or car speed. Line pressure is supplied to the governor from the Manual Valve (to be covered later). The governor operates on the principle of centrifugal force. That is, as an object spins off center at changing speeds, its outward force is a function of the rotating speed.
  • Page 414 AUTOMATIC TRANSMISSION mission to shift to a lower gear for additional per- Manual Valve formance when the accelerator depressed all the The manual valve is mechanically connected to the shift lever. Its function is to direct hydraulic pressure The detent valve is mechanically connected to the to the various circuits to establish the base hydraulic throttle linkage.
  • Page 415 1973 OPEL SERVICE MANUAL will move the shift valve to a downshifted position regardless of car speed. 2 3 ,Shift Valve and 3 - 2 Control Valve The function and operation of the 2 3 Shift and Shift Control Valves is the same as for the I 2 valve except as described below.
  • Page 416 AUTOMATIC TRANSMISSION and forces the low control valve into the same posi- valve will be held in downshifted, or second gear, tion as in manual “Low”. This causes the third condition regardless of car speed. clutch to be applied. Manual Low and Reverse Control Valve Boost Control Valve As described in the text on “Mechanical Operation”, To obtain the required pressure increase previously...
  • Page 417 1973 OPEL SERVICE MANUAL MODULATOR Figure 7C-42 Low Speed Downshift Timing Valve Figure 7C-43 High Speed Downshift Timing Valve During a “coast” condition, the vacuum is high and the modulator pressure is zero. The spring holds the Second Clutch Orifice Valve...
  • Page 418 AUTOMATIC TRANSMISSION ACCUMULATOR SERVO Figure 7C-46 1-2 Accumulator Figure 7C-47 Low Servo Accumulator Low Servo In order to obtain a smooth 1-2 upshift, it is neces- The low servo provides a dual function. See Figure sary to control the rate of pressure build-up in the second clutch.
  • Page 419 1973 OPEL SERVICE MANUAL a . N E U T R A L & P A R K - E N G I N E R U N N I N G Neutral - Engine Running Third Clutch - Released Reverse Clutch.
  • Page 420 A U T O M A T I C T R A N S M I S S I O N b . D R I V E R A N G E . F I R S T G E A R Third Clutch.
  • Page 421 1973 OPEL SERVICE MANUAL c. DRIVE RANGE. SECONO GEAR Third Clutch - Released Reverse Clutch - Released Low Band -Applied Second Clutch -Applied Sprag - Overrunning In Drive Range. Second Gear, the low band and second clutch are applied. The input shaft drives the third clutch drum and the second clutch composition plates. When the second clutch piston is applied, the rotating second clutch composition plates are locked w the second clutch steel plates.
  • Page 422 A U T O M A T I C T R A N S M I S S I O N 7C- 61 d. DRIVE RANGE - THIRD GEAR Drive Range - Third Gear Third Clutch -Applied Reverse Clutch - Released Low Band - Released Second Clutch.
  • Page 423 Third Clutch -Applied Low Band. Released...
  • Page 424 AUTOMATIC TRANSMISSION ?C-...
  • Page 425 1973 OPEL SERVICE MANUAL HYDRAULIC OPERATION...
  • Page 426 O p e r a t i o n o f C o n t r o l s i n N e u t r a l E n g i n e R u n n i n g Third Clutch Released Reverse Clutch Released Second Clutch Released...
  • Page 427 1973 OPEL SERVICE MANUAL...
  • Page 429 1973 OPEL SERVICE MANUAL II II...
  • Page 430 Reverse Clutch Released Third Clutch Released Second Clutch Applied L o w B a n d A p p l i e d O v e r R u n n i n g 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 the I 2 shift valve spring pressure and allovn drive oil 10 pasr through the valve Second clutch oil passes through the second clutch orifice control valve, seating the ball and is metered to the second clutch piRon to begin to apply the second clutch, while...
  • Page 431 1973 OPEL SERVICE MANUAL...
  • Page 432 O p e r a t i o n o f C o n t r o l s i n D r i v e R a n g e T h i r d Geat Reverse Clutch Released Third Clutch-Applied S e c o n d Clutchs...
  • Page 433 1973 OPEL SERVICE MANUAL...
  • Page 434 Operation of Controls in Second Range Second Gear Reverse Clutch Re eased Third Clutch Released Seconds Clutch Applied L o w B a n d A p p l i e d O v e r R u n n i n g The selector lever is moved to the Intermediate position an the quadrant.
  • Page 435 1973 OPEL SERVICE MANUAL...
  • Page 436 f . O p e r a t i o n o f C o n t r o l s i n L o w R a n g e F i r s t Gea Reverse Clutch Released T h i r d C l u t c h A p p l i e d Second Clutch Released L o w B a n d A p p l i e d...
  • Page 437 1973 OPEL SERVICE MANUAL...
  • Page 438 Reverse Clutch -Applied Third Clutch. Applied Second Clutch Released Low Band. Released L o c k e d When the selector leer is moved to the Reverse position on the quadrant, the manual valve valve into the Reverse oil passage. The reverse oil applies the reverse clutch.
  • Page 439 1973 OPEL SERVICE MANUAL...
  • Page 440 h . O p e r a t i o n o f Controlr d u r i n g D e t e n t D o w n s h i f t V a l v e s i n Second G e a r P o s i t i o n Reverse Clutch Released Third...
  • Page 441 1973 OPEL SERVICE MANUAL...
  • Page 442: Checking Procedures

    1. Road test and bring the transmission to operating When checking oil level in the Opel Three Speed temperature, approximately 180 degrees F. Automatic Transmission, the procedure outlined in Specifications should be followed to obtain the most 2.
  • Page 443 1 9 7 3 O P E L S ERVICE MANUAL A U T O M A T I C T R A N S M I S S I O N T R O U B L E DIAGNOSIS CHART C o n d i t i o n Concerns Transmission Oil...
  • Page 444 AUTOMATIC TRANSMISSION 7C- Cause Condition Starting 1. No starting in any drive a) Low oil level. range. b) Clogged suction screen. c) Manual valve linkage or inner trans- mission selector lever disconnected. d) Input shaft broken. position. 2. No starting in any drive range Manual valve position does not coincide with valve body channels: for a time.
  • Page 445 1973 OPEL SERVICE MANUAL Condition C a u s e a) Reverse clutch failure. 8. No starting in “R” range (proper driving in all other r a n g e s ) . 9. Drive in selector lever a) Inadequate selector lever linkage.
  • Page 446 T R A N S M I S S I O N 7C- 85 C o n d i t i o n 8. After full throttle upshifting a) Detent valve stuck in open position, transmission shifts immediately b) Detent cable stuck. into lower gear upon easing off c) Modulator vacuum line interrupted.
  • Page 447 1973 OPEL SERVICE MANUAL Cause Condition 6. Abrupt 3-2 coast downshift. a) Low speed downshift timing valve stuck open. 7. Flare on high speed forced a) Low oil pressure. b) Band adjustment loose downshift. 8. Flare on low speed forced a) Low oil pressure.
  • Page 448: Hydraulic Pressure Checks

    A U T O M A T I C T R A N S M I S S I O N HYDRAULIC PRESSURE CHECK SHIFT POINTS SPECIFICATIONS HYDRAULIC PRESSURE CHECKS OPERATING CONDITIONS Detent Downshift Possible NOTE: ON REPLACING PLUG, TOROUE TO 6.7 LEFT. 4.
  • Page 449 1973 OPEL SERVICE MANUAL CONVERTER O U T PRIMING VALVE B O R E a !EI 2ND CLUTCH REVERSE CLUTCH CONVERTER i O U T MODULATOR - EXHAUST REVERSE CLUTCH INTERMEDIATE 2ND CLUTCH 3RD CLUTCH B O O S T...
  • Page 450 AUTOMATIC TRANSMISSION 7C- DRIVE SERVO LINE REVERSE SERVO APPLY MODULATOR OR Figure 7C75 Valve Body Top...
  • Page 451 1973 OPEL SERVICE MANUAL , UNE REVERSE SUCTION BOOST SHIFT SERVO RELEASE LOW SERVO A P P L Y - R E G U L A T O R DRIVE RNOR Figure 7C-76 Case Bottom...
  • Page 452: Maintenance And Adjustments

    For proper model iden- tification, see Figures 7C-61, 7C-62, 7C-63, and 7C- Figure JC-81 GT Models Figure JC-79 Opel 1900 and Manta Figure JC-93 GT Models Removal age.
  • Page 453 1973 OPEL SERVICE MANUAL Figure 7C-86 Figure 7C-84 Figure 7C-85 5. Unhook detent cable from detent valve. See Figure Figure 7C.87 Pry detent cable pipe out of retainers. Adjustment 7. Unscrew upper and lower adjuster nuts and remove detent cable (on Manta models, loosen lock Before carrying out any adjustment to the detent nut and screw adjuster out of bulkhead).
  • Page 454: Servicing Selector Lever

    AUTOMATIC TRANSMISSION 7C- 93 2. Unplug cigar lighter and lamps from console and (on Manta models, turn adjuster) until ball end of cable rests firmly against lever. From below vehicle, remove selector rod from 2. At this point, measure length of exposed detent intermediate selector lever.
  • Page 455: Major Repair

    Figure 7C-93 MAJOR REPAIR REMOVAL AND INSTALLATION OF AUTOMATIC TRANSMISSION Removal - Opel 1900 and Manta 2. Remove dipstick. 3. Remove screws from fan shroud. 4. Remove 2 upper starter bolts. 5. Raise car and provide support for front and rear and drain oil.
  • Page 456 J-21366. Lower transmission and 4. Remove screws from fan shroud. move to bench. 5. Raise car and provide support for front and rear. Opel 1900 and Manta Installation. 6. Remove heat protection shield from right side to make room for exhaust pipe removal.
  • Page 457 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. See Figure 7C-97.
  • Page 458 AUTOMATIC TRANSMISSION JC- 97 Figure 7C-103 Figure 7C-101 Figure 7C-102 Figure 7C-104 19. Pry detent cable and oil cooler pipes out of retain- 23. Mark flex plate and converter for reassembly in ers on transmission oil pan. same position. Unscrew speedometer cable and pull it out of 24.
  • Page 459 1973 OPEL SERVICE MANUAL 6. Install lower bolt on starter. Torque to 40 lb.ft. 7. Connect modulator line. 8. Connect speedometer cable. 9. Connect shift linkage. 10. Install transmission support. 11. Install drive shaft. Torque U-bolts to 18 lb.ft. 12. Install flywheel cover pan.
  • Page 460: Removal Of Oil Pan

    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.
  • Page 461: Removal Of Servo Piston

    1973 OPEL SERVICE MANUAL F i g u r e 7C-1 14 Figure 7C-1 12 2 . Using pliers, remove servo piston snap ring. See Figure X-1 15. Figure 7C-1 13 6. Remove the two check balls located in the oil Figure 7C-1 15 passages in the transmission case.
  • Page 462: Removal Of Modulator Assembly

    AUTOMATIC TRANSMISSION Figure 7C-118 GT Models Figure 7C-1 16 -117 Figure 7C-119 Figure 7C-1 17 GT Models that one case services both models and is machined 5. Remove selector lever shaft. See Figure 7C-120. to accept selector lever on either side with the unused hole being plugged.
  • Page 463: Removal Of Detent Valve Assembly

    1973 OPEL SERVICE MANUAL Figure 7C-122 Figure 7C-120 Removal of Extension Housing This operation can be performed with transmission in vehicle 1. Remove bolt holding speedometer driven gear housing retainer and carefully remove retainer and pull speedometer driven gear assembly from exten- sion housing.
  • Page 464: Removal Of Speedometer Drive Gear, Governor Body And Governor Hub

    A U T O M A T I C T R A N S M I S S I O N 3. Remove extension housing and gasket. See Figure Figure Figure 7C-126 4. Remove parking paw1 actuator rod from transmis- 3.
  • Page 465: Removal Of Third Clutch Assembly, Planetary

    1973 OPEL SERVICE MANUAL bolts which are the outer bolts in the housing. See Figure 7C-129. PLATES Figure 7C-13 I Removal of Third Clutch Assembly. Planetary Figure 7C-129 Carrier Assembly, Reaction Sun Gear and Drum Assembly and Low Band 3. Remove...
  • Page 466: Disassembly, Inspection And Reassembly Of

    A U T O M A T I C TRANSMISSION 7C-105 Figure 7C-135 Figure 7C-133 thrust bearing and race from case by pulling straight out. See Figure 7C-134. Figure 7C-134 4. Remove needle thrust bearing and race from rear 6. If necessary to remove case vent, install new case of case.
  • Page 467 1973 OPEL SERVICE MANUAL REVERSE OIL PUMP Figure 7C-140 Figure 7C-138 7. Inspect front face of converter housing for oil leak. 2. Remove selective washer from oil pump shaft. See See Figure 7C-141. If problem is diagnosed as a front Figure 7C-138.
  • Page 468 AUTOMATIC TRANSMISSION 12. Mark relative location of oil pump gears and remove oil pump gears. See Figure 7C-144. J-8092 CONVERTER Figure 7C-144 13. Using compressor tool J-2590-12 with adapter Figure 7C-142 J-21420-1 on reverse clutch retaining seat, compress clutch return springs. See Figure 7C-146. 10.
  • Page 469 1973 OPEL SERVICE MANUAL 1. RETAINING PIN 2. PRESSURE REGULATOR BOOST VALVE SLEEVE 3. PRESSURE REGVLATOR BOOST VALVE 4. PRESSURE REGULATOR VALVE SPRING SEAT PRESSURE REGULATOR VALVE SPRING 6. PRESSURE REGULATOR VALVE 7. OIL PUMP BODY 8. OIL PUMP PRIMING VALVE, SPRING 8 SPRING SEAT 16.
  • Page 470 AUTOMATIC TRANSMISSION Figure 7C-149 27. Install priming valve assembly from front face of 21. Using a drift on tap, press out oil pump bushing pump. Priming valve retainer should be pressed in with arbor press. Use rag or cloth to protect oil pump flush with surface of oil pump body.
  • Page 471 1973 OPEL SERVICE MANUAL SEAL REVERSE CLUTCH Figure 7C-151 Figure 7C-153 Figure 7C-154 Figure 7C-152 34. Install retaining seat. 30. Install new oil seals on reverse clutch piston. See Figure 7C-153. 31. Install reverse clutch piston onto rear face of oil 35.
  • Page 472: Disassembly, Inspection And Reassembly Of Second Clutch

    A U T O M A T I C T R A N S M I S S I O N Disassembly, Inspection and Reassembly of Second Clutch 1. Remove ring gear retaining ring from second clutch drum. See Figure X-157. OIL PUMP /’...
  • Page 473 1973 OPEL SERVICE MANUAL SECOND TO THIRD CLUTCH SECOND CLUTCH SPACER ----I Figure 7C-159 Figure 7C-161 8. Remove snap ring using snap ring pliers such as 5. Remove second clutch steel and composition J- 8059. See Figure 7C-162. plates. The plates should be kept in the same se- quence as they were installed in the clutch.
  • Page 474 AUTOMATIC TRANSMISSION 15. Clean in solvent to remove any foreign matter. 12. Inspect the piston return springs. Evidence of Install new second clutch hub bushing using tool J- extreme heat or burning in the area of the clutch may would 23 130-6 and driver handle J-8092.
  • Page 475: Disassembly, Inspection And Reassembly Of Third Clutch

    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.
  • Page 476 AUTOMATIC TRANSMISSION INPUT SPRAG RACE 8 RETAINER ASSEMBLY GEAR CLUTCH HUB Figure 7C-169 Figure 7C.17 I 7. Remove snap ring using snap ring pliers such as 3. Push sprag assembly and retaining rings from sprag race and retainer. See Figure 7C-170. SPRAG RACE RETAINER , SPRAG ASSEMBLY...
  • Page 477 1973 OPEL SERVICE MANUAL DRUM THIRD CLUTCH PISTON Figure 7C-176 Figure 7C-174 damaged, replace piston. Install new lip seal on pis- ton. See Figure 7C-175. CHECK Figure 7C-177 so that lip seal is not damaged upon installation. See Figure 7C-178.
  • Page 478 AUTOMATIC TRANSMISSION 23. Inspect sprag assembly for wear, damage or gear for chipped or nicked teeth or abnormal wear. Replace part if necessary. 24. Install sprag onto third clutch hub with groove on sprag cage outer diameter toward input sun gear. See Figure 7C-179.
  • Page 479 1973 OPEL SERVICE MANUAL Inspection and Reassembly of 26. Align third clutch composition plates and install Carrier third clutch hub to index with the third clutch plate 1. Inspect the planetary carrier and output shaft for must also spline into third clutch drum. See Figure distortion or damage.
  • Page 480 driver and remove secondary valve spring retainer. See Figure 7C-187. S ,ECONDARY SECONDARY VALVE Figure 7C-187 2. Remove secondary valve spring, secondary valve, primary valve, and roll pin from governor body. See Figure 7C-188. Figure 7C-185 REACTION SUN GEAR D R U M GOVERNOR SECONDARY VALVE...
  • Page 481 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.
  • Page 482 AUTOMATIC TRANSMISSION 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. Disassembly, Inspection and Reassembly of Valve B o d y 1.
  • Page 483 1973 OPEL SERVICE M A N U A L 1. SERVO PISTON RETURN SPRING 7 . S E R V O P I S T O N 2. SERVO PISTON APPLY ROD 8. SERVO PISTON RETAINING RING 3. SERVO PISTON ADJUSTING SLEEVE 9.
  • Page 484 AUTOMATIC TRANSMISSION 8. Inspect accumulator oil ring for damage or edge 7. Remove accumulator piston, oil ring, and spring. wear and piston for damage. Replace if necessary. See Figure 7C-200. For steps 9 through 21 refer to Figure 7C-201. ACCUMULATOR PISTON 9.
  • Page 485 1973 OPEL SERVICE MANUAL 14. Remove the downshift timing valve plug retain- clean out the valve body passages and valve bore. ing pin and remove downshift timing valve plug. Compressed air may be used to blow out the pas- Remove the low speed downshift timing valve and sages.
  • Page 486 AUTOMATIC TRANSMISSION 1. Drain Converter. If clutch disc material or foreign matter has been found while draining con- verter, replace entire converter assembly as it can not be cleaned properly. 2. Air check converter for leaks using converter checking tool J-21369. Install tool and tighten. Ap- ply 80 psi air pressure to tool.
  • Page 487 1973 OPEL SERVICE MANUAL n-205 6. INPUT SUN GEAR ASSEMBLY BEARING 7. INPUT SUN GEAR ASSEMBLY TO PLANETARY 2. 2ND CLUTCH ASSEMBLY TO 3RD CLUTCH CARRIER ASSEMBLY WASHER ASSEMBLY BRONZE THRUST WASHER 9. REACTION SUN GEAR BEARING ASSEMBLY 3. 2ND CLUTCH ASSEMBLY TO 3RD CLUTCH ASSEMBLY STEEL THRUST WASHER 11.
  • Page 488 AUTOMATIC TRANSMISSION ?C-127 INPUT SHAFT Figure 7C-2 10 Figure 7C-208 1. Place needle thrust bearing race on rear of Installation of Output Shaft and Planetary Carrier case around the case bushing. Secure with petroleum jelly (unmedicated). 1. Install input sun gear to planetary carrier washer and bearing into carrier.
  • Page 489 1973 OPEL SERVICE MANUAL Installation of Reverse Clutch 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. See Fig- ure x2- 212. A. Dry composition plates with compressed air and inspect the composition surface for: 1.
  • Page 490 AUTOMATIC TRANSMISSION 2. Insert guide pin into oil pump for alignment of 4. Install reverse clutch cushion plate (wave washer) into case. converter housing and lower housing onto pump. 3. Install new oil seal washers on converter housing Determining Selective Washer Size to oil pump bolts, and loosely install bolts into con- verter housing.
  • Page 491 1973 OPEL SERVICE MANUAL Figure 7C-219 Figure 7C-2 17 into case. See Figure 7C-218. Use liberal amount of transmission fluid on oil seal rings. GOVERNOR Figure 7C-220 Figure 7C-2 18 7. While depressing retaining clip, slide speedometer gear over output shaft and install gear and retaining clip.
  • Page 492 AUTOMATIC TRANSMISSION 4. Bolt extension housing to rear of case. Torque to 20-30 Ibs. ft. See Figure 7C-221. Figure 7C-22 1 Figure Installation Speedometer Driven Gear 2. Install detent valve, sleeve, spring, spring seat 1. Install speedometer driven gear and housing into into case bore using liberal amount transmission...
  • Page 493 1973 OPEL SERVICE MANUAL Figure 7C-226 Figure 7C.224 Figure 7C-227 Figure 7C-225 2. Install new case to transfer plate 4. Using 3/16” hex head wrench on servo adjusting gasket. bolt, adjust servo apply rod by tightening adjusting bolt to 40 lbs. in. Back off bolt five (5) turns.
  • Page 494 AUTOMATIC TRANSMISSION BODY x-220 Figure 7C-230 Figure 7C-228 Figure 7C-229 Figure 7C-231 6. Install small end of manual valve link “A” into Torque to 13-15 Ibs. ft. selector lever and install valve body and transfer plate assembly over guide pins. See Figure 7C-23 1. 11.
  • Page 495 12,ooO miles. Checking and Adding Fluid The Opel three-speed automatic is designed to oper- ate at the full mark on the dipstick at normal operat- ing temperature (180 degrees F.) and should be checked under these conditions.
  • Page 496 Assembly 2. lmmediately check fluid level with selector lever in Park, engine running, and vehicle on LEVEL sur- The fluid capacity of the Opel Three Speed Auto- face. matic transmission and converter assembly is ap- At this point, when a reading is made, fluid level on...
  • Page 497 1973 OPEL SERVICE MANUAL sand,. mud, or snow, move the selector lever from “D” to “R” in a repeat pattern while simultaneously straight-ahead position. applying moderate pressure to the accelerator. Do Rocking Car not race engine. Avoid spinning wheels when trying it becomes necessary to rock the car to free it from free the car.
  • Page 498 A U T O M A T I C T R A N S M I S S I O N X-137 F. OPEL AUTOMATIC TRANSMISSION LINKAGE ADJUSTMENT 1. REMOVE LOCK CLIP 2 . P L A C E L E V E 3.
  • Page 499 1973 OPEL SERVICE MANUAL Figure Special Tools. Automatic Transmission...
  • Page 500 AUTOMATIC TRANSMISSION SPECIAL TOOLS Transmission Holding Fixture J-8763-01 Leak Test Fixture Converter J-8400-1 Cape Chisel Holding Fixture Base J-3289-20 J-23130-3 Rear Case Bushing Remover and Installer Driver Handle J-8092 J-21359 Converter Housing Oil Seal Installer Extension Housing Oil Seal Installer J-21426 Converter Housing Seal Remover - Without Disassembling Transmission 9.
  • Page 501 J-7004-1 SLIDE HAMMER J-2291 3 MAIN SHAFT ASSEMBLY TOOL J-22929 SPEEDOMETER DRIVEN GEAR REMOVER AND INSTALLER J - 2 2 9 2 2 J-22926 SPEEDOMETER DRIVEN TRANSMISSION CASE EXTENSION GEAR PIN REMOVER HOUSING SEAL INSTALLER J-21715 DETENT PIN PLUG REMOVER J-22934 CLUTCH PLATE ALIGNING ARBOR J-22923...
  • Page 502 G R O U P 8 HOOD, Section Page No. FENDERS, Hood Fenders, and Grille’. GRILLE...
  • Page 503 HOOD, FENDERS, AND GRILLE CONTENTS Page No. Subject DESCRIPTION AND OPERATION: GT Headlamp Operation ..........DIAGNOSIS: (Not Applicable) MAINTENANCE ADJUSTMENTS...
  • Page 504 REMOVAL AND INSTALLATION OF FENDER (OPEL 1900. MANTA) 2. Remove and install radiator grille. 3. Remove and install headlamp covering. 4. Remove and install side panel trim pad.
  • Page 505 1973 OPEL SERVICE MANUAL 2. In engine compartment unscrew headlamp cover- ing. Se:e Figure SA-7. Figure SA-5 Location of Fender Attaching Bolts 9. Fit new fender apply a sealing compound, as required, to joint. See Figure SA-6. Figure 8A-7 Headlamp Covering Attaching Bolts Installation 1.
  • Page 506 HOOD, FENDERS, AND GRILLE 6. To avoid damage cover headlamp upper and lower 2. Remove headlamp assembly and remove multiple edges with tape. plug from wire set. Turn headlamp 90 degrees and carefully remove 3. Disconnect Bowden control wire(B). Loosen link- headlamp housing in direction of arrow.
  • Page 507 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...
  • Page 508 (2) plastic caps. 2. Install hex head screw and washer holding grille extension to baffle plate. REMOVAL AND INSTALLATION OF RADIATOR GRILLE (OPEL 1900. MANTA) A. Removal (Model 57) Figure 8A-16 Removing Radiator Grille 1. Remove the five (5) radiator grille attaching Installation (Model 57) screws.
  • Page 510 GROUP 9 Section Title Page No. HEATER O p e l CONDITIONING ACCESSORIES Refrigerant C o m p o n e n t s Air Conditioner System O p e l 1900~Manta. Air Conditioner System RADIO G T ....O p e l...
  • Page 511: Flow-through Ventilation System

    HEATER SYSTEM - GT CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Flow-Through Ventilation System ........ Heater System Description ..........Heater System Operation ..........DIAGNOSIS: Heater and Defroster ............MAINTENANCE AND ADJUSTMENTS: Control Cable Adjustment ..........MAJOR REPAIR: Removal 81 Installation Instrument Panel Fresh Air Outlet ..............
  • Page 512 HEATER SYSTEM. GT Figure 9A-‘2 Heater Assembly-Rear View control (See Figure 9A-4) opens and closes the air The heater-defroster air door directs the air to the inlet and heater-defroster air door which channels floor outlets, defroster outlets, or apportions the air flow to both outlets depending on the position of the the air flow to either the heater outlets or to defroster door.
  • Page 513: Heater System Operation

    Check thermostat operation by measuring tempera- ture of coolant at radiator. Temperature should be within 5 degrees F. of thermostat rated value (189 degrees F.). Check that air doors and water temperature control Check for plugged heater core--backflush heater core as necessary.
  • Page 514: Major Repair

    HEATER SYSTEM - GT 2. Detach coolant feed (A) and return (B) hoses, in MAJOR REPAIR engine compartment from heater core. See Figure R E M O V A L A N D I N S T A L L A T I O N I N S T R U M E N T PANEL FRESH AIR OUTLET R e m o v a l 1.
  • Page 515 b. Remove retaining screw in headlamp lever handle 6. Remove two multiple wire plug connectors from and remove handle. steering column harness. 7. Detach speedo cable type studs, unsnap studs by prying cover up and work cover upwards over shift lever and rubber shift 8.
  • Page 516 HEATER SYSTEM - GT 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.
  • Page 517: Removal & Installation Defroster Outlet

    1973 OPEL SERVICE MANUAL 12. Install the console shift cover between the seats Installation using the following instructions: 1. Install heater blower and case assembly, securing a. Install console cover over shift lever and rubber with one (1) bolt at the top and two (2) nuts from the shift lever boot.
  • Page 518: Removal 81 Installation Heater Valve

    HEATER SYSTEM. GT REMOVAL AND INSTALLATION HEATER VALVE Removal Installation 1. Install valve into heater hoses and install hose 1. Remove lower radiator hose and drain and collect clamps. coolant. 2. Connect control cable. 2. Disconnect control cable. 3. Install lower radiator hose and add collected coo- 3.
  • Page 519 1973 OPEL SERVICE MANUAL HEATER SYSTEM OPEL 1900 - MANTA CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Heater System . . . , ..............
  • Page 520 HEATER SYSTEM. OPEL 1900. MANTA 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. Lever positions: Left to Center - Motor Switched Off...
  • Page 521 1973 OPEL SERVICE MANUAL (ground wire only on vehicles with radio interference Check that air doors and water temperature control suppression). See Figure 9A-33. valve are operating properly. Check for plugged heater core-backflush heater core as necessary. TROUBLE Inadequate defrosting action.
  • Page 522 HE iATER S Y S T E M - O P E L 1 9 0 0 - M A N T A Figure SA-35 Heater Core Figure SA-36 Removing Heater Switch Lever Installation 5. Remove radio. 6. On right side, viewed in driving direction, remove 1.
  • Page 523 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. See Figure 6. Install radio.
  • Page 524 HEATER SYSTEM. OPEL 1900. MANTA Figure 9A-4 1 Bowden Wire Attachment Figure 9A-43 Blower Switch Wires A - Yellow Wire B - Grey Wire C - Brown Wire 3. Attach bowden control wire to air distribution flap. See Figure 9A-42.
  • Page 525 1973 OPEL SERVICE MANUAL Figure 9A-46 Heater Motor Attaching Screws Figure 9A-44 Shroud Cover Attachments Figure 9A-47 Sealing Shroud Figure 9A-45 Heater Motor Wires Installation 3. Seal shroud cover front and rear contacting areas 1. Install heater motor, attaching with three (3) with sealing cement.
  • Page 526: Specifications: Specifications

    Receiver-Dehydrator . Opel 1900 . Manta ....9 0 - 5 8 GT ..........Removal and Installation Evaporator and Expansion Valve - Opel 1900 . Manta ....G T ............Disassembly and Reassembly of Clutch Drive Plate and Shaft Seal ............
  • Page 527: Description And Operation

    1973 OPEL SERVICE MANUAL DESCRIPTION AND OPERATION ject. :Like water, which always flows down-hill, heat always flows down a temperature scale - from a warm level down to a colder one. When we hold our FUNDAMENTAL PRINCIPLES OF REFRIGERATION hands out toward the fireplace, heat flows from the hot fire out to our cold hands (Fig.
  • Page 528 REFRIGERANT COMPONENTS ALL MODELS sometimes heat will disappear without leaving a sin- gle clue. Ice vs. Water for Cooling would forget to refill the ice-box. Occasionally, as the last sliver of ice melted away, somebody would come up with a bright idea. He would remember that the water in the drain-pan always felt ice-cold when he had emptied it other times.
  • Page 529 1973 OPEL SERVICE MANUAL a gas. It just depends on the temperature whether If we were to put a thermometer in the cold drain water, we would see the temperature gradually creep water for example was a liquid, or a solid (ice), or gas (steam) (Fig.
  • Page 530 REFRIGERANT COMPONENTS ALL MODELS put a flask of R-12 inside a refrigerator cabinet, it about heat instead of refrigeration. But in doing so, would boil and draw heat away from everything sur- we have learned how a simple ice-box works. It’s rounding it (Fig.
  • Page 531 1 9 7 3 O P E L S E R V I C E M A N U A L 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.
  • Page 532 REFRIGERANT COMPONENTS ALL MODELS Figure 98.14 Evaporator Assembly to do is remove the heat it contains. Since heat is the only thing that expanded the refrigerant from a liq- uid to a vapor in the first place, removal of that same heat will let the vapor condense into a liquid again.
  • Page 533 1973 OPEL SERVICE MANUAL three. It doesn’t do any real work, it does act as sort of a traffic officer in controlling the flow of the refrigerant through the system. To get a better idea of what this does. let’s first do a li,ttle exoerimentine with an ordinary’...
  • Page 534 REFRIGERANT COMPONENTS ALL MODELS opened barely enough to allow just exactly the right amount of refrigerant liquid to enter the freezer to take the place of that leaving as a vapor. Thermostatic Expansion Valve Automotive air conditioning systems use a thermo- static expansion valve in place of the float system.
  • Page 535 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.
  • Page 536 REFRIGERANT COMPONENTS ALL MODELS that line, they still hadn’t gotten anywhere. So, they Thus if a gauge is attached to a container of R- 12 and started from scratch and juggled molecules around the room temperature is 70 degrees, the gauge will to make an entirely new refrigerant.
  • Page 537 1973 OPEL SERVICE MANUAL Thus, from the standpoint of comfort, complete air its temperature is above the freezing point, the mois- conditioning should control the relative humidity of ture does not collect in the form of ice or frost. the air as well as its temperature.
  • Page 538 REFRIGERANT COMPONENTS ALL MODELS AS A HIGH PRESSURE-HIGH TEMPERATURE VAPOR REFRIGERANT RETURNS TO VAPOR COMPRESSOR AS LOW PRESSURE EXPANSION VALVE FROM AIR VAPORIZES LOW PRESSURE LIQUID REFRIGERANT HIGH PRESSURE TO LOW PRESSURE LIQUID AT THIS POINT LIQUID REFRIGERANT IS STORED UPON REMOVAL OF HEAT HERE UNTIL NEEDED VAPOR BECOMES HIGH...
  • Page 539 refrigerant penetrates to every nook and cranny of This has been a difficult combination to find. While some desiccants excel in several of the desirable char- the unit. acteristics, they are unsatisfactor:y in others. Among the many desirable properties of R-12, is its stability under operating conditions.
  • Page 540 REFRIGERANT COMPONENTS ALL MODELS When adding oil, the container should be exception- clean system, heat alone can start a chain of harmful chemical reactions. ally clean and dry due to the fact that the refrigera- tion oil in the container is as moisture-free as it is While temperature alone can cause the synthetic rub- possible to make it.
  • Page 541 1973 OPEL SERVICE MANUAL inserting it in the connection. Another precaution - Although high temperature and dirt are responsible for many difficulties in refrigerating systems, in most inspect the fitting for burrs which can cut the “0” instances it is the presence of moisture in the system ring.
  • Page 542 REFRIGERANT COMPONENTS ALL MODELS tons are on the compression portion of their stroke That the attraction of the drying material for mois- (upstroke), and close on the intake stroke. High pres- ture is so powerful that if the receiver is left open, sure gas exits from discharge ports in the discharge moisture will be drawn in from the outside air.
  • Page 543 1973 OPEL 3ERVlCE MANUAL Figure 98.26 Compressor Front and Rear Heads shaft. The wash plate and shaft are serviced as an and circulated through the system via a 3/16 inch assembly. The shaft is driven by a pulley when the...
  • Page 544 REFRIGERANT COMPONENTS ALL MODELS flows from the suction port through the suction pas- THRUST UNIT sage in the cylinder assembly, and into the suction CONTROLS PISTON SHOES ARE USED cavity of the front head. HEAD CLEARANCE TO GIVE TO .OOlO 9.
  • Page 545 1 9 7 3 O P E L S E R V I C E M A N U A L COIL 8 HOUSING CLUTCH S P A C E R RING R E T A I N E R R I N G SHAFT NUT CLUTCH DRIVEN...
  • Page 546 REFRIGERANT COMPONENTS ALL MODELS 9 9 . 3 7 in front of the radiator so that it receives a high the flow of refrigerant into the evaporator. The ex- volume of air flow. Air passing over the condenser pansion valve is the dividing point in the system absorbs the heat from the high pressure gas and between the high and low pressure liquid refrigerant.
  • Page 547: General Information

    1973 OPEL SERVICE MANUAL expand and return to the original gaseous state. To pressures. Outlet tube restrictions will be indicated accomplish this transformation it begins to boil. head pressures and little or no cooling. An excessively cold receiver-dehydrator outlet may be indicative of a restriction.
  • Page 548: Leak Testing System1

    REFRIGERANT COMPONENTS MODELS more apparent at underside of fittings. The flame In all instances where the indications of refrigerant color will turn yellow-green when a small leak is shortage continues, additional refrigerant should be detected. Large leaks will turn the flame blue or added in l/4 lb.
  • Page 549 280 psi maximum. If evaporator pressure rises above 30 psi, change the expansion valve. In the case of the Opel 1900 and the Manta, a ther- Also, check if compressor may be the cause due to mometer should be placed in a position to read the...
  • Page 550: Maintenance And Adjustments

    REFRIGERANT COMPONENTS ALL MODELS Operating Normal Check for the following: 2. Do not carry cylinder in passenger compartment Restriction or leakage in air ducts, A/C outlets not of car. opening. 3. Do not subject cylinder to high temperatures. 4. Do not weld or steam clean on or near cylinder. MAINTENANCE AND ADJUSTMENTS 5.
  • Page 551 1973 OPEL SERVICE MANUAL M P R E S S O R SCHRADER VALVE L I N E ADAPTER J-5420 1 LOW PRESSURE MANIFOLD -GAUGE J-5725-01 L I NE S (5) J-5418 Figure 98.41 Set-Up For Discharging System from the low pressure gauge and connect this tion.
  • Page 552 REFRIGERANT COMPONENTS ALL MODELS 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.
  • Page 553 Continue charging until the scales show that 2 Ibs. Disposable Can Method Opel 1900 - Manta and 2 l/4 lbs. GT, of refrigerant have been transferred from refrigerant drum to sys- After having depress&ed, repaired (if necessary) tem.
  • Page 554 REFRIGERANT COMPONENTS ALL MODELS If system is charged using J-6272-02, close the 3. Connect high pressure gauge line to compressor valve of opener after all cans are empty. Release the high pressure gauge fitting. locking lever and discard the three (3) empty cans. If this tool will be used to complete the charge with 4.
  • Page 555 1973 OPEL SERVICE MANUAL shut off vacuum pump. Open refrigerant control cover of receiver-dehydrator with the system operat- ing, IO see if there are any bubbles evident. valve and allow some refrigerant to enter system. Locate and repair all leaks.
  • Page 556: Adding Oil To The System

    REFRIGERANT COMPONENTS ALL MODELS culates throughout the system. The compressor is center flexible line of gauge set to the B. Connect initially charged with 10 oz. of 525 viscosity oil. fitting on the valve. After system has been in operation the oil content in the compressor will vary depending on the engine C.
  • Page 557: Flushing The System

    REMOVAL AND INSTALLATION OF removed for flushing. When a component is not removed, disconnect all refrigerant lines or hoses COMPRESSOR - OPEL 1900 - MANTA attached to component. To perform flushing operat- R e m o v a l ion, connect a cylinder of refrigerant-12 to the com-...
  • Page 558 See Figure 9B-54. Refer to EVACUATING THE. SYSTEM. Figure 98-5 1 Location of Idler Pulley, Bracket and Ground Wire Opel 1900 - Manta 6. After system is completely discharged, remove refrigerant hoses from compressor adapter fitting and cap hoses and adapter fitting to keep contami- nants from entering.
  • Page 559 1973 OPEL SERVICE MANUAL Figure 98.53 Compressor Installation Opel 1900 Manta 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 Hose Installation - Opel Figure 98.55...
  • Page 560: Opel 1900 . Manta

    Figure 98.57 Receiver Dehydrator Support Bracket. Opel 1900 - Manta Figure 9B-60 Receiver Dehydrator Hoses and O-Rings Opel 1900 Manta Figure 98-59 Receiver Dehydrator O-Ring and Drain Hose Location - Opel 1900 - Manta Figure 9B-61 Removing Left Side Distributor Duct...
  • Page 561 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. See Figure 9B-62.
  • Page 562 Figure Evaporator Blower Assembly Brackets and Attachments - Opel 1900 - Manta Figure 98.70 Evaporator and Expansion Valve A s s e m b l y - O p e l 1 9 0 0 M a n t a 14.
  • Page 563 1973 OPEL SERVICE MANUAL valve. The filter screen at the inlet port may be re- valve hoses are installed correctly. See Figures 9B-63 placed. Remove screen by threading a lo-32 NF and 64. 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.
  • Page 564 Opel 1900 - Manta 12. Remove condenser. Installation Figure 98.76 Clearance Between Lower Radiator Tank and Fan Blades - Opel 1900 Manta If refrigerarit circuit or condenser has been exposed to the atmosphere and moisture may be present in 6. On vehicles with automatic transmissions, fasten...
  • Page 565: Assembly - Gt

    7. Install fan shroud. 9. Install lower radiator hose and add collected coo- lant. All Opel 1900’s and Manta’s are provided with a Figure 99.81 Idler Pulley and Bracket Assembly and radiator initial fill of an anti-freeze solution contain- Support Bracket GT ing corrosion inhibitor.
  • Page 566 REFRIGERANT COMPONENTS ALL MODELS Figure 98-84 Compressor Installation GT...
  • Page 567: G T

    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. Disengage from compressor and tape closed openings in both lines and ports in rear head.
  • Page 568 REFRIGERANT COMPONENTS ALL MODELS 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. 3. Evacuate and charge system. Refer to CHARG- ING AND DISCHARGING SYSTEM.
  • Page 569 1973 OPEL SERVICE MANUAL EVAPORATOR EVAPORATOR DRAIN HOSE DRAIN HOSE Figure 98-93 Evaporator Mounting Bracket Bolts Passenger Side - GT ----- Figure 96-91 Drain Hose GT OUTLET TUBE SEAL Figure 98-94 Inlet and Outlet Pipes and O-Rings GT 11. Remove blower case and blower motor attaching screws and remove assembly.
  • Page 570 REFRIGERANT COMPONENTS ALL MODELS 5. Install resistor assembly. 6. Install evaporator assembly into car and install mounting bracket. See Figure 9B-96. 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.
  • Page 571 14. Connect the negative battery cable. 15. Charge system. Refer to CHARGING SYS- TEM. REMOVAL AND INSTALLATION OF CONDENSER DEHYDRATOR ASSEMBLY - GT Removal 1. Disconnect negative battery cable. 2. Discharge system. Refer to DISCHARGING SYSTEM. 3. While the system is discharging, remove the charcoal cannister, washer jar, battery and battery tray.
  • Page 572: Disassembly And Reassembly Of Clutch Drive Plate And Shaft Seal

    2. Install condenser into car and secure with 4 at- parts on the GT, however, the compressor must be taching screws. See Figure 9B-101. removed from the Opel 1900 - Manta. 3. Untape discharge line and pipe and install using new o-rings lubricated with No. 525 viscosity oil.
  • Page 573 6. Thoroughly clean the area inside the compressor 4. Using No. 21 Truarc pliers (J-5403) take out neck surrounding the shaft, the ezxposed portion of retainer ring from hub of clutch drive plate (see Fig- the seal seat and the shaft itself of any dirt or foreign ure 9B-106).
  • Page 574 REFRIGERANT COMPONENTS ALL MODELS FRONT HEAD \ Figure 98.109 Removing or Installing Shaft Seal Figure 96-l 11 Installing Seal Seat O-Ring 5. Install the new seal seat retainer ring with its flat side against the seal seat, using No. 21 Truarc pliers (J-5403).
  • Page 575: Compressor

    1973 OPEL SERVICE MANUAL LEAK TEST FIXTURE \ Js - s -- COMPRESSOR (TOP VIEW) ADAPTERS J-5420 LOW PRESSURE PRESSURE GAGE USE LINE ONLY GAGE D U R I N G - COMPRESSOR GAGE SEAL TEST *-LINE (3) J-54 18...
  • Page 576 COIL AND HOUSING ASSEMBLY It is not necessary to remove the compressor or dis- connect refrigerant lines to remove or install clutch parts on the GT, however, the compressor must be removed from the Opel 1900 - Manta. Disassembly 1. Disassemble clutch plate.
  • Page 577 1973 OPEL SERVICE MANUAL J-9395: Figure 99-l 19 Removing Bearing From Pulley Assembly 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. Figure 9B-120 Removing or Installing Coil and...
  • Page 578 REFRIGERANT COMPONENTS ALL MODELS Disassembly of Rear Head, Oil Pump, Rear Discharge Valve Plate, and Rear Suction Valve J - 8 0 9 2 J-9481 R e e d D i s c 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”.
  • Page 579 1973 OPEL SERVICE MANUAL SUCTION SCREEN TEFLON Figure 96-l 26 Removing Rear SfJction Valve Reed Disc Figure 96-l 24 Rear Head Removal 8. Take out and discard shell to head “0” ring. plate and 9. Carefully pry out rear discharge valve rear suction valve reed disc with screwdrivers (see Figures 9B-125 and 9B-126).
  • Page 580 SEALING Figure 9%128 Removing Internal Cylinder Assembly Figure 96.131 Front Head Sealing Surfaces SUCTION PASS COVER Figure 9B-130 Removing Front Head If sealing surfaces of front head (see Figure 9B- 13 1) Figure 98-132 Removing Suction Pass Cover are damaged, replace front head. There is no Teflon on front head sealing surface.
  • Page 581 1973 OPEL SERVICE MANUAL RUBBER MALLET Figure 98-135 Piston Identification Ringless Examine shaft and wash plate assembly and replace as necessary. Figure 98-133 Separating Cylinder Halves 6. Wash all salvaged parts of cylinder assembly in bath of trichlorethylene, alcohol, or similar solvent parts tray (J-9402) the following: number “1, 2 and...
  • Page 582 REFRIGERANT COMPONENTS ALL MODELS Installing Piston Into Cylinder Half Service Piston Sliown Figure 9B-137 Shaft and Front Needle Thrust B in Cylinder Half 8. Repeat preceding step for reassembly of pistons 3. Generously coat with clean petroleum jelly two No. “2” and No. “3”. “zero”...
  • Page 583 piston drive ball and wash plate and draw leaf or (a) Using a feeler gage, select a leaf or combination leaves out again, simultaneously measuring “drag” of leaves which result in satisfactory “feel” when on leaf or leaves (see Figure 9B-143). If correct leaf inserted between rear piston drive ball and wash (leaves) has been selected, spring :scale will read be- plate (see Figures 9B-141 and 9B-142).
  • Page 584 REFRIGERANT COMPONENTS ALL MODELS Shoe Disc Table SERVICE ID. NO. PART NO. STAMPED SHOE DISC 6557000 Shoe Disc) 6556175 17 l/2 6556180 6556185 1 8 % 6556190 6556195 19 l/2 6556200 6556205 6556210 6556215 21 l/2 6556220 EXAMPLE Piston’ 3 r d 2 n d Figure 98.144 Gaging Clearance Between Rear N o .
  • Page 585 1973 OPEL SERVICE MANUAL race. If, for example a feeler gage reading of 0.009 lected shoe discs onto No. “1” piston, and apply inch results, a thrust race with a number “9”, clear petroleum jelly to piston pockets and shoe discs stamped on it should be selected.
  • Page 586 REFRIGERANT COMPONENTS ALL MODELS 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 squeezed together (see Figure 9B-147).
  • Page 587 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 Figure 98.152 Installing Discharge Tube O-Ring and...
  • Page 588 REFRIGERANT COMPONENTS ALL MODELS HELL TO HEAD O - R I N G (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-Ring Installment the hole for the oil inlet tube in the cylinder assembly is aligned with the reservoir hole in the shell, and reassemble the oil inlet tube and “0”...
  • Page 589 1973 OPEL SERVICE MANUAL 9. Reassemble shaft seal onto front of shaft and plate assembly. Do not reassemble clutch drive plate at this time. ‘Testing Compressor Leak 1. After the shaft seal pressure test has been per- formed, change the test circuit to the configuration shown in Figure 9B-160.
  • Page 590 REFRIGERANT COMPONENTS ALL MODELS COMPRESSOR ADAPTERS DISCHARGE USE LINE ONLY DURING COMPRESSOR- GAGE I SEAL T&T J-541 6 MANIFOLD AND GAGE SET J-5725-01 CYLINDER Figure 96-160 Compressor Infernal Leak Test...
  • Page 591: Specifications

    Apply hand brake. pressures to within the limits specified in the Func- tional Charts. When testing the Opel 1900 and 2. Turn blower switch to HI position, to read the temperature of the air discharging from the right-hand A/C outlet.
  • Page 592 REFRIGERANT COMPONENTS ALL MODELS FUNCTIONAL TEST - OPEL 1900. MANTA Temp. of Air Entering Cond. Engine RPM 2 0 0 0 2 0 0 0 2000 2 0 0 0 2 0 0 0 200-210 270.280 155.165 195.205 Suction Press.’...
  • Page 593 COMPRESSOR EVAPORATOR CONDENSER L.P. VAPOR H.P.T.X.V. POWER ELEMENT H.P. VAPOR Figure 96-l 61 Cycle of Operation...
  • Page 594 REFRIGERANT COMPONENTS ALL MODELS 10 11 12 13 15 lb 13. Coil and Housing Assemblv I. Rear Head Thrust Race Thrust &zarin~ Pulley and Bearing Assembly Discharge Valve Plate 2 7 . Thrust Race Rear Pulley Bearing Rear Suction Reed Plate Compressor Shell 17.
  • Page 595 REFRIGERANT COMPONENTS ALL MODELS SUCTION IT DISCHARGE VALVE PLATE FRONT HEAD ,-SEAL SEAT O-RING ,-SHAFT SEAL FRONT CYLINDE<\. REAR CYLINDER ’ REAR NEEDtE”q. PRESSURE RELIEF VALVE T H R U S T BEARlNG / PORT (SERVICE ONLY1 [SERVICE ONLYI VALVE PLATE Figure 96-l Compressor...
  • Page 596 1973 OPEL SERVICE MANUAL Figure gB-165 Special Tools...
  • Page 597 A I R C O N D I T I O N E R S Y S T E M - O P E L 1900 - M A N T A J 6 0 8 4 J 14OVS J 2 2 1 3 2 . 0 2 J 9 4 5 9 J 5428.03 J 2 3 3 9 0...
  • Page 598: Air Conditioner System

    AIR CONDITIONER SYSTEM OPEL 1900 - MANTA CONTENTS Page No. Subject DESCRIPTION AND OPERATION: General Description of System ........”...
  • Page 599 AIR CONDITIONER SYSTEM -OPEL 1900 - MANTA 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). Figure 98.170...
  • Page 600 1973 OPEL SERVICE MANUAL MAJOR REPAIR AIR SENSING CAPILLARY, SWITCH REMOVAL AND INSTALLATION OF BLOWER SWITCH R e m o v a l Remove the face plate retaining screws and remove the face plate assembly. See Figure 9B-172. BUMPER BLOWER...
  • Page 601 AIR CONDITIONER SYSTEM. OPEL 1900. MANTA 2. Remove the left side of distributor duct, and the in-line fuse. See Figure 9B-174. Figure SB-176 Glove Bdx Removed Figure SB-174 Location of Distributor Duct (Left Side) Retaining Screws Figure SB-178 Location of Refrigerant Hoses, Pipes,...
  • Page 602 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. Figure 98-183 Drain Hose BLOWER MOTOR Figure SB-182 Evaporator and Blower Assembly bracket with the electrical connector side of the mo-...
  • Page 603 AIR CONDITIONER SYSTEM -OPEL 1900 - MANTA Figure 98.186 Delay Restrictor and Check Valve Hose Assembly 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.
  • Page 604 LIGHT BLUE STRIPE DARK GREEN DARK GREEN RESISTOR WIRE CUTOUT S W I T C H r FUSE BLOCK ‘WIRE ‘RIPE BLACK WITH RED STRIPE BLACK WITH RED Sl Figure 9B-188 Wiring Schematic Figure 9B-188 Wiring Schematic SPECIFICATIONS Blower Motor Type ...................... 12 VDC Blower Fan Type ....................
  • Page 605 AIR CONDITIONER SYSTEM - GT AIR CONDITIONER SYSTEM CONTENTS Subject Page No. General Description of System ........Operation of Controls .
  • Page 606 1973 OPEL SERVICE MANUAL pressure gauge, should pull down to the pressure DIAGNOSIS shown in the chart in SPECIFICATIONS in Refrig- erant Components Section. GUIDE TROUBLE DIAGNOSIS 3. Remove the duct assembly mtaining screws and Insufficient Cooling remove the duct assembly noting the position of the...
  • Page 607 AIR CONDITIONER SYSTEM - GT 5. If the low side pressure was less than the pre- scribed pressure at the end of each cooling cycle, turn adjusting screw a partial turn clockwise. See Fig- ure 9B-192. Figure 98.192 Adjusting Thermostatic Switch 6.
  • Page 608 1973 OPEL SERVICE MANUAL 3. Remove all evaporator cover attaching screws 2. Remove the retaining screws from the duct as- and remove cover. See Figure 9B’-195. 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.
  • Page 609 AIR CONDITIONER SYSTEM. GT REMOVAL AND INSTALLATION OF BLOWER MOTOR ASSEMBLY battery. Figure Electrical Connections I n s t a l l a t i o n 1. In611 the resistor assembly and two (2) attach- ing screws. See Figure 9B-198. Figure 98.200 Luggage Tray Figure...
  • Page 610 1973 OPEL SERVICE MANUAL 5. Remove the electrical plug connector from the 2. Discharge system. Refer to DISCHARGING resistor assembly, and unplug blower motor connec- SYSTEM in Refrigerant Components Section. tion and remove ground wire. See Figure 9B-203. 3. While system is discharging remove the luggage 6.
  • Page 611 AIR CONDITIONER SYSTEM. GT Figure 98.206 Evaporator Mounting Bracket Bolts Passenger Side Figure 98.209 Evaporator and Blower Assembly 11. Remove blower case and blower motor attaching 8. Remove inlet and outlet pipes from evaporator and remove assembly. and tape closed the refrigerant lines and also the open ends of the inlet and outlet pipes of the evapora- Installation tor.
  • Page 612 1973 OPEL SERVICE MANUAL 8. While system is being evacuated: the el&trical connector side of the motor to the right side of the bracket. 9. Connect 2 drain hoses underneath the evaporator 2. Assemble the fan housing case halves and attach housing.
  • Page 613 RADIO. GT RADIO CONTENTS Subject Page No. DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: Radio Trouble Diagnosis ..........MAINTENANCE AND ADJUSTMENTS: Antenna Trimmer Adjustment .
  • Page 614 1973 OPEL SERVICE MANUAL antenna. This adjustment must always be made after c. Adjust trimmer screw for maximum volume. installation of a receiver or an antenna, or after re- d. If antenna trimmer does not have a definite peak, pair to these units. This adjustment should also be performed whenever radio reception is unsatisfac- check for defective antenna by substitution.
  • Page 615 RADIO - GT Using a 8mm socket, remove hex head screw. See is achieved. Figure 9C-2. Remove access trim cover on left side of console. MAJOR REPAIR See Figure 9C-3. REMOVING AND INSTALLING RADIO 5. Using a 4mm socket, remove hex head screw. See Figure 9C-4.
  • Page 616 1973 OPEL SERVICE MANUAL 11. Grasp instrument cluster and pull straight back, being careful of wires, etc. See Figure 9C-7. Figure Removing Instrument Cluster 12. Disconnect radio harness plug and antenna lead- in cable from back of radio. See Figure 9C-8.
  • Page 617 RADIO - OPEL 1900 - MANTA RADIO OPEL 1900 - MANTA CONTENTS Subject Page No. DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: Radio Trouble Diagnosis ..........
  • Page 618 a. Wheel static may be eliminated by installation of c. Adjust trimmei screw for maximum volume, static collectors in the front wheels. It is important d. If antenna trir&ner does not have a definite peak, to make sure the button on the end of the spiral collector rides evenly in the spindle.
  • Page 619 RADIO - OPEL 1900 - MANTA MAJOR REPAIR REMOVING AND INSTALLING RADIO Removal ~ 1. Rem&e control knobs and ornamental cover plate. See Figure 9C- 15. 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.
  • Page 621 ....... Opel 1900 ......
  • Page 622 S y s t e m Opel 1900 & Manta ..... L u b r i c a t i o n S y s t e m G T .
  • Page 623 O C - 7 GTO Opel ......Strainer-Transmission ....
  • Page 624 A u t o & t i c ......Wiring Diagrams Complete Opel 1900 1 J-l 03 Procedure ......
  • Page 625 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. Wayne Torman Sacrificed his near mint 1973 Shop Manual for the project Mark Wootton Scanning and conversion to PDF...

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