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14

1973 OPEL SERVICE MANUAL

POWER FLOW 1st SPEED

M A I

N

DRIVE G E A R

(

I N P U T

)

COUNTERSHAFT GEAR UNIT 1st SPEED GEAR

1 SPEED GEAR

AND 2nd GEAR SLIDING GEAR

AND 2nd SP

EE

D

GE

AR GUIDE

U

NIT

COUNTERSHAFT GEAR

DRIVE GEAR

SPEED GEAR
AND 2nd GEAR SLIDING GEAR
AND 2nd SPEED SLIDING GEAR GUIDE

MAINSHAFT (OUTPUT)

Figure

F i r s t S p e e d

After synchronizing the speeds of the mainshaft and
the 1st speed gear, the 1st and 2nd gear sliding gear
shifts to the rear of the transmission and locks the 1st
speed gear to the mainshaft through the 1st and 2nd
speed sliding gear guide unit. This 1st and 2nd speed
sliding gear guide unit is internally splined to the 1st
and 2nd gear sliding gear and is

splined to

the mainshaft. Both the

3rd

speed gear and the 2nd

speed gear are idling. The reverse idler gear is
engaged with any gear and, therefore, it is idle.

With a 1st speed gear ratio of

the main drive

gear (input) must turn 3.428 revolutions for every
one revolution of the main shaft (output).

I T

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Summary of Contents for 1900 1973

Page 1: ......

Page 2: ...the use of specific service methods that can damage the vehicle or render it unsafe are stated in this service manual It is also important to understand these warnings are not exhaustive BUICK could...

Page 3: ...I j BUICK MOTOR DIVISION GENERAL MOTORS CORPORATION IFLINT MICHIGAN 48550 0 GENERAL MOTORS CORPORATION 1972 Litho in U S A...

Page 4: ...ly All infotmation illustrations and specifi cations contained in this manual are based on the latest product information aveil able at the time of publication approval Therefore the right is reserved...

Page 5: ...Diagrams 2 Body and Bumpers General Body Information I Frame Body Mountings Windows Window Moldings DONS Rear Compartment Lid Roof Sun Roof Seat Interior Trim Headlining Bumpers 3 Suspension and Stee...

Page 6: ...PARAGRAPHS are used when necessary for clarity or to provide distinc tion between component procedures SPECIAL TOOLS References are made throughout the Manual to special tool numbers desig nated by th...

Page 7: ......

Page 8: ...GENERAL INFORMATION GROUP 0 Section OA OB oc Title Page General Information OA 1 Vehicle Lifting Points 06 4 Maintenance and Lubrication OC 5...

Page 9: ......

Page 10: ...lock facing See Figure OA 2 VEHICLE IDENTIFICATION Model Identification Plate The model identification plate as illustrated in Fig ure OA 3 is attached to the inside right front inner fender panel on...

Page 11: ...57 2Dr Spi Cpe 57R 2Dr R ye Spt Cpe Manta LUXUS 57L 2Dr Lu sSpt Cpe GT 77 2Dr Splf Cpe I VVHEEL FRONT REAR CURB OVERAL BASE TREAD TREAD WEIGHT WIDTH LENGT 2138 2183 164 6 2227 l 2183 l 9 5 7 52 4 52...

Page 12: ...Glow Y Y Chrome Yellow Chrome Yellow M M Deep Burgundy Deep Burgundy B B Regency Blue Regency Blue S S Grecian Silver Grecian Silver X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X...

Page 13: ...i If it is necessary to use any liftink device other thin the briginal equipment jack such as a hydraulic scissors or floor jack or a servicJzstation or dealer hoist see Figure OB 1 for acceptable lif...

Page 14: ...C 5 LUBRICATION AND MAINTENANCE LO Engine Oil current ISCOI ifVl SE u9 Lubriplate 9F Hvdraulic Brake Fluid Delco supreme NO 11 CAPAClTlES O P E L 1900 Coding System M A N T A G T OW 6 6 U U 3ocl Figur...

Page 15: ...hs or 3 OW mile3 1 Engine Oil EMISSION CONTROL MAINTENANCE Every 24 months or 31 1 Engine Conpression 24 ooO 32 heI cap Tank and Lines EVsN 24 m miles I 33 IAir Cleaner E eme t I Alsa an Emision Contr...

Page 16: ...rake master cylinder battery engine axle transmission and windshield washer Engine coolant also should be checked for proper level and for corrosion and freeze protection to at least 20 F or to the lo...

Page 17: ...eze and water for protection of 20 F D 6 NOT REMOVE RADIATOR CAP WHEN SOLUTION IS HOT AND UNDER PRESSURE Wheel Bearings Clean and repack front wheel bearings with a lubri cant as specified on the lubr...

Page 18: ...or and other acces sories at first 4 months or 6 ooO miles of vehicle operation At each subsequent 4 month 6 000 mile interval check belts for cracks fraying wear and tension Adjust or replace as nece...

Page 19: ...nd behind the car set the parking brake and firmly apply the foot brake Do not depress accelerator pedal Be prepared to turn off ignition switch immediat y if engine should start L Starter Safety Swit...

Page 20: ...ent Proper functioning of the carburetor is particularly essential to control of emissions Correct mixtures for emission compliance and idle quality have been preset by Opel Plastic idle mixture limit...

Page 21: ...r cylinder would be l 05 pounds 150 x 70 105 Fuel Cap Fuel Lines and Fuel Tank Inspect the fuel tank cap and lines for damage which could cause leakage Inspect fuel cap for correct seal ing ability an...

Page 22: ...II IJ Title Battery and Cables Starting System Ignition System Charging System Washers and Wipers Lighting Systems Signal Systems instrument Panel Gauges Wiring Circuit Diagram Page No lA 2 lB 10 lC 1...

Page 23: ...tion Plan Booklet Care of Wet Batteries in Storage Batteries in stored new cars as well as batteries in stock must be given regular attention to prevent sulphation of plates that may result from inact...

Page 24: ...n a dry place away from excessive heat A dry charged battery should p kept in its original carton until ready to be put into service This type of battery will retain its charged condition indefinitely...

Page 25: ...noid switch is closed it indicates that the battery is run down or there is a condition in cranking mb tor or engine which causes an excessive current drain on the battery A low battery will be indica...

Page 26: ...the high limit may allow enough increase to keep the battery at a safe state of charge If the high limit setting does not maintain a safe state of charge an occasional booster charge should be given t...

Page 27: ...d corrosion may have taken place in the loose connection Check condition of cables and replace if badly corroded or frayed Special attention must be given to the battery posi tive cable position to el...

Page 28: ...ries designated as good that are suspected of being questionable because of owner complaint or age of the battery should be further tested by the Hydrometer Test HYDROMETER TEST OF BATTERY The 421 Bat...

Page 29: ...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 electrical suppl...

Page 30: ...fully charged condition by the quick charge method The battery can be substantially recharged or boosted but in order to bring the battery to a fully charged condi tion the charging cycle must be fini...

Page 31: ...which carries the over running clutch and pinion assembly The armature shaft is supported in sin tered bronze bushings in the commtitator end frame and the drive end housing These bushings are packed...

Page 32: ...ed 5 Ignition switch damaged 1 Replace ignition switch loose parts preventing switch I from closing or burnt parts 6 Solenoid switch damaged 1 Repair or replace as required 7 Excessive voltage drop in...

Page 33: ...difference in readings taken in Operations 2a and 2b above represents the volt drop through the cables and solenoid switch Voltdge drop should Got exceed 5 volt 4 Locate excessive resistance as follo...

Page 34: ...e by the socket See Figure lB 4 STARTER OVERHAUL Starter R moval 1 Dixon t starter wiring 2 Remove starter support bracket 3 Removk two starter bolts one nut and lockwash en 4 Removi starter Starter D...

Page 35: ...ator diameter is less than 1 15 32 inches armature must be replaced 3 0 1 6 6 Figure 1B 6 Turning Down Commutator 3 Undercut mica approximately 020 below com mutator surface Finish and thoroughly clea...

Page 36: ...replace positive brushes cut off wires at the connecting strap of the field coil Clean soldered joint and solder stranded wire of new brushes Hold wire with flatnose pliers so that no tin enters wire...

Page 37: ...ard 2 Slide pinion stop retainer down over shaft with recessed side outward 3 Place a new snap ring on drive end of shaft and hold it in place with a hard wood block Strike block with hammer to force...

Page 38: ...10 6 Amperes 30 50 RPM 7300 8500 Cranking Amperes Test In Car Engine at Operating Temp 175 205 Lock Test Volts 6 Min Amperes 280 320 Volt ge Required to Close Solenoid Contacts 7 5 Minimum Diameter o...

Page 39: ...irt and the distributor is located at the left front of the engine IGNITION SWITCH The combined ignition switch and steering lock ian be switched to any one of the below listed positions Insert key wi...

Page 40: ...shaft is driven by a helical gear on the camshaft and in turn drives the engine oil pump The ignition condenser is mounted on the outside of the housing The engine output is to a large extent in fluen...

Page 41: ...int set screw then recheck dwell 5 Install rotor and cap Start engine and recheck dwell It is important that dwell be rechecked as instal lation of rotor and cap will sometimes change the dwell angle...

Page 42: ...terference 2 Wipe ignition wires with a cloth moistened with solvent and wipe dry Bend wires to check for brittle cracked or swollen insulation Defective insulation will permit missing or cross firing...

Page 43: ...ns check centrifugal advance only at 2500 RPM Discon ect and plug all vacuum hoses Maximum vacuum ad vance should be l 5 degrees at 4 5 5 0 in hg 8 Replace centrifugal or vacuum advance parts as requi...

Page 44: ...t or rotor tip points to notch in distributor housing See Figure lC 7 3 Ball imbedded in flywheel should be approxi mately aligned with pointer in housing See Figure lC 4 4 Remove distributor hold dow...

Page 45: ...cleaning partly pull distributor shaft together with centrifugal advance mechanism out of distribu tor housing Do not disassemble advance mech anism 6 C lean and check all parts Replace any defective...

Page 46: ...stallation 1 Makeisure oil pump slot is in position to receive distributor shaft tang See Figure lC 17 Figure lC 17 Oil Pump Slot 2 Inspect paper gasket on distributor housing and replace if necessary...

Page 47: ...grees at RPM 28 32 at 3600 Vacuum Advance Engine Degrees and In of Vacuum Start Advance at In of Vacuum 5 at 2 9 4 1 In Maximum Advance Degrees at In of Vacuum l 5 at 4 5 5 0 In Vacuum Retard Engine D...

Page 48: ...IGNITION SYSTEM lC 27 9 3OlC19 Figure 1 C l 3 Distributor Exploded...

Page 49: ...aled in grease supply which eliminates the need for periodic lubrication Two brushes and two slip rings are used One brush conducts the current provided by the voltage regulator to one end of the fiel...

Page 50: ...e through the alternator However whenever alternator voltage is higher than battery voltage current flows freely through the diodes in the other direction to charge the battery A current regulator is...

Page 51: ...ting 1 Always test alternator output first as describedlin subparagraph a above Leave all test instrumeqts connected but make sure field jumper is removed if used 2 With engine speed at 2500 RPM turn...

Page 52: ...g Figure l 1D 7 Removing Drive End Frame and Rotor Assembly 3 Remoie drive end frame and rotor assembly from generator See Figure lD 8 301D8 Figure I11D B Drive End Frame and Rotor Assembly 4 Pull ve...

Page 53: ...y from diodes Unsolder quickly using a very hot sol dering iron as the diodes are very sensitive to heat See Figure lD 14 Figure 1 D l 6 Brush Wire Installation Figure 1 D l 4 Unsoldering Connections...

Page 54: ...own to a diameter of l 1 4 inches When doing this remove only enough material to just clean up the worn surface then polish slip rings and blow clean with compressed air 18 If alternator current outpu...

Page 55: ...g Diode 2 Using Tool J 23526 press diode from support See Figure lD 23 Installing Diodes Positive Diodes 1 Press new diode into diode support See Figure lD 24 Figure lD 24 Installing Diode Negative Di...

Page 56: ...t 4 Posit a belt tension gage such as Gage J 23600 Figure 1 D 26 Alternator Installation on belt Pull alternator outward until gage reads 45 Ibs then tighten adjusting brace bolt 5 Tighten alternator...

Page 57: ...I I 1 D 36 1973 OPEL SERVICE MANUAL I Figure 1 D 27 Alternator Exploded View 301D27...

Page 58: ...windshield washer fodt pump Depressing the washer pump will allow the bipers to operate while the pump is de pressed i DIAGNO SIS PRELIMINj9RY INSPECTION 1 Make c in of firm wire connections at wiper...

Page 59: ...be remove Qn all 1900 and Manta Models the defroster ducts are secured to the instrument panel cover by two 2 spring clips and should not be removed from dayh cover Remove cover and duct as a unit 4 R...

Page 60: ...7 Figure lE 7 Removing Left Panel Motor and Linkage 5 Remove nut and lockwasher from wiper motor shaft and remove complete wiper linkage 6 Install in reverse sequence checking all parts for wear Repla...

Page 61: ...ature in transmission hous ing with a screw driver 3 Rem ove armature from transmission housing 4 Remove five 5 transmission housing cover screws See Figure lE 11 Figure 1 E l 1 Remove Transmission Ho...

Page 62: ...24 inch 4 Check d ven gear for wear and replace if neces s a r y Assembly f Wiper Motor 1 Fill transmission driven gear housing with l 8 inch layer of grease meeting GM Specification 02383 I 2 Install...

Page 63: ...tion increases Then back off adjust ing screw l 2 turn Secure driven gear adjusting screw with lock nut and armature adjusting screw with paint See Figures lE 18 and lE 19 Installation 1 Connect wiper...

Page 64: ...__ _ 16 High Speed ___ _ 17 Minimum Commutator Diameter __ 86 in Brush Spring Pressure New Brush _ __ 6 35 to 8 47 oz Used Brush __ 3 5 oz minimum Minimum Brush Length 24 in The windshield wiper motor...

Page 65: ...GEAR 23 ARMATURE WASHER 24 ATTACHING SCREWS THREADED END 25 LOCKWASHER PLAY PIN 26 ANGLE BRACKE TS SLEEVE 27 MOTOR HOUSING MOUNTING PLATE 28 MAGNET RING GASKET 29 MAGNET THREADED TOOTHED WASHERS Pi N...

Page 66: ...0 1 F 50 1 F 50 lF 51 lF 51 lF 51 1 F 52 1 F 52 1 F 53 1 F 53 1 F 53 1 F 53 DESCRIPTION AND OPERATION DESCRIPTION OF LIGHTING SYSTEM The three baition light switch on Opel 1900 and Manta corjtrols the...

Page 67: ...r to Group 110 Section F for service procedures on the GT head lamp mechanism A white indicator lamp in the instrument panel lights if the headlamps are not completely opened lor closed The switches o...

Page 68: ...trument cluster cover See Section H I 2 Press ddwn retaining clip and pull switch out See Figure lF 2 Figure 1 F 3 Removing Headlight Retainer Models 51 53 54 3 Disconnect wiring connectors 4 Remove h...

Page 69: ...emove two screws holding lamp lens 2 Remove two screws holding housing See Figure lF 5 Figure lF 5 Remove Parking Light Housing 3 Disconnect wiring harness 1 Apply sealer to housing 2 Connect wiring h...

Page 70: ...om housing 2 III luggage compartment unscrew three 3 hous ing attaching nuts See Figure lF 9 Figure lF 9 Tail Light Housing Attaching Nuts Models 57 57R 3 Disconnect wire connector Installation 1 Plug...

Page 71: ...VS INTERIOR LIGHTS Courtesy Light Removal 1 Pry courtesy light out of roof frame as shown in Figure 1 F 11 t 2 Pull wires off flat plugs See Figure lF 12 Figure lF 12 Courtesy Light Wire Connections I...

Page 72: ...Installation 1 Con t electrical wires 2 Install lamp housing and lens Removal f Headlamp Sealed Beam 1 Rotate fieadlamp to open position 2 Remove headlamp shield See Figure lF 15 3 Removk headlamp at...

Page 73: ...limp opening tbe marker lamp assembly can be removed See Figuie lF 18 Installation 1 Install side marker 2 Replace directional signal lamp Removal of License Plate Lamp 1 Remove adjacent tail and dir...

Page 74: ...ht Removal I 1 Disco ect battery 2 Remohe lens 3 RemoF base plate by removing two 2 screws 4 Unplulg wires I I Installation I 1 Connect wires to proper plugs 2 Install base plate 3 Install lens 4 Con...

Page 75: ...Jersey With headlights off moving the lever repeatedly to wards steering wheel flashes headlights as a passing signal With headlights on moving the lever repeat edly towards steering wheel up to firs...

Page 76: ...defects in the directional signal system as follows 1 Indic tor light on dash gives only one quick flash One of tie switched on directional signal lamp bulbs is defective The other signal lamp will co...

Page 77: ...TURE GAGE OIL PRESSURE INDICATGR LIGHT CHARGING INDICATOR LIGHT TACHOMETER AND OIL PRESSURE GAGE RALLYE ONLY AIR CONDITIONING 20 AMP INLINE F USE 8 5 16 5 OPEL GT 77 WINDSHIELD WIPERS WINDSHIELD WASHE...

Page 78: ...mdnt panel lights can be turned off by turning the lightSwitch knob counterclockwise past the first detent I The fog lights are automatically turned off if the ignition switch is on and the headlights...

Page 79: ...lights taillights license plate lights and rear side marker lights Parking Light and instrument Panel Light SwitCh Assembly The left switch of this assembly is the Parking Light Switch By pushing inw...

Page 80: ...lation inlet The Heiter Blower Switch is a three position switch By depressing the lower half of the switch to the first stop th blower will operate at low speed When depressdd to the second stop the...

Page 81: ...rds steering wheel and remove plate 6 Remove two screws for lower housing attach t See Figure lH 6 Figure 1 H 6 Lower Housing Attaching Screws 7 Disconnect speed0 cable at cluster by turning cou pling...

Page 82: ...ch 3 Disconnect wiring connector 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 Remov...

Page 83: ...igure 1 H l 3 Steering Column Attaching Bolts 7 Disconnect ignition white and directional signal black wire set plugs 8 Support steering column assembly and remove both hex head bolts See Figure lH 13...

Page 84: ...retention of these parts 1 Plug antenna lead in cable and power source to radio I 2 Put i trument cluster in position and replace six 6 screbs in cluster 3 Connect speedometer cable 4 Raise steering...

Page 85: ...ove instrument housing I 2 Disconnect electrical wire 3 Remove hex nut on back of cigar lighter base 4 Remove cigar lighter base Installation 1 Install cigar lighter base 2 Install hex nut on back of...

Page 86: ...CATIONS DIAGNOSIS I TEM ERATURE FUEL GAUGE SYSTEM DIAGNOSIS OPEL 1900 MANTA Condition Possible Cause I Page No 1 l 65 1 l 67 1 l 67 1 l 68 1 l 68 1 l 69 1 l 69 1 l 69 1 l 70 1 l 70 1 l 70 1 l 70 1 l 7...

Page 87: ...m tank terminal If dashgauge does not read rull check dash gauge attaching nuts for secureness and tighten if required Requires removal of dash panel Momentarily touch dash gauge attaching studs to 12...

Page 88: ...ire light blue with black tracer from the tank unit An inoperative gas gauge reading can normally be found to result from a poor grounding condition within the circuit Using the procedure as outlined...

Page 89: ...s shown in Figure 11 2 and remove both instrument cluster lens Figure 1 l 2 Removing Instrument Cluster Lens 3 Remove three speedometer attaching screws L X Figure 11 3 Installation 1 Replace speedome...

Page 90: ...1 Removt glove compartment 2 Remo e radio if equipped 3 Remoje screws holding instrument carrier from instrumejf pane 4 Disconpect wres from instrument gauge 5 Removal attaching nuts from gauge and re...

Page 91: ...trument housing 2 Remove speedometer See Figure 11 9 1 Installation 1 Install speedometer 2 Install instrument housing paragraph 11 71 per Removal of Tachometer 1 Remove instrument housing 2 Remove ta...

Page 92: ...move 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 1 Re...

Page 93: ...Buzzer and Clock GT Headlamps Opel 1900 Headlamps Manta j Headlamps and Fog Lights Rallye Headlamps Parking Tail and Instrument Panel Lighting GT Left Parking and Tail Lights Opel 1900 Manta i Right P...

Page 94: ...Seat Belt Warning System Automatic Page No Transmission GT lJ 99 Heated Rear Glass Opel 1900 Manta 15 100 Heated Rear Glass GT lJ 101 Opel 1900 Color Schematic lJ 103 Manta Color Schematic 1 J 105 GT...

Page 95: ...j 1J 74 1973 OPEL SERVICE MANUAL i I m Figure 13 1 Windshield Wiper and Horn Opel 1900 Manta...

Page 96: ...I I WIRING DIAGRAMS lJ 75 Figure lJ 2 Windshield Wiper and Horn Rallye...

Page 97: ...1 J 76 1973 OPEL SERVICE IMANUAL L J Figure lJ 3 Wind hield Wiper and Horn Gl...

Page 98: ...I I I WIRING DIAGRAMS 1J 77 I I Figure 1 J 4 Turn Signal and Hazard Flasher Opel 1900 Manta I...

Page 99: ...I i L I lJ 78 1873 OPEL SERVICE MANUAL Figure lJ 5 Turn Signal and Hazard Flasher GT...

Page 100: ...I WIRING DIAGRAMS 15 79 I I Figure lJ 6 Oil Fuel Temp Tach Stop and Brake Warning Light GT I...

Page 101: ......

Page 102: ...I WIRING DIAGRAMS lJ 81 r Figure 1 J 8 Blower and Lighter GT...

Page 103: ...I I lJ 82 1973 OPEL SERVICE MANUAL Figure lJ 9 indicator Lights and Gauges Opel 1900 Manta...

Page 104: ...I I WIRING DIAGRAMS IJ 83 I Figure 1 J 10 Indicator Lights and Gauges Ratlye...

Page 105: ...Nl 14 RED TO STEERING COLUMN CONN 20 RED 12 RED FROM BATTERY 18 G R A Y 12 RED I J DOME LIGHT S W I T C H 1 1 _ S T E E R I N G COLUMN CONNECTOR TRUNK LIGHT SWITCH IGNITION SWITCH BUZZER SWITCH HELD C...

Page 106: ...EhMB SWITCH R GHiDOOR 301J12...

Page 107: ...1 J 86 1973 OPEL SERVICE MANUAL i Figure 1 J l 3 Headlamps Opel 1900...

Page 108: ...I I I WIRING DIAGRAMS lJ 87 Figure lJ 14 Headlamps Manta...

Page 109: ...1 J 88 1973 OPEL SERVICE MANUAL I 1 Figure lJ 15 Headlamp and Fog Lights Rallye...

Page 110: ...301516...

Page 111: ......

Page 112: ...WIRING DIAGRAMS lJ 91 R Figure lJ 18 Right Parking Tail and Instrument Panel Lighting Opel 1900 Manta...

Page 113: ...1 J 92 1973 OPEL SERVICE MANUAL d 5 Figure 1 19 Starting lgniiion and Charging Opel 1900 Manta...

Page 114: ...I I WIRING DIAGRAMS lJ 93 I Figure lJ 20 Starting Ignition and Charging GT...

Page 115: ...1 J 94 1973 OPEL SERVICE MANUAL i I I Figure lJ 21 Instrument Panel GT...

Page 116: ...I I 1 I WIRING DIAGRAMS lJ 95 Figure lJ 22 A C Generator and Regulator All Models...

Page 117: ...301523...

Page 118: ...WIRING DIAGRAMS lJ 97 c I N I I Figure 1 J 24 Seat Belt Warning System Automatic Transmission Opel 1900 Manta...

Page 119: ...I I I 10 RED AMP GAGE 301J25...

Page 120: ...WIRING DIAGRAMS lJ 99 Figure lJ 26 Seat Belt Warning System Automatic Transmissionl GT...

Page 121: ...lJ 100 1973 OPEL SERVICES MANUAL I Figure 1 J 27 Heated Rear Glass Opel 1900 Manta...

Page 122: ...I WIRING DIAGRAMS 1 J 101...

Page 123: ...1 J 102 1973 OPEL 9ER IC MANUAL...

Page 124: ...tion 2A 2B 2 C 2D 2E 2F 2G 2H Title General Information Frame and Body Mountings Windows and Window Moldings Doors _ Rear Compartment Lid Roof and Sun Roof Seats Interior Trim and Headlining Bumpers P...

Page 125: ...detergent If rust or salt corrosion should ap pear they may be removed with Buick Rust Eraser or equivalent Do not use scouring powders or stiff brushes STAIN REMOVAL Before attempting to remove spot...

Page 126: ...impossible Rub the stain with a clean cloth saturated with cold water until no more of the stain will come out Care must be taken so that clean portions ofcloth are used for rubbing the stain This tre...

Page 127: ...st r r ZA 4 1973 OPEL SERVICE MANUAL 9 Shoe Polish and Dressings On types of shoe dressing which contain starch or dextrine or some water soluble vehicle allow the polish to dry then brush the spot vi...

Page 128: ...SPECIAL BODY TOOLS GENERAL INFORMATION 2A 5 W REGULATOR INING INSTALLER J 21828 J 21549 2A 1...

Page 129: ...SCRIPTION AND OPERATION Not Applicable DIAGNOSIS Not Applicable MAINTENANCE AND ADJUSTMENTS Not Applicable MAJOR REPAIR Not Applicable SPECIFICATIONS Frame and Body Mounting Specifications Page No 28...

Page 130: ...outside edge of right front frame rail to rear outside edge of left front frame rail From centerline of lower ball joint stud to centerline of second side drain hole Centerline of right lower control...

Page 131: ...mber attaching bolt hole to center of rear spring seat Rear spring seat to datum line Center of spring seat to center of track rod to body attaching bolt hole Centerline of front crossmember right att...

Page 132: ...Rear Quarter Window GT Rear Quarter Window Lock SPECIFICATIONS Not Applicable Page No 2c 9 2c 10 2c 11 2c 11 2c 12 2c 12 2c 12 MAJOR REPAIR REMOVAL AND INSTALLATION OF WINDSHIELD 3 With Tools J 2 1828...

Page 133: ...into large sealing lip of rubber channel so that both ends are crossed at bottom cen ter of windshield See Figure 2C 5 6 With a sealer gun coat outside of pinchweld flange with sealing compound See F...

Page 134: ...position of window lifter guide rail screws 6 For unscrewing window lifter guide rail block sash window or support it with the hand CJ t window and take it out of door See Figure REMOVAL AND INSTALLAT...

Page 135: ...Attaching SCW S 4 Carefully push rail off window On rear quarter window lock drill off pin and unscrew retainer from window See Figure 2C 13 Figure 2C 13 Drilling Off Quarter Window Lock Pin REMOVAL A...

Page 136: ...e 2D 2 2 Place new striker in installation position and tem porarily tighten striker observing marking on lock pillar Close door and check whether this can be done without exerting any force If this i...

Page 137: ...g 2 Remove door inside handle escutcheon 3 Remove lock knob 4 Remove arm rest See Figure 2D 5 Figure 20 2 Door Striker Figure 20 5 Removing Arm Rest Figure 20 3 lnsarting Tool Between Handle and Nylon...

Page 138: ...nel b Install door trim pad REMOVAL AND INSTALLATION OF FRONT DOOR BELT REVEAL MOLDING 1 Bend up ends of molding 2 With a wooden wedge pry off molding towards the top See Figure 2D 8 Figure 2D 6 Insta...

Page 139: ...e window upwards and block it 10 Remove window lifter through opening in inner door panel upper part See Figure 2D 11 Figure 2D 1 1 Removing Window Lifter Installation 1 Install window lifter through...

Page 140: ...ation 1 Install window guide rail if removed 2 Engage actuating lever and install lock See Figure 2D 14 Figure 2D 14 Engaging Actuating Lever 3 Install guide rail through access hole and install bolt...

Page 141: ...outside door handle 3 Install lock ring into handle See Figure 2D 16 4 With window closed install outside handle and hex nut See Figure 2D 15 5 Install door trim pad REMOVAL AND INSTALLATION OF FRONT...

Page 142: ...or weatherstrip using a clip remover See Figure 2D20 Il Remove door rubber bumper 12 Drive out upper and lower door hinge sleeve and remove door using Tool J 21688 See Figure 2D 21 Figure ZD 21 Removi...

Page 143: ...25 Cable and Pully Location 3 Loosen sheave adjustable bracket Unscrew win dow regulator from inner door panel and remove regulator and cable through access hole See Figure 2D 26 Figure 2D 24 Sash Cha...

Page 144: ...inges on tailgate remove bolts securing tailgate to hinges and lift off tailgate HINGE TRIM PANEL1 I Figure ZD 28 Removing Tailgate Hinge Trim Panel 4 Release and remove torque rods See Figure 2D 29 F...

Page 145: ...PARTMENT LID WEATHERSTRIP 1 Detach old weatherstrip and clean sealing surface 2 Coat new weatherstrip and contacting surface with rubber cement and allow cement to dry for a few minutes 3 Install new...

Page 146: ...rests in opening of the lock See Figure 2E 5 REMOVAL AND INSTALLATION OF LUGGAGE COMPARTMENT LID Removal 1 With a wooden wedge remove letters and orna ment 2 From below push ornament out of luggage c...

Page 147: ...2F 24 2F 26 iF 27 2F 29 2F 29 2F 30 2F 31 2F 3i DIAGNOSIS SUN ROOF DIAGNOSIS _ CONhTlON PAUSE I C RRECTI X Sun roof does not operate Transporter cable lengths parallel equal Close sun roof slide sun r...

Page 148: ...ie flat Sparingly lubricate lifter guide Sun roof frame becomes detached Attaching clips have lost elasticity Install new clips Water enters car interior Water drain hoses blocked Bent water drain hos...

Page 149: ...roof proceed as follows 1 Close sun roof 2 Loosen screws securing front guides to front of sun roof panel see Figure 2F 2 Rotate height adjust ment ring until desired height is attained 3 Readjust gu...

Page 150: ...contacts stop when lifter is approximately 90 degrees to guide rail Pull sun roof frame forward and reattach to sun roof panel MAJOR REPAIR REMOVAL AND INSTALLATION OF SUN ROOF PANEL AND SUN ROOF FRA...

Page 151: ...contact guide rails and are not cocked NOTE To achieve proper clearance of front guides to guide rail the guides should lightly touch edge of d should have a clearance of no 3 Reconnect riar lifter g...

Page 152: ...ss cement being careful not to con tact velvet strip Removal of Velvet Strip and Wea therstrip on Rear of Sun Roof Panel 1 Remove sun roof panel 2 Carefully detach weatherstrip and velvet strip from s...

Page 153: ...and crank handle 8 Install sun roof panel and reposition front guides to original position on guide rails Be sure front Figure ZF 1 1 Cable Box guides squarely touch guide rails and are not cocked Als...

Page 154: ...on of sun roof 2 Rotate cable crank to its limit in a clockwise direc tion and install reverse of removal procedure ROOF AND SUN ROOF 2F 31 REMOVAL AND INSTALLATION OF FRONT AND REAR WATER DRAINAGE HO...

Page 155: ...nto place by use of rubber cement or nitrile vinyl trim adhesive 3M Vinyl Trim Adhesive Permalastic Vinyl Trim Adhesive or equivalent 5 Complete installation reverse of removal proce dures Removal of...

Page 156: ...ide Panel Trim Pad SPECIFICATIONS Not Applicable 26 33 26 33 26 34 26 34 26 35 26 37 MAJOR REPAIR REMOVAL AND INSTALLATION OF FRONT SEAT 1 Pull hook out of seat lock See Figure 2G 2 2 TZ Gy3at towards...

Page 157: ...REMOVAL AND INSTALLATION OF GLOVE COMPARTMENT DOOR LOCK 1 Unscrew nut of glove compartment lid lock using Figure ZG 6 Removing Glove Compartment Lock 2 Install new glove compartment lid lock REMOVAL A...

Page 158: ...o door openings rear quarter window openings rear quarter pillar and from under rear window rubber channel On rear quarter pillars slightly bend down cardboard of rear quarter trim pad to facilitate r...

Page 159: ...cement When pulling headlining toward rear be sure that the listing wires are not pulled out of line A folded cloth should be used to smooth down cemented portions of headlining 5 Cut off surplus hea...

Page 160: ...back sedans only 12 In trunk area instail cardboard against rear seat cross brace and bend over tabs sedans only 13 Install rear seat cushion sedans only 14 Connect battery REMOVAL AND INSTALLATION O...

Page 161: ...bumper attaching screws on inside left and right and from left and right brackets See Figure 2H 2 2 From the front unscrew bumper guard attaching screws See Figure 2H 2 Remove bumper and bumper guard...

Page 162: ...grille 2 Disconnect bumper at points shown in Figure 2H 5 and remove bumper 2 Disconnect bumper at points shown in Figure 2H 5 and remove bumper Installation Installation 1 Install bumper and secure...

Page 163: ...MBLY GT Removal 1 Remove tail lamp assembly See Figure 2H 6 2 Remove bumper attaching nuts accessible through lamp opening See Figure 2H 7 Installation 1 Install bumper and secure with attaching nuts...

Page 164: ...ND DRILL TWO 112 HOLES IN THE VERTICAL PORTION OF THE REAR BODY PANEL PLACE THE 3 16 SPACERS ON THE 112 x l l 2 HEX BOLTS AND BY REACHING THROUGH THE TAIL LAMP OPENINGS INSERT THE BOLTS THROUGH THE BO...

Page 165: ...THE INNER FLOOR NOTE HOLD DRILL VERTICAL WHILE DRILLING THROUGH THE INNER FLOOR ENLARGE BOTTOM HOLE SLIGHTLY TO ACCEPT SPACER STEP 4 ATTACH TRUNK PLATE AS ILLUSTRATED PLACE THE FLOOR PLATES ON THE 2 l...

Page 166: ...CENTER OF THE TRUCK FLOOR AND DRILL A l 2 HOLE THROUGH THE FLOOR USING THE HOLE IN THE DRAW BAR AS A GUIDE ATTACH THE FLOOR PLATE AND FLOOR STRAP AS ILLUSTRATED DRILL THE TWO REMAINING HOLES IN THE F...

Page 167: ......

Page 168: ...Section Title Page No 3A Front Suspension 3A 2 3B Steering Linkages 38 l 9 3 C Front End Alignment 3C 22 3D Steering Gear _ 3D 27 Steering Column 3E 1900 Manta _________ 3E 35 GT 3E 42 3F Rear Suspens...

Page 169: ...ting brackets but rest on a separate cross mem ber The front suspension cross member is reinforced in the area of the attachment to the frame A one part damper plate is installed between cross member...

Page 170: ...SSMEMBER ROTOR LOWER BALL JOINT FRONT SPRING Figure 3A 2 GT Front Suspension Disc Brakes the upper and lower control arm are not in parallel anti dive The lower control arm is connected to the steerin...

Page 171: ...has a small amount of end play and a loose nut when adjusted in the above manner MAJOR REPAIR REMOVAL AND INSTALLATION OF FRONT SUSPENSION COMPLETE ASSEMBLY Removal GT 1 Prior to raising front end of...

Page 172: ...line retainers on both sides The brake system remains closed Unscrew brake calipers and suspend them in wheel house Figure 3A 9 Removing Guard Plate 7 Suspend engine with a suitable engine lifter simi...

Page 173: ...steering column downwards until a l 8 clearance is obtained between steering wheel hub and switch cover 8 With steering wheel in centered position and front wheels straight ahead tighten the clamp bol...

Page 174: ...Torque values must be used as specified durikg reas sembly to assure proper retention of these parts Figure 3A 13 Upper Ball Joint 1 Install upper control arm ball joint with the off center holes in f...

Page 175: ...sconnect shock absorber to lower control arm 3cz Figure 3A 16 Spring Compressa attachment bolt and swing shock absorber out of the Way 6 Remove castle nut from ball joint stud Prior to the removal of...

Page 176: ...en fracture may occur Replacement ball joints may or may not have marking notch as shown in Figure 3A 20 If it does not have a marking notch the joint is completely symetrical and may be installed in...

Page 177: ...rtant attaching parts in that they could affect the the perfonmmce of vital components and systems and or could result in ma jor repair expense They must be replaced with one of the same part number o...

Page 178: ...with rubber damper bushings in the control arms of the front suspension so that the rubber parts under load are in an almost twist free condition This position exists if the hooks J 23697 are used 3...

Page 179: ...uckle 10 Loosen nut that retains lower control to front cross member 11 Slowly lower hoist to release spring tension 12 Swing lower control arm downwards and remove front spring 13 Remove nut that ret...

Page 180: ...ember to body support 8 Install shock absorber and torque lower attaching nut and bolt to 30 lb ft 9 Install nuts on upper shock absorber attaching studs Tighten nuts until a distance from top of nut...

Page 181: ...ring compressor 6 Install hub and disc on spindle and tighten spindle nut as stated under MAINTENANCE AND AD JUSTMENTS in this section 7 Install caliper on steering knuckle and torque bolts to 72 lb f...

Page 182: ...o stud is approxi mately l 2 inch See Figure 3A 25 5 Install plastic cover Installation GT 1 Inspect shock absorber for damage and seal leaks Always replace the upper and lower rubber grom mets when r...

Page 183: ...rm hooks J 23697 2 Raise car and stipport with stands Hoist should be left in the raised position to maintain pressure on lower control arm 3 Remove front wheel 4 Detach both stabilizer supports from...

Page 184: ...t they co d affect the performance of vital com ponents and systems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalent part if rep...

Page 185: ...Arm to Steering Knuckle 1900 Manta Brake Backing Plate or Brake Disc Shield and Steering Arm to Steering Knuckle GTJ Hex Head Bolt M 10 Hex Head Bolt M 8 Brake Backing Plate to Steering Knuckle 1900 M...

Page 186: ...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 gear housing protect the rack and axial joints against dirt dust a...

Page 187: ...to prevent damage to rack teeth Figure 38 5 Bending Lock Plate Over Ball Stud GT 2 Bend round edges of lock plate over flat on ball stud to lock ball stud in position 3 Position rubber bellows and ho...

Page 188: ...bolt CAUTION Fasteners for tie rods are important attaching parts in that they could affect the per formance of vital components and systems and TIE ROD r CLAMP OUTER y BALL STUD RETAINER RING SEALIN...

Page 189: ...l joints and bolts must be of proper torque and in usable condition Caster and camber adjustments need not be consid ered unless visual inspection shows these settings to be out or unless the car give...

Page 190: ...ts in that they could affect thickness front and rear washer must equal 48 the performance of uital components and sys tems and or could result in major repair expense There are only two possible cast...

Page 191: ...and one 12 in the rear caster decrease of 1 degree Never add FRONT OF CAR 3G5 Figure 3C 5 Caster Adjustment Washer Location Opel 1900 Manta several washers in one place The washers B installed in pro...

Page 192: ...by rotating the tie rod sleeves Refer to Figure 3C 6 1 Recheck caster and camber before proceeding with toe in adjustment If correct adjust toe in 2 Set wormshaft and ball nut to steering gear high po...

Page 193: ...ering gear housing is warranted CHECKING THEORETICAL KING PIN INCLINATION When checking theoretical king pin inclination car must be on a level surface both transversely and fore and aft must have tri...

Page 194: ...in the lower housing The pinion is not adjustable A rubber 0 ring seal is provided for sealing needle bearing and a second 0 ring for sealing pinion bushing The rack and pinion shaft are held in mesh...

Page 195: ...ing in adjusting screw when steering gear is set to highpoint the MAJOR REPAIR sintered bronze she0 l s pushed against the rack SO that the rack is blocked REMOVAL AND INSTALLATION OF STEERING 3 Back...

Page 196: ...ew nut 5 Using remover J 21687 press ball studs out of steering arms see Figure 3D 5 I J 21 68 Figure 3D 5 Removing Ball Stud 6 Remove four attaching bolts securing steering gear to front suspension c...

Page 197: ...the cause D Installation Opel 1900 Manta CAUTION Fasteners are important attachingparts in that they could affect the performance of vital com ponents and systems and or could result in maJbr repair e...

Page 198: ...d rack with open end wrench to avoid damage to the teeth See Figure 3D 11 The axial joint is maintenance free must not be disassembled and has to be replaced as an assembly only Figure 3D 1 1 Removing...

Page 199: ...red bronze shell into steering gear hous ing and fill adjusting hole with Calcium Soap No 2 6 Reassemble thrust spring adjuster screw and lock nut on gear assembly Final adjustment of adjuster screw i...

Page 200: ...the gear assem SPECIFICATIONS Tightening Specifications Part Location Bolt Bolt Nut Nut Nut Bolt Bolt Nut Nut Nut 4 Reassemble special washer flat washer and new pinion nut onto pinion shaft Torque p...

Page 201: ...E COUPLING BOLT PINION SHAFI RUBBER BOOT es RETAINER ew O RING lNTERED METAL BUSHING 1 y STEERING GEAR HOUSING NEEDLE BEARlNG y 7 RACK GUIDE BUSHING RACK he THRUST SPRING i RUBBER ADJUSTER SCREW BUSHI...

Page 202: ...ATION DESCRIPTION AND OPERATION OF DIRECTIONAL SIGNAL LEVER high to low beam or vice versa On all 19M Rallye cars when switching from low to high beam posi tion with the fog lamp instrument panel swit...

Page 203: ...for the respective attaching bolts A metal piece See Figure 3E 4 is located in each slot which is attached to the slide off base with injected plastic The open sides of the slots face the driver so t...

Page 204: ...nut from steering mast jacket attach ment at front of dash panel See Figure 3E 7 Figure 3E 7 Steering Mast Jacket Attachment 4 Pull off signal switch as well as steering and igni tion lock wire sets 5...

Page 205: ...g wheel remover J 21686 as shown in Figure 3E 9 and pull off steering wheel Installation 1 Before installing steering wheel lubricate return pin and sliding area on directional signal switch re turn c...

Page 206: ...crew slide off base from underside of instru ment panel and remove upper part of signal switch housing cover See Figure 3E 11 7 Place a thick piece of wood onto front seat and let down steering mast j...

Page 207: ...od into stop pin hole on side of steering and ignition lock See Figure 3E 13 and take out steering and ignition lock cylinder 4 Remove two screws securing electrical switch to steering and ignition lo...

Page 208: ...Column Tightening Specifications Part Location Toraue 1b k Nut Steering Wheel Retaining 1900 Manta _ _ Bolt Steering Column Flexible Coupling 1900 Manta _ Nut Slide Off Base Attaching 1 900 Manta _ _...

Page 209: ...of the car is suddenly halted while the secondary force the driver continues its forward direction A severe col lision generally involves these two forces the pri mary and the secondary forces The se...

Page 210: ...R S A L J O I N T STEERING C E N T E R S T E E R I N G S H A F T LOWER UNIVERSAL JOINT Figure 3E 15 GT Steering Column Assembly _ 7 FORCE PRIMARY FORC FORCES BEFORE COLLISION I ST STAGE PRIMARY COLLIS...

Page 211: ...ch engages in a hole of the connect ing brace As soon as a sufficiently large secondary energy becomes effective the steering mast jacket slides to wards the front whereby the bolt B as well as the bo...

Page 212: ...E 18 Installation 1 Insert lock cylinder into lock cylinder housing 2 Install steering wheel as outlined previously in this section REMOVAL AND INSTALLATION OF STEERING COLUMN ASSEMBLY Removal 1 Posit...

Page 213: ...mes necessary Do not use a replacement part or lesser quality or substitute design Torque values must be used as specitied during reassembIy to assure proper retention of these parts 1 Install steerin...

Page 214: ...t and move it further to the right so that the left retaining screw ear is positioned under the left signal switch return cam See Figure 3E 22 c Insert direc Figure 3E 2 1 tion signal switch lever int...

Page 215: ...UPPER STEERING BEARING AND OR DIRECTION SIGNAL SWITCH 1 Remove ignition switch and steering lock see previous paragraph in this section 2 Disconnect direction signal black wire set plug 3 Remove wires...

Page 216: ...Bearing SERRATED SOCKET E Z lh I I 11 u BEARING HOUSINGy SE 28 Figure 3E 28 Removing Lower Bearing 5 Remove bearing retainer snap ring and remove bearing Installation 3 Install steering shaft together...

Page 217: ...1 3E 50 1973 OPEL SERVICE MANUAL PART Bolt Bolt LOCATION Steering Wheel Upper Universal Joint Lower Clamp Upper Universal Joint Hex Head Lower Universal Joint TORQUE LB FT 15 14...

Page 218: ...er control arms are of tubular design and function as two links of the three link suspension system They are attached to the underbody through brackets welded to the side rails and to the rear axle as...

Page 219: ...r rings are properly positioned in the spring seats and position the springs in their respective position in the damper rings See Figure 3F 4 2 Properly install upper damper rings on springs CAUTION F...

Page 220: ...oosely at tach stabilizer to underbody retainers 2 Connect stabilizer rod to shackles 3 With the vehicle standing on its wheels or the rear axle assembly lifted tighten stabilizer rod to under body br...

Page 221: ...SERVICE MANUAL UPPER RUBBER DAMPER RING COIL SPRING TRACK ROD LOWER RUBBER DAMPER RING REAR AX E ASSEMBLY COIL SPRING SEAT STABILIZER ROD 3 SHOCK ABSORBER LOWER CONTROLA R M Figure 3F 5 Exploded View...

Page 222: ...ced front wheels can be generally felt as steering wheel nib ble Next road test the car with the owner if possible and have the owner explain the specific ride disturb ance After road testing raise ca...

Page 223: ...and dynamic wheel and hub balancing Correct by rebalancing Figure 3G 2 It is recommended that an on the car balancer be used for balancing A tire wheel assembly that is in balance may still be causing...

Page 224: ...re wheel assemblies that are causing the disturbances be repositioned Since normally only one and occasionally two tire wheel assemblies per vehicle could be causing the disturbing vibration it is rec...

Page 225: ...inches may be considered as offending assemblies Offending tire wheel assembly should be deflated and the tire repositioned indexed 180 degrees from original location 5 After repositioning rebalance...

Page 226: ...TION TREAD CONTACT WITH ROAD PROPER INFLATION TREAD CON WI ROAD lOVERINFLATION OVERINFLATION DERS OF TREAD WORN CENTER OF TREAD WOI FEATHERED EDGE _ ONE SIDE OF TREAD WORN SHOULDER OF TREAD FINS WORN...

Page 227: ...outside shoulder of the right tire and the inside shoulder of the left tire take the side thrust and naturally receive the most wear The only possible correction is to advise slower speeds on curves D...

Page 228: ...appearance however will be exaggerated by underinflation im proper toe in or both Cupped or Scalloped Type Tire Wear Cupping or scalloping is associated with wear on a car driven mostly at highway spe...

Page 229: ...original balance of the tire and wheel assembly may change as the tire wears Severe acceleration severe brake applications fast cornering and side slip wear the tires out in spots and often upset the...

Page 230: ...less than one mile Hot tire inflation pressure After vehicle has been driven 10 miles or more at 60 70 MPH 4 Vehicles with luggage racks do not have a vehicle load limit greater than specified 5 When...

Page 231: ......

Page 232: ...GROUP 4 PROPELLER SHAFT AND DIFFERENTIAL Title Page No Propeller Shaft and Central Joint 4A 2 Rear Axle 4B 7...

Page 233: ...iversal joints See Figure 4A 1 The front universal joint attaches to the transmission out put shaft by a splined slip joint The rear universal joint attaches to the pinion extension shaft flange by Pa...

Page 234: ...ough the oil seal and onto the transmission output shaft Make certain trans mission rear seal is not damaged 3 Align rear universal joint and pinion flange locat ing marks and secure with respective b...

Page 235: ...mponents and systems and or could result in major repair expense They must be replaced with one of the samepartnumber or with an equivalentpart ifreplacement becomes necessary Do not use a replacement...

Page 236: ...soft face mallet at least far enough to install nut 6 Assemble flange holder J 8614 to flange install new self locking nut and torque to 87 lb ft 7 Install torque tube assembly onto differential car...

Page 237: ...a reliable to rque wrench Specifications are for clean and lightly oiled threads Part Bolt Bolt Bolt Torque Bolt Location Drive Pinion Extension Shaft Flange to Universal Joint _ Central Joint Suppor...

Page 238: ...ed into the sides to form a complete assembly An oil feed passage to the pinion bearings and an oil return hole are provided to allow lubricant to circulate A removable steel cover is bolted on the re...

Page 239: ...propeller shaft d Front or rear U joint angle too great e Mis indexed propeller shaft at companion flange tJ Companion flange runout too 6 A knock or click 6 A brinelled rear wheel bearing approximate...

Page 240: ...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 plug in rear of transmission to prevent loss of lubri...

Page 241: ...brake pipe and install retaining clip 12 Thread parking brake cable over exhaust system and connect to lower control arm brackets parking brake actuating lever and brake backing plate Install brake dr...

Page 242: ...nsert axle shaft into housing using a mallet drive axle shaft completely into housing 7 Install lock washers and nuts Torque to 20 Ib ft 8 Install brake drum and wheel assembly 9 Remove supports and l...

Page 243: ...5 Removing Axle Shaft 18 9 Mark differential side bearing caps and carrier with a prick punch so the caps can be reinstalled in their original positions 10 Remove differential side bearing cap bolts...

Page 244: ...drift BARREL SPLINE SLEEVE REMOVER Figure 48 9 Removing Barrel Spline Sleeve REMOVER J 2291 2 7 48 10 Figure 48 10 Removing Rear Pinion Bearing Assembly and Installation of Drive Pinion Prior to asse...

Page 245: ...ht block J 21691 3 firmly against the face of gauge plate J 21691 4 Allow the movable plunger to bear against the machined sur face of gauging arbor J 21691 6 and tighten the plunger set screw See Fig...

Page 246: ...and pinion bearings 5 Remove the rear pinion bearing outer race using a brass drift 6 Install pinion depth shims selected in Step f in the rear pinion bearing outer race bore and install the rear pini...

Page 247: ...specification is exceeded replace the collapsible spacer 10 Remove installer J 22938 and install washer and pinion preload nut Using Special Tool J 22932 hold barrel spline and tighten preload nut unt...

Page 248: ...1 Dial indicator reading 095 2 Subtract concave thrust washer thickness oso 3 Total 045 4 Subtract an additional 002 002 5 Shim thickness to be used 043 5 Turn case over and repeat the above procedur...

Page 249: ...ollows a Position differential case assembly less side bear ing shims into the side bearing bores of the carrier See Figure 4B 28 Figure 48 28 Installing Differential Case Assembly b Using two sets of...

Page 250: ...ust washers side and pinion gears and install the side gears with respective thrust wash ers in the differential case 15 Rotate case assembly several times to seat the bearings Check backlash and prel...

Page 251: ...ng gear on case making certain their mating surfaces are free of burrs or foreign material Tighten bolts to 47 lb ft 6 Check lateral runout of installed ring gear Max imum permissible runout is X03 If...

Page 252: ...ss between each bearing outer race and the carrier to remove all end play Make certain the feeler stock is pushed to the bottom of the bearing bores See Figure 4B 34 e With zero end play and correct b...

Page 253: ...heck backlash and preload using a torque wrench on a ring gear attaching bolt See Figure 4B 35 Torque required to turn case should be 20 to 30 Ib in for new bearings or 10 to 20 lb in for used bearing...

Page 254: ...ve shims Thickness In 1900 039 04 1 043 045 047 049 05 1 053 055 G T 0394 0433 0473 Number of Notches in Circumference 0 1 2 0512 3 Max Permissible Axle Shaft Bearing Seat Radial Runout _ 002 Max Perm...

Page 255: ...Bolt Ring Gear to Case Bolt Side Bearing Cap t o Carrier i Bolt Differential Housing Cover 22 Nut Track Rod Attaching GT 4 0 Nut and Bolt Stabilizer Rod t o Rear Axle Shackle 25 Bolt Stabilizer Rod to...

Page 256: ...GASKET DRIVE PINION SlDE BEARlNG GEAR REAR PINION BEARING x PRELOAD NUT DIFFERENTIAL CASE SIDE GEAR PINION GEAR THRUST WASHER AXLE SHAFT BEARING RETAINER FLAT WASHER TORQUE TUBE 40 37 PRdPELLER SHAFT...

Page 257: ...18 71 0280 93 0366 15 5906 51 Ol 72 0284 94 0370 16 6299 31 0122 52 0205 73 0287 95 0374 17 6693 32 0126 53 cRo9 74 0291 96 0378 18 7087 33 0130 54 ml3 75 0295 97 0382 19 7480 34 0134 55 0217 76 SE 99...

Page 258: ...I REAR AXLE 48 27 J 21691 6 J 22935 J 22936 J 22919 J 22931 J 8872 J 2241 1 I J 7818 J 22938 J 24093 J 22937 J 22588 Figure 48 39 Differential Special Tools...

Page 259: ......

Page 260: ...BRAKES GROUP 5 Section 5A 5B 5 C Title Brake Booster and Master Cylinder Disc Brakes _ __ _____ Drum Brakes Page No 5A 2 5B 10 5C 22...

Page 261: ...d around the push rod and fills the cavity inside the hub of the power piston This keeps dirt and dust from entering the vacuum booster The push rod which operates the air valve projects out of the en...

Page 262: ...er piston rod and lock nut of the adjuster VACUUM CONTROL VALVE hose between the intake manifold and the brake booster and serves to prevent air from flowing back vacuum release when the engine is shu...

Page 263: ...lines 1 Inspect and replace as necessary 2 Vacuum failure 2 Check for a Faulty vacuum check valve or grommet replace b Collapsed or damaged vacuum hose replace c Plugged or loose vacuum fitting repair...

Page 264: ...g brake pedal several times 2 Then depress brake pedal and start engine If the vacuum system is working correctly the brake pedal kept under even foot pressure moves farther down wards due to the addi...

Page 265: ...e booster 2 The arrows on the vacuum control valve housing must point towards the intake manifold otherwise no air can be drawn out of the brake booster which renders the brake booster ineffective 3 T...

Page 266: ...reme No 11 or equivalent Do not use any other cleaning solvents Dry with compressed air Free up compensating and feed ports 2 Polish cylinder bore of housing with crocus cloth If lapping scores and ru...

Page 267: ...careful not to loosen the front housing Disassembly 1 Prior to brake master cylinder disassembly pour brake fluid out of brake fluid reservoir 2 Remove reservoir from master cylinder body by removing...

Page 268: ...nd primary pistons 2 Install new snap ring while holding primary piston in a forward position 3 Install check valve spring check valve and check valve connector and torque to 26 Ib ft 4 Install stop s...

Page 269: ...e inside of the wheel hub flange by four bolts and centered on a shoulder of the hub The brake caliper consists of two halves the mounting half arranged on the inside of the brake disc and the rim hal...

Page 270: ...stment of the pads is effected by the pistons which push the friction pads ahead towards the brake disc for a distance equivalent to the amount of friction pad wear This means that the greater the wea...

Page 271: ...too great during braking the rubber seals in the annular grooves of the brake caliper bores deflect laterally in the direction of piston movement See Figure 5B 22 View A The seal remains deflected for...

Page 272: ...efective lining grease or brake fluid on lining or defective wheel cylinders Repair as necessary 8 Loose suspension parts 9 Loose calipers 8 Check all suspension mountings 9 Check and torque bolts to...

Page 273: ...irs with approved brake fluid Check for leaks 3 Adjust rear brake per specifications 4 Air trapped in system 4 Bleed system 5 Bent shoe and lining 5 Replace axle set of shoe and lining Dragging Brakes...

Page 274: ...wheel disc brakes as this is done automatically by the pistons in the brake calipers Lubricating Front Wheel Bearings When removing one or both brake discs check lu brication of front wheel bearings...

Page 275: ...components and sys tems and or could result in major repair expense It must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a repla...

Page 276: ...urface 6 After truing disc on both sides check thickness with a micrometer A disc with a thickness of less than 394 inch is liable to warp after hard braking and therefore must be discarded 7 Reinstal...

Page 277: ...removal markposition ofbrake disc in relation to wheel hub See Figure 5B 30 Figure 58 30 Removing Brake Disc to Hub Bolts 4 Pull brake disc from wheel hub Do not drive if off Install in reverse seque...

Page 278: ...asket with chassis lubricant 2 Install disc and tighten disc shield and steering arm to steering knuckle bolt to a torque of 47 lb ft CAUTION This steen Og arm and steering knuckJe to backing plate fi...

Page 279: ...usable parts complete brake caliper and pistons with denatured alcohol and dry with compressed air Prior to cleaning screw bleeder valve out of caliper 7 Lightly coat new rubber fluid seals with brake...

Page 280: ...Disc Type _ I 2 Piston Fixed Caliper Disc Front Wheels Only Solid Cast Iron use uameter 9 370 Disc Lateral Runout Maximum 004 Disc Thickness New 430 Disc Thickness Minimum 394 Disc Parallelism Thickne...

Page 281: ...te by a hold down pin spring and re tainer The bottom of the shoes pivot in a support plate and the top of the shoes rest directly on the wheel brake cylinder push rods The brake shoes are connected b...

Page 282: ...ough retaining guides and attaches at either end to the lower end of a parking brake lever See Figure 5C 43 The parking brake levers and struts actuate the rear wheel brakes Service Brake Control Syst...

Page 283: ...t rod coming in contact with the support plate on the cowl The thrust rod master cylinder push rod connects di rectly into the brake pedal providing no pedal height adjustment See Figure 5C 45 OPERATI...

Page 284: ...ted between the close both ends of the cylinder to exclude foreign pistons so that when fluid pressure is applied matter A valve for bleeding brake pipes and both pistons move outward in the wheel cyl...

Page 285: ...5C 26 1973 OPEL SERVICE MANUAL...

Page 286: ...aching Bolt and Eccentric Figure 5C 50 Brake Pedal Height Adjustment If binding does occur take pedal assembly apart and clean Check for broken parts Lubricate and replace Adjustment at Wheels At each...

Page 287: ...The plastic brake fluid reservoir is attached to the master cylinder which is located under the hood on the left side of the cowl Thoroughly clean reservoir cover before removal to avoid getting dirt...

Page 288: ...h brake system circuits be thoroughly flushed whenever the master cylinder is replaced or if there is any doubt as to the grade of fluid in the system Flushing of the brake system is performed in the...

Page 289: ...ed 2 Adjust rear wheel brakes 3 Adjust parking brake 4 Check fluid level in master cyliner and add fluid if necessary 5 Check brake pedal for proper feel and for proper return 6 Remove jacks and road...

Page 290: ...d wheels BRAKE WHEEL CYLINDER OVERHAUL 1 Remove wheel drum and brake shoes Be careful not to get grease or dirt on brake lining 2 Disconnect brake pipe or hose from wheel cylinder and cover opening wi...

Page 291: ...produce in creased friction which prevents accurage measurement of tightness Part Name Torque Nut Bolt Brake Hose to Front Wheel Brake Cylinder Brake Backing Plate to Steering Knuckle Uccer Bolts Lb...

Page 292: ...e No Engine Mechanical and Mounts All Models Cooling System All Models Fuel System All Models Exhaust Systems All Models Carburetor And Throttle Linkage Emission Control Systems All Models 6A 2 6B 32...

Page 293: ...ression ratio of 7 6 1 and operates on regular low lead grade fuel Engine Construction The cyfinderhead is made of high grade chromium grey cast iron The valve guides are cast intergal with the head T...

Page 294: ...y each diameter of the four bearings and journals being slightly smaller than the preceding Camshaft end play is controlled at forward end by the camshaft front bearing seat outer face in one directio...

Page 295: ...The fuelpump is located at bottom left hand side of timing case and operated by a cam integral with distributor drive gear riveted to distributor drive shaft The aluminum alloy cast intake manifold wi...

Page 296: ...sump through the screen and pumps it through drilled passages in timing case to the full flow filter From there it passes to the cylinder block main oil gallery with a branch in tim ing case to no 1...

Page 297: ...e disassembly to correct for oil consumption NOISY VALVES AND LIFTERS If the preceding check indicates valve mechanism is abnormally noisy remove the rocker arm cover so that the various conditions th...

Page 298: ...r arms push rod ends for scoring Check push wire to spark plug This determines which cylinder rods for bends valve lifters and camshaft surfaces is at upper top center on the firing stroke Adjust the...

Page 299: ...tor hose 4 Remove upper and lower radiator hoses 5 Remove radiator and fan shrbud 6 Disconnect heater hoses 7 Disconnect brake booster vacuum hose 8 Remove air cleaner 9 Disconnect electrical connecti...

Page 300: ...manifold to avoid inter ference during engine lowering 6 Remove throttle linkage and carburetor 7 Disconnect heater hoses 8 Disconnect water valve bracket to manifold 9 Remove gear shift lever 10 Usi...

Page 301: ...rter 2 Using suitable equipment raise assembly into vehi c l e 3 Install components as removed in steps 1 thru 21 ENGINE OIL PAN REMOVAL AND INSTALLATION Removal Opel 1900 and Manta To remove the engi...

Page 302: ...nd Manta 1 Apply a light bead of sealer to the clean sealing surfaces of the oil pan and affix a new gasket 2 Bolt oil pan and gasket assembly to engine block 3 Roll front suspension and floor jack un...

Page 303: ...he bolts in the sequence illustrated in Figure 6A 16 Torque bolts to 33 lb ft Figure 6A 16 Manifold Bolt Tightening Sequence 4 Connect parts removed in Steps 1 thru 8 above CYLINDER HEAD REMOVAL AND I...

Page 304: ...0 Give bolts a final torque in the same sequence Torque to 72 lb ft cylinder head cold Use same procedure for cylinder head to timing chain cover bolts with final torque at 17 lb ft See Figure 6A 20 T...

Page 305: ...ther evidences of poor seating If a valve head must be ground until the outer edge is sharp in order to true up the face discard the valve because the sharp edge will run too hot J 22917 1 0030 O S J...

Page 306: ...Tse new valve seals whenever valves are reconditioned 9 Lube valves with engine oil and reinstall valves valve springs caps and cap retainers using J 8062 Install valve spring with closely wound coils...

Page 307: ...2 Place a piece of the plastic type gauge material Figure 6A 25 Checking Bearing Cleatance With Plastic Type Gauge lengthwise along the bottom center of the lower bear ing shell Figure 6A 25 view A th...

Page 308: ...aring clearance with a plastic type gauge 4 When checking a crankshaft bearing with plastic type gauging material turn crankshaft so that oil hole is up to avoid dripping of oil on the gauge material...

Page 309: ...el several times last movement fore with the thrust bearing cap bolts finger tight 16 After bearing is installed and tested loosen all bearing cap bolts l 2 turn and continue with other bearings When...

Page 310: ...ring roughness or ridges which indicate excessive wear Check cylinder bores for taper and out of round with an accurate cylinder gage at top middle and bottom ofbore both parallel and at right angles...

Page 311: ...w pistons with micrometer contacting at points exactly 90 degrees to piston pin Figure 6A 32 then select the smallest piston for the first fitting The slight variation usually found between pistons in...

Page 312: ...in piston grooves and for gap in cylinder bores how ever the flexible oil rings are not checked for gap The cylinder bores and piston grooves must be clean dry and free of carbon and burrs To check t...

Page 313: ...ear Piston pin bores and piston pins must be free of varnish or scuffing when being measured The piston pin should be measured with a niicrometer and the piston pin bore should be measured with a dial...

Page 314: ...in slots in rear main bearing cap and engine front cover 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 Ope...

Page 315: ...r proper operation and reusability 6 Install timing case rubber gaskets to cylinder block Stick on with grease as necessary Gaskets will somewhat overlap with oil pan gasket 7 Position timing cover on...

Page 316: ...alve lifter Place lifters in a suitable hold ing fixture so that they may be reinstalled in original position 7 Install belts and torque to proper tension 45 lb ft 4 Remove cover from access hole on l...

Page 317: ...attaching oil pump cover assembly to timing chain cover Remove cover assembly and slide out oil pump gears See Figure 6A 44 2 Wash off gears and inspect for wear scoring etc Replace any gears not foun...

Page 318: ...y 1 Remove oil pan 2 Clean oil pan Make sure the gasket surfaces and pan and block are clean Figure 6A 47 Installation of Pipe and Screen Assembly 4 Clean the screen and housing thoroughly in sol vent...

Page 319: ...Bolt 10 MM Head 30 Lb In Torque Lb Ft GENERAL SPECIFICATIONS Type No of Cylinders Valve Arrangement I nlinzai Bore and Stroke Piston Displacement Cu In 3 66 x1 Compression Ratio 7 6 1 Octane Requireme...

Page 320: ...ton Groove _ 0013 OO24 In Oil Control Ring Side Clearance in Piston Groove __ __ _ 0013 X024 In Piston Ring Gap No 1 Compression Ring 014 022 In No 2 Compression Ring _ ___ __ 014 022 In Oil Control R...

Page 321: ...haft is Placed in V Blocks so That Main Bearing Journals Next to Each Other Are Supported 0005 In Max Permissible Runout of Crankshaft to Flywheel Contact Area 0008 In Crankshaft End Play GOl7 CO61 In...

Page 322: ...ENGINE MECHANICAL AND MOUNTS 6A 31...

Page 323: ...the heater is in operation before engine has reached full operating temperature MAINTENANCE AND ADJUSTMENTS Checking and Filling Cooling System The coolant level should be checked only when the engin...

Page 324: ...Cooling System Protector and Water Pump Lubricant or equivalent be added to the cool ing system as soon as possible If any other cooling System protector is used be certain it is labeled to indicate...

Page 325: ...diator cap then remove lower radiator hose and drain radiator coolant into suitable con tainer 2 On vehicles with automatic transmission unscrew oil lines from connectors on lower radiator tank and pl...

Page 326: ...APACITIES Cooling System Type Liquid Filler Cap Type Pressure _ _ __ _ _ Water Temperature Control Thermostat Open At __ __ _ __ Cooling System Capacity Fan Drive Cooling With Circulating Pump 13 2 15...

Page 327: ...of the eccentric the lighter diaphragm spring will push the diaphragm to replace any fuel used in the carburetor The diaphragm seldom operates through a full stroke under normal driving conditions the...

Page 328: ...s idling In this way the fuel vapors escaping to the outside during engine idle are collected by the activated carbon container and fed into the combustion chambers 5 The vent lines are connected to t...

Page 329: ...ollowing a Strainer must be properly seated with projections facing upward b A new cap gasket must be positioned over strainer c Sealing ring must be in place on cap retaining screw 6 Reconnect fuel s...

Page 330: ...Take off tiller cap and unscrew tiller neck from side panel Pull off fuel tank hose and plug connect ing tubes on tank See Figures 6C 4 and 6C 6 3 With a jack and suitable support wooden board 12 x 12...

Page 331: ...ttaching brackets Spare tire hold down and support attaching brackets are attached to the rear wheel house panel and are Figure 6C 1 1 Tank Vent and Filler Hoses Figure 6C 9 Spare Tire Hold Down and B...

Page 332: ...plastic line place the line in hot water to make it flexible Using the old line as a pattern form the new line Let the line cool com pletely then route it in the same location as the old line To prev...

Page 333: ...rubber damper rings for muffler and tail pipe hanger and replace as necessary 1 Coat I D of rear muffler inlet neck and O D of center exhaust pipe outlet rear of pipe with exhaust sealer compound sev...

Page 334: ...EXHAUST SYSTEM KEJ 1 2 3 4 5 6 7 DESCRIPTION MUFFLER FRT W CTR EXHAUST PIPE FRT EXHAUST MUFFLER RR W TAIL PIPE BUMPER MUFFLER SUSPENSION RR BOW MUFFLER SUSPENSION RR BRACKET MUFFLER SUSPENSION RR DAM...

Page 335: ...take mani fold The secondary barrel does not have a choke valve or an accelerator pump See Figure 6E 2 The throttle valve of the primary barrel is opened through the throttle linkage When the primary...

Page 336: ...e choke valve spindle through a pull rod The vacuum which develops below the throttle valve takes effect on the diaphragm through a vacuum passage See Figure 6E 4 As soon as the engine starts this vac...

Page 337: ...Fuel line connecting tube 13 Carburetor cover gasket 14 Leaf spring 15 Float amber 16 Pressure reduction valve 17 Pump lever 18 Diaphragm 19 D iophragm spring 20 Ball valve suction valve 21 Float 22...

Page 338: ...this tendency the fuel level drops in the emulsion tube bore and more emulsion tube transverse bores are exposed Air from the high speed air jet Figure 6E 2 enters the emulsion tube through these tran...

Page 339: ...ragm is moved inward by the pump con necting rod and the pump lever Fuel is injected into the primary bore through the injector tube The amount of fuel is determined by the pump stroke The inlet ball...

Page 340: ...e inlet check ball 4 Defective accelerator pump pressure relief valve 5 Defective accelerator pump diaphragm 6 Maladjusted accelerator pump linkage Condition II Hard Start Afier Hot Soak Correction Pe...

Page 341: ...going through the system 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 R P M higher than the...

Page 342: ...creasing Fast Idle Speed a Unhook accelerator pedal return spring b Remove lock spring at upper end of vertical con trol rod and detach rod c Lengthen or shorten control rod so that wide open throttle...

Page 343: ...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 Install in reverse ord...

Page 344: ...control wire is kinked or damaged in any way it must be replaced 1 Feed ball and plastic bushing from engine com partment through opening in dash panel and hook in accelerator pedal lever See Figure...

Page 345: ...spring from float chamber 9 Pull accelerator pump discharge nozzle assembly Figure 6E 23 Removing Vacuum Case Reduction Jet out of carburetor housing Nozzle is press fitted See Figure 6E 24 GATORPUMP...

Page 346: ...m bly See Figure 6B28 18 Install gasket and shield between automatic choke cover and automatic choke body Figure 6E 28 Installing Vacuum Case Assembly 19 Install automatic choke cover so that the catc...

Page 347: ...spring to push plunger against lever so that a zero clearance exists Then retighten the screws See Figures 6E 3 1 and 6E 32 27 Insert accelerator pump discharge nozzle so that the bent tube end points...

Page 348: ...seated in casting 36 Install new air horn gasket so that the holes in the gasket coincide with the screw holes in carbu retor housing See Figure 6E 35 34 Install leaf spring so that spring ends rest...

Page 349: ...bending valve lever Figure 6E 35 Installing Cover Gasket SPECIFICATIONS GENERAL SPECIFICATIONS Compression Ratio 7 6 to 1 Fuel Required Low Lead Fuel Tank Capacity Gallons Opel 1900 and Manta 11 9 GT...

Page 350: ...CARBURETOR AND THROTTLE LINKAGE 6E 59 Figure 6E 37 Carburetor Specifications...

Page 351: ...ust system The purpose of this law is to keep the atmosphere cleaner particularly in popu lous areas where these impurities add to the smog problem Basically excessive exhaust emissions are caused by...

Page 352: ...s about 135 degrees the door will close tight not allowing any more warm air from the mainifold to enter the snorkel of the air cleaner Obviously if underhood temperatures rise above 135 degrees the a...

Page 353: ...el in the intake manifold and in the vacuum motor to drop Whenever vacuum drops below 5 inches the diaphragm spring will close the air door in order to get the maxumum outside air flow required for ma...

Page 354: ...er cover and in stall a temperature gage such as J 22973 as close as possible to se r Keinstall air cleaner cover Let car stand idle for l 2 hour or more before proceeding to step 2 2 Start the engine...

Page 355: ...eplacing Sensor Assembly so that you can install new sensor in same position Then remove sensor 4 Install sensor and gasket assembly in air cleaner in same position as noted in Step 3 This is to elemi...

Page 356: ...und in each engine compartment Economical trouble free operation can better be as sured if a complete tune up is performed at first 4 months or 6 ooO miles of operation then at 12 month or 12 000 mile...

Page 357: ...t reading number See Figure 6G 2 EXAMPLE After checking the compression pressures in all cylinders it was found that the highest pressure obtained was 182 psi The lowest pressure reading was 145psi By...

Page 358: ...Inspection should be made with engine operating at normal temperature cooling system completely filled temperature control lever fully open and nor mal pressure in the system Normal pressure should b...

Page 359: ...and In of Vacuum Start Advance 5 at 2 9 4 1 In Maximum Advance 1 5 at 4 5 5 0 In Vacuum Retard Engine Degrees at Closed Throttle 5 Condenser Capacity in MicroFarads 23 32 Breaker Spring Tension in Oun...

Page 360: ...GROUP 7 TRANSMISSION 7A I Clutch 7A 1 7B I Manual Transmission 1 76 12 1 7c I Automatic Transmission 1 7C 36 1 I I I...

Page 361: ......

Page 362: ...ke through a sheathed cable attached directly to the upper end of the pedal lever Pedal return is accomplished through a spring attached to the pedal below the pivot shaft and to the pedal assembly mo...

Page 363: ...l new driven plate and correct oil leak at its source 3 Worn facing or facing 3 Replace driven plate tofn from driven plate 4 Warped pressure plate or 4 Replace same flywheel 5 Weak diaphragm spring 5...

Page 364: ...eplace spring Noisy 1 Worn throw out bearing 1 Replace bearing 2 Fork off ball stud heavy clicking 2 Install properly Pedal stays on floor when disengaged 1 Bind in cable 1 Lubricate and free up cable...

Page 365: ...pedal position has to be corrected to ensure proper clutch operat ion To sure proper clutch operation observe the fol lowing adjustment instructions For all adjustment dimensions refer to Figure 7A 7...

Page 366: ...WHEEL HOUSING 2 CLUTCH RELEASE LEVER 3 RELEASE LEVER BOOT 4 RELEASE BEARING SLEEVE S CLUTCH RELEASE BEARING i A 2 Figure 7A 2 6 If assembly marks on clutch assembly and fly wheel have become indistinc...

Page 367: ...clutch release bearing for scoring or exces sive wear on front contact face Test for roughness of balls and races by pressing and turning front race slowly Inspect main drive gear pilot bushing in cra...

Page 368: ...ed Vibration Dampening 4 Torsional Springs Bolt Tightening Specifications CLUTCH CONTROL CABLE REMOVAL AND INSTALLATION SEE FIGURE 7A 6 OR 7A 7 If a new cable was installed or the cable adjustment was...

Page 369: ...SPRING 4 WASHER 14 RELEASE LEVER 5 SLEEVE 15 RUBBER BELLOWS 6 DASH PANEL 16 BALL STUD LOCK NUT 7 BOWDEN CONTROL CABLE 17 CLUTCH HOUSING 8 BRACKET 18 BALL STUD 9 WASHER HAIRPIN CLIP 19 BOWDEN CONTROL C...

Page 370: ...ERATING DAMPER 15 CLUTCH HOUSING 5 GROMMET 16 BALL STUD LOCK NUT 6 WASHER 17 RUBBER BELLOWS 7 E RING 18 CABLE SUPPORT BRACKET 8 ADJUSTMENT SWITCH 19 NUT CABLE SUPPORT BRACKET 9 CLUTCH PEDAL 20 DISTANC...

Page 371: ...y marks 4 Clutch assembly 5 Flywheel 6 Flywheel ring gear 7 Thrust pin 8 Retaining spring 9 Crankshaft 10 Clutch gear pilot bushing 11 Oil seal 12 Flywheel bolt 13 Clutch housing 16 Felt ring 17 Clutc...

Page 372: ...Figure 7A 9 Exploded View of Clutch Pedal and Housing...

Page 373: ...arshift Blocker Shift Lever Installation Servicing Gearshift Lever MAJOR REPAIR Transmission Removal Installation of Transmission Removing and Installing Speed0 Driven Gear Transmission Removed Replac...

Page 374: ...HAFT G E A R UNIT COUNTERSHAFT GEAR UNIT f t 3RD SPEED GEAR REVERSE SPEED GEAR COUNTERSHAFT GEAR UNIT 2ND SPEED GEAR POWER FLOW NEUTRAL POSITION Figure 78 1 Neutral Position DRIVE INPUT1 ERSHAFT R U N...

Page 375: ...he 1st speed gear the 1st and 2nd gear sliding gear shifts to the rear of the transmission and locks the 1st speed gear to the mainshaft through the 1st and 2nd speed sliding gear guide unit This 1st...

Page 376: ...eed gear the 1st and 2nd gear sliding gear shifts toward the front of the transmission and locks the 2nd speed gear to the mainshaft through the 1st and 2nd speed sliding gear guide unit This 1st and...

Page 377: ...the 3rd speed gear the gear shifter sleeve shifts to the rear of the transmission and locks the 3rd speed gear to the mainshaft through the gear shifter sleeve car rier This gear shifter sleeve carrie...

Page 378: ...shifts forward and locks the main drive gear to the mainshaft through the gear shifter sleeve carrier This carrier is internally splined to the gear shifter sleeve and is externally splined to the ma...

Page 379: ...everse speed gear the drive is bridged between the countershaft gear unit and the mainshaft through the guide unit The direc tion of the mainshaft is reversed The guide unit is located between the 1st...

Page 380: ...n synchronizer sleeve 6 Worn or broken blocking rings 7 Bent mainshaft Sticking in Gear 1 Clutch not releasing fully 2 Low lubricant level 3 Incorrect lubrication 4 Defective tight main drive gear pil...

Page 381: ...er pivot pin retaining washer and tension spring Reposition protective cap and bel lows and button cap from below Replace console 3 In Figuie 7B 11 distance A 8 07 Figure 7B 10 7 l1 Figure 78 1 1 4 Af...

Page 382: ...ut of stop sleeve in installa tion position shows to the left The spiral pins must not protrude on either side 7 Clamp tight Bowden control wire with threaded pin Prior to tightening pull ring must re...

Page 383: ...frame or wheel stands in the front or frame stands in the rear 5 Loosen front exhaust pipe to manifold flange 6 Remove clutch cable from fork by pushing fork to disengage the clutch and unsnap cable...

Page 384: ...n hous ing It may be necessary to tap lightly on tool J 22929 when installing assembly Be sure speedo driven gear lock pin hole on guide lines up with hole in transmission case extension housing Also...

Page 385: ...cket See Figure 7B 2 1 3 Remove selector lever and bracket Selector lever will just slip off selector ring 4 Remove lock nut and selector ring 5 Remove transmission case extension bolt See Fig ure 7B...

Page 386: ...second speed intermediate lever See Figure 7B 25 3 Push selector shaft out of case and remove inter mediate levers 4 With screwdriver pry out selector shaft oil seals on transmission case Removing Fi...

Page 387: ...ler Gear 1 Using a brass drift and from the front of the trans mission drive out reverse gear shifter shaft and plug See Figure 7B 28 The reverse speed shifter yoke will remain in transmission case Fi...

Page 388: ...d0 drive worm gear 5 Remove drive gear lock ball from mainshaft See Figure 7B 34 6 Press mainshaft inner bearing from mainshaft us ing Special Tool J 21684 Press Plate as shown in Figure 7B 35 and the...

Page 389: ...e carrier See Figure 7B 39 TRANSMISSION REASSEMBLY A Assembling Mainshaft 1 From front of the mainshaft install third speed f cz mto mainshaft Gear must turn freely on main 3 Install rear synchronizer...

Page 390: ...ooth contact is obtained 10 Using Tool J 22913 press first speed gear needle bearing inner sleeve onto mainshaft 11 Using Tool J 22913 install tirst and second speed shoes long style and install first...

Page 391: ...ave groove end toward front See Fig ure 7B 46 Continue to drive reverse idler gear shaft forward with plastic hammer until rear end of shaft is flush with rear case face 2 Position reverse speed shift...

Page 392: ...shaft through shifter shaft cam which should be positioned as shown in Figure 7B 50 3 Install spiral pins to secure shifter yoke and shifter shaft cam to first and second gear shifter shaft Installin...

Page 393: ...rlock plugs into case holes until they bottom in interlock plug hole seats Grooves in plugs will be showing Installing Countershaft Gear Unit 1 Coat thrust washers with ball and roller bearing grease...

Page 394: ...r to Intermediate Shaft and Bearing Retainer 4 Install shifter shaft with spring washers on inside of shifter shaft ends and flat washers on outside of shaft 5 Secure each end of shifter shaft and was...

Page 395: ...79 34 1973 OPEL SERVICE MANUAL 1 9 Engine Transmission Figure 78 57 Exploded View of Manual Transmission...

Page 396: ...and 4th Speed Shifter 32 Bearing Trans Main Shaft R R 33 Snap Ring Trans Main Shaft Ball Bearings 34 Washer Main Shaft Between Inner Ball Bearing and 1st Speed Gear 3j 36 37 ii 40 41 42 43 44 45 46 47...

Page 397: ...f Selector Lever and Shaft Removal of Modulator Assembly Removal of Detent Valve Assembly Removal of Extension Housing Removal of Speedometer Drive Gear Governor Body and Governor Hub Removal of Conve...

Page 398: ...rter Housing Oil Pump and Clutch Assembly Installation of Governor Assembly Installation of Extension Housing Installation of Speedometer Driven Gear Installation of Detent Valve Modulator Valve and M...

Page 399: ...LES OF OPERATION Torque Converter The torque converter acts as a coupling to transmit engine torque through oil to the transmission power train It also multiplies the torque from the engine under cert...

Page 400: ...mp 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 To pre vent this a stator assembl...

Page 401: ...of their physical arrangement and are used because they permit constant mesh operation cannot clash operate in a minimum of space and distribute the load over several gears The simplest planetary gea...

Page 402: ...on rear sun gear is held stationary The input front sun gear rotates in a clockwise direction when viewed from the front turning the short planet pinions counterclockwise and the long planet pinions c...

Page 403: ...tuation thus causing the planetary carrier output shaft and gears to rotate clockwise as a solid unit to provide direct drive See Figure 76x12 LONG PINION PLANiTARY CARRIER X 11 Figure 7C 1 1 Second G...

Page 404: ...ting member or a stationary member The method of apply in an automatic transmission is a hydraulic piston One set of plates is lined with friction material and the other plates are steel Whether the p...

Page 405: ...outer race while the other diagonal is less See Figure 7C 17 This I b SPRAG DISTANCE A Figure 7C 17 Sprag Operational Schematic transmissio case stationary anchor and is ope rated by a servo piston O...

Page 406: ...AUTOMATIC TRANSMISSION 7c 45 Figure 7C 20 Converter Converter Housing And oil Pump INPUT SHAFT AND THIRD CLUTCH DRUM Figure 7C 21 Input Shaft And 3rd Clutch Drum...

Page 407: ...he outside of the third clutch drum mak ing the third clutch drum the hub for the second clutch The ring gear is splined to the second clutch drum See Figure 7C 23 The reverse clutch piston assembly i...

Page 408: ...e 7C 23 Second Clutch Drum Piston Springs Clutch Plates Spacer And Ring Gear REVERSE CLUTCH ASSEMBLY SECOND CLUTCH DRUM SECOND CLUTCH REVERSE CLUTCH ASSEMBLY DRUM Figure 7C 24 Oil Pump Reverse Clutch...

Page 409: ...adrant In every case with the engine running torque is transmitted via the flex plate and converter 7G25 cover to tht pump member of the converter The converter is always tilled with oil from the tran...

Page 410: ...sump With the pump cavity filled with air the pump cannot develop enough suction to lift the oil from the sump For this reason a priming valve is located in the pump pressure passage As the air in th...

Page 411: ...provide the required capacity in the band and clutches it is desirable to have a variable line pressure that will increase with engine torque This PRESSURE REGULATOR Y 7c30 Figure 7C 30 Pressure Regul...

Page 412: ...ation with the pressure regulator system In addition higher car speeds will produce a some what lower modulator and line pressure for any given vacuum by virtue of the governor pressure acting on the...

Page 413: ...inward against the spring force until the outer spool closes the line port If the pressure between the spools still creates a force larger than the spring force the valve will continue to move inward...

Page 414: ...cause the trans mission to shift to a lower gear for additional per formance when the accelerator is depressed all the way The detent valve is mechanically connected to the throttle linkage A spring h...

Page 415: ...Since line pressure can never be less than governor pressure the force established by line pressure on the shift valve plus the spring force will move the shift valve to a downshifted position regard...

Page 416: ...t valve is in the downshifted position Because the servo release passage is open to exhaust the low band will remain applied When the selector lever is placed in Reverse line pressure acts on the end...

Page 417: ...r speeds This permits an unre stricted flow for servo apply At higher car speeds approximately 25 to 35 MPH depending on axle ratio and engine governor pressure forces the valve over against the sprin...

Page 418: ...he bot tom side of the accumulator piston This pressure assists the spring and the clutch pressure will have to build up to a higher value before the accumulator piston will move See Figure 7C 46 SERV...

Page 419: ...rotate around their own axis and no torque is trans mitted to the planet carrier assembly and output shaft Park Engine Running The same power flow conditions in the neutral position are in effect in t...

Page 420: ...t ary gear set in first gear The input shaft drives the third clutch drum in a clockwise direction which turns the sprag race and retainer assembly clockwise The sprags wedge and drive the input sun g...

Page 421: ...ied the rotating second clutch composition plates are locked w the second clutch steel plates Since the second clutch drum is now rotating in a clockwise direction the ring gear is driven clockwise As...

Page 422: ...e low band is released and both the second and third clutches are applied In this condition the ring gear is locked o the input sun gear With two planetary members connected inthis manner the entire p...

Page 423: ...Third Clutch Applied Low Band Released...

Page 424: ...AUTOMATIC TRANSMISSION C 63...

Page 425: ...712 64 1973 OPEL SERVICE MANUAL HYDRAULIC OPERATION I r n...

Page 426: ...egulator MIYB the return oil from the converter being directed through the coalerand back into the transmisGon s lubricating system Line oil directed to the vacuum modulator valve becomes regulated to...

Page 427: ...7C 66 1973 OPEL SERVICE MANUAL...

Page 428: ......

Page 429: ...7C 68 1973 OPEL SERVICE MANUAL II II I...

Page 430: ...in to apply the second clutch while portion of the oil is directed 10 the accumulator As the upper portion of the accumulator fills with second clutch oil it overcomes the leer prewre of 1 2 accumulat...

Page 431: ...7C 70 1973 OPEL SERVICE MANUAL d...

Page 432: ...ected to the 3 2 control valve acting against the spring and modulator oil cutting off modulator oil pressure to the 2 3 shift control yalve Third control oil also is directed to the Reverse and Law c...

Page 433: ...7C 72 1973 OPEL SERVICE MANUAL...

Page 434: ...ator boost control cavity seating the check ball at the reverse passage Intermediate oil is then directed to the pressure regulator valve downward to increaSe the oil prepare in the circuit At the sam...

Page 435: ...7C 74 1973 OPEL SERVICE MANUAL...

Page 436: ...at the Reverse and Law control valve to flow to the 2 3 shift valve which is bottomed in its bore by intermediate oil pressxe and the valve spring The detent oil pazses through the 2 3 shift vahre an...

Page 437: ...712 76 1973 OPEL SERVICE MANUAL...

Page 438: ...reverse oil pasring into the intermediate oil passage It is then directed to the pressure regulator boast valve forcing Reverse oil is also directed to act on the end of the Reverse and Law control v...

Page 439: ...a 1973 OPEL SERVICE MANUAL...

Page 440: ...l linkage holding the detent nlve open allows the detent regulated oil to pass into the detent oil passdgeand is directed to the 2 3 shift control valve acting against the spring and governor oil pres...

Page 441: ...7C 80 1973 OPEL SERVICE MANUAL...

Page 442: ...RANSMISSION 7C 81 is used in the transmission oil at the assembly plant and will indicate if the oil leak is from the transmis sion The use of a Black Light to locate the point at which the oil is lea...

Page 443: ...s on front of transmission 4 External oil leaks in the area of transmission case and extension a Shifter shaft seal b Extension seal c Oil pan gasket d Extension to case gasket e Vacuum modulator gask...

Page 444: ...lector lever shaft nut loose 3 No starting after shifting lever from P to D S or L inadequate engine acceleration a Parking paw1 does not disengage 4 Sudden starting only after increase of engine RPM...

Page 445: ...ns in 2nd gear at all speeds a 2 3 shift valve stuck b Large leak in governor pressure circuit 3 Upshifts in D and S only at full throttle a Failed vacuum modulator b Modulator vacuum line leaky or in...

Page 446: ...flares a Low oil pressure b Sealing ball in valve body dropped out c Second clutch piston seals leaking d Second clutch piston centrifugal ball stuck open e Second clutch piston cracked or broken f Se...

Page 447: ...ing pawl d Governor hub Noises 1 Excessive noises in all drive ranges a Too much backlash between sun gear and planetary gears b Lock plate on planetary carrier loose c Thrust bearing defective d Bear...

Page 448: ...C PRESSURE CHECKS NOTE ON REPLACING PLUG TOROUE TO 6 7 LEFT D 65 4 After pressure gage and hose is install replace rear crossmember s 65 and side bolts and proceed with pressure checking procedure L 8...

Page 449: ...SERVICE MANUAL CONVERTER OUT 2ND CLUTCH a EI 1 CONVERTER i O U T x PRIMING VALVE BORE REVERSE CLUTCH q MODULATOR EXHAUST REVERSE CLUTCH INTERMEDIATE 2ND CLUTCH 3RD CLUTCH B O O S T 7674 Figure 7C 74 O...

Page 450: ...AUTOMATIC TRANSMISSION 7C 89 DRIVE SERVO LINE REVERSE I NTERMEDlATE T SERVO APPLY MODULATOR OR Figure 7C75 Valve Body Top...

Page 451: ...7C 90 1973 OPEL SERVICE MANUAL SHIFT BOOST SUCTION REVERSE UNE MO DULATOR SERVO RELEASE LOW SERVO A P P L Y R E G U L A T O R DRIVE RNOR 7076 Figure 7C 76 Case Bottom...

Page 452: ...procedures on various models are identical the location of the upper or throttle end of the detent cable may vary For proper model iden tification see Figures 7C 61 7C 62 7C 63 and 7C 64 Figure JC 79...

Page 453: ...nuts and retainer on Manta models screw adjuster into bulkhead 3 Hook detent cable to valve and install retainer Figure 7C 86 Figure 7C 87 Adjustment Before carrying out any adjustment to the detent...

Page 454: ...console remove four 4 screws The fourth screw is accessible after removal of ash tray See Figure 7C 88 Figure 7C 88 Figure 7C 89 2 Unplug cigar lighter and lamps from console and remO e co sole 3 Fro...

Page 455: ...in new retaining pin 15 Install assembly to support housing and install intermediate selector lever 16 Install assembly to vehicle and install neutral start switch 17 Install console lights and cigar...

Page 456: ...t cable to transmission 5 Connect oil cooler lines 6 Install lower bolt on starter Torque to 40 lb ft 7 Connect shift linkage to transmission 8 Connect modulator line 9 Connect speedometer cable 10 In...

Page 457: ...far as possible 14 Drain transmission oil 15 Detach selector rod from ball pin of the outer transmission selector lever on right transmission side See Figure 7C 98 16 Unscrew oil cooler pipes from tr...

Page 458: ...m torque converter housing Slacken front attaching bolt only See Figure 7C 105 22 Remove torque converter housing cover plate Figure 7C 104 23 Mark flex plate and converter for reassembly in same posi...

Page 459: ...l drive shaft Torque U bolts to 18 lb ft 12 Install flywheel cover pan 13 Reconnect exhaust system and heat shield 14 Install engine support brackets 15 Lower car 16 Install starter bolts Torque to 40...

Page 460: ...oval of Valve Body This operation can be performed with transmission in vehicle 1 Remove the manual detent roller and spring re tained by two bolts See Figure 7C 110 2 Remove the three attaching bolts...

Page 461: ...ess servo piston using servo piston com pressor tool J 23075 Figure 7C 1 14 2 Using pliers remove servo piston snap ring See Figure X 1 15 Figure 7C 1 15 3 Loosen servo piston compressor tool J 23075...

Page 462: ...r inner lever locking nut from se lector lever shaft 3 Remove selector inner lever from selector lever shaft 4 Remove selector lever shaft spring pin by pulling upwards with small pliers Figure 7C 119...

Page 463: ...ly tap detent valve assembly from front of case and remove detent valve sleeve spring and spring seat from rear of easel See Figure 7C 122 Removal of Extension Housing This operation can be performed...

Page 464: ...shaft See Figure 7C 125 7c 125 Figure 7C 125 2 Remove the four 4 attaching bolts from the gov ernor body and remove governor and gasket See Figure 7C 126 Figure 7C 126 3 Remove governor hub snap ring...

Page 465: ...30 4 Remove reverse clutch plates from transmission case See Figure 7C 131 T RSE L T H PLATES 7c 131 Figure 7C 13 I Removal of Third Clutch Assembly Planetary Carrier Assembly Reaction Sun Gear and Dr...

Page 466: ...race from rear of case See Figure 7C 135 5 Remove low band by slightly compressing band and pulling straight out See Figure 7C 137 6 If necessary to remove case vent install new case vent Do not atte...

Page 467: ...plate A See Figure 7C 140 Figure 7C 140 7 Inspect front face of converter housing for oil leak See Figure 7C 141 If problem is diagnosed as a front seal leak presence of red oil coming from bottom of...

Page 468: ...l J 2590 12 with adapter J 21420 1 on reverse clutch retaining seat compress clutch return springs See Figure 7C 146 14 Remove snap ring using snap ring pliers such as J 8059 See Figure 7C 146 Figure...

Page 469: ...ssive dirt has passed through transmission 18 Pressure regulator and boost valve may be removed by using a pari of wire cutters to remove the retaining pin Due to the difficulty of removing the retain...

Page 470: ...p shaft until seated in the bore Care must be taken so that bush ing is pressed in straight using the scribe marks as a guide until firmly seated 23 Inspect and thoroughly clean the pressure regula to...

Page 471: ...the springs to take a heat set and would justify replacement of the springs 33 Install the twenty four reverse clutch piston re turn springs Figure 7C 154 34 Install retaining seat 35 Compress return...

Page 472: ...the oil pump face Clearance should be between 0005 to 0035 See Figure 7C 156 Disassembly Inspection and Reassembly of Second Clutch 1 Remove ring gear retaining ring from second clutch drum See Figur...

Page 473: ...and reverse clutch spring cotnpres sor tool J 2590 12 with adapter J 21420 1 on second clutch piston return spring retainer and compress second clutch piston return springs SECOND TO THIRD CLUTCH Figu...

Page 474: ...l J 23080 so as not to damage lip seal See Figure 7C 165 Use liberal amount of transmission fluid for ease of installation and to pre vent seal damage SECOND CLUTCH D R U M J 23 060 Figure 7C 165 17 R...

Page 475: ...7C 166 I DRUM 7c 167 Figure 7C 167 Disassembly Inspection and Reassembly of Third Clutch 1 Compress third clutch sprag race and retainer assembly retaining ring and remove assembly from third clutch d...

Page 476: ...me sequence as they were installed in the clutch 5 Remove input shaft thrust washer and needle thrust bearing See Figure 7C 171 6 Using compressor tool J 23075 on third clutch piston retaining seat co...

Page 477: ...Install third clutch piston into third clutch drum using a 020 music wire crimped into a piece of cop per tubing and a liberal amount of transmission fluid Figure 7C 176 Figure 7C 177 so that lip seal...

Page 478: ...clutch plates into third clutch drum beginning with a steel plate composition plate steel plate composition plate etc Use a liberal amount of transmission fluid 21 Inspect thrust washer and needle th...

Page 479: ...t input sprag ra assembly into third clutch drum 28 Air check the 3rd clutch piston assembly See Figure 7C 183 THlRD CLUTCH ASSEMBLY 7C183 Figure 7C 183 Figure 7C 184 4 Replace entire assembly if dama...

Page 480: ...valve spring secondary valve primary valve and roll pin from governor body See Figure 7C 188 1 GOVERNOR SECONDARY VALVE SPRING RETAINER 2 GOVERNOR SECONDARY VALVE SPRING 3 GOVERNOR SECONDARY VALVE 4 G...

Page 481: ...cracks or chipped teeth in splines Replace governor hub if required Figure 7C 191 Disassembly Inspection end Reassembly of Extension Housing 1 Inspect extension housing for damage Replace housing if n...

Page 482: ...the valve body so that the transfer plate is facing upward and remove the two bolts holding the transfer plate to the valve body See Figure 7C 196 3 Remove transfer plate and gasket Figure 7C 193 3 D...

Page 483: ...SERVO PISTON RETAINING RING 3 SERVO PISTON ADJUSTING SLEEVE 9 SERVO PISTON ADJUSTING BOLT 4 SERVO PISTON CUSHION SPRING SEAT 10 SERVO PISTON ADJUSTING BOLT NUT 5 SERVO PISTON CUSHION SPRING 11 SERVO...

Page 484: ...high speed downshift timing valve retaining pin and spring and remove valve 1 RETAINING PIN 2 1 2 SHIFT CONTROL VALVE SLEEVE 3 1 2 SHIFT CONTROL VALVE 4 l 2 SHIFT CONTROL VALVE SPRING 5 1 2 SHIFT VAL...

Page 485: ...and retain ing pins in their proper location and order into the valve body using a liberal amount of transmission fluid See the spring data chart which includes the spring identification sizes in the...

Page 486: ...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 a...

Page 487: ...EMBLY BEARING Figure 7C 205 Location 2 Inspect band for cracks flaking burring or loose ness Replace if required Figure 7C 206 6 INPUT SUN GEAR ASSEMBLY BEARING 7 INPUT SUN GEAR ASSEMBLY TO PLANETARY...

Page 488: ...on first then race on front face of reaction sun gear See Figure 7C 210 Secure with petroleum jelly unmedicated Figure 7C 2 10 Installation of Output Shaft and Planetary Carrier 1 Install input sun ge...

Page 489: ...sition plates with compressed air and inspect the composition surface for 1 Pitting and flaking 2 Wear 3 Glazing 4 Cracking 5 Charring 6 Chips or metal particles imbedded in lining If a composition dr...

Page 490: ...ize is obtained The washer selected should be exactly flush or slightly below inner shaft for correct end play in transmission Selective washer removed from transmission may be oil soaked and discolor...

Page 491: ...governor hub Torque to 6 8 lbs ft The two governor valves should move freely after governor body is torqued 6 Install speedometer drive gear retaining clip into output shaft See Figure 7C 220 Figure...

Page 492: ...rt spring pin to secure detent valve assembly Detent valve sleeve must be installed with slots facing oil pan Care should be taken so that spring pin is inserted into the groove provided in sleeve and...

Page 493: ...and sleeve firm with hex head wrench See Figure 7C 227 installation of Valve Body 1 I all steel balls in oil passages in case See Figure 7C 228 Figure 7C 227 2 Install new case to transfer plate gask...

Page 494: ...ng in the center of the valve body and working outward Torque to 13 15 lbs Ft 8 Install reinforcement plate to case Torque to 13 15 lbs ft 9 Inspect oil strainer If foreign matter is present install n...

Page 495: ...ne is regularly idled for long periods the oil pan should be drained and the strainer replaced every 12 ooO miles 1 Checking and Adding Fluid The Opel three speed automatic is designed to oper ate at...

Page 496: ...l lever in Park position start engine DO NOT RACE ENGINE Move manual control lever through each range i Immediately check fluid level with selector lever in Park engine running and vehicle on LEVEL su...

Page 497: ...Torque Specifications Location Oil Pan to Case Transfer Plate to Valve Body Reinforcement Plate to Case Valve Body to Case Servo Cover to Case Modulator Assembly Converter Housing to Oil Pump Convert...

Page 498: ...L E V E R I N r 0 1 POSITION 2 3 PLACE TRANSMISSION SHIFT LEVER IN L OR 1 POSITION 4 ADJUST CONTROL ROD ALLOWING IT TO FIT OVER PIN IN LOWER SELECTOR LEVER FREELY 5 INSTALL LOCK CLIP _ _ S E L E C T O...

Page 499: ...7C 138 1973 OPEL SERVICE MANUAL 4 5 I Figure 7C 234 Special Tools Automatic Transmission 7C223...

Page 500: ...ousing Oil Seal Installer Converter Housing Seal Remover Without Disassembling Transmission Use With J 7004 Slide Hammer 2nd and Reverse Clutch Piston Spring Compressor Clutch Piston Compressor Adapte...

Page 501: ...TALLER J 22922 J 22926 TRANSMISSION CASE EXTENSION SPEEDOMETER DRIVEN HOUSING SEAL INSTALLER GEAR PIN REMOVER J 21715 DETENT PIN PLUG REMOVER J 22934 CLUTCH PLATE ALIGNING ARBOR TRWARC PLIERS J 22923...

Page 502: ...HOOD FENDERS AND GRILLE G R O U P 8 I I Section I I Page No 1 8A 1 Grille 1 814 2 Hood Fenders and...

Page 503: ...vert the movement of the lever to a rotation of 180 degrees The pivots of the headlamps lie below the centerline so that with head lamps in closed position the headlamp housing is flush with front she...

Page 504: ...ons on engine hood See Figure SA 4 Figure EA 2 Headlamp Assembly Front Adjustment Location Figure CIA 3 Headlamp Assembly Rear Adjustment Location Figure CIA 4 Marking Hinge Position 2 Unscrew engine...

Page 505: ...L AND INSTALLATION OF HEADLAMP COVERING OPEL 1900 MANTA Removal 1 Remove radiator grille 2 In engine compartment unscrew headlamp cover ing Se e Figure SA 7 Figure 8A 7 Headlamp Covering Attaching Bol...

Page 506: ...at its circumference and remove it See Figure 8A 3 Figure EA 10 Removing Headlamp Assembly 6 To avoid damage cover headlamp upper and lower edges with tape Turn headlamp 90 degrees and carefully remo...

Page 507: ...Headlamp Trunion Block Installation 10 Thread cable through bearing and clip retainers Figure 8A 14 Removing Ball Seat at Control Lever 11 Install adjusting lock nut approximately l 2 on thread See F...

Page 508: ...taching screws See Figure 8A 15 Figure 8A 15 Radiator Grille Attaching Screws 2 Remove radiator grille towards the top so that the lower guide pins do not break off See Figure 8A 16 Figure 8A 16 Remov...

Page 509: ......

Page 510: ...e No HEATER 9A GT 9A 2 O p e l 1900 Manta 9A 1 0 AIR CONDITIONING Refrigerant C o m p o n e n t s 9B 1 7 9B Air Conditioner System O p e l 1900 Manta 9B 9 0 Air Conditioner System G T OB 9 7 RADIO 9c...

Page 511: ...rate ventilation system for direct intake of outside air is controlled by two plastic fresh air inlet nozzles in the side kick panels and two lever operated inlet nozzles located on either end of the...

Page 512: ...the heater control The heater controls function as follows Air Inlet Defroster Control Upper Lever This control See Figure 9A 4 opens and closes the air inlet and heater defroster air door which chann...

Page 513: ...e within 5 degrees F of thermostat rated value 189 degrees F Check that air doors and water temperature control valye are operating properly Check for plugged heater core backflush heater core as nece...

Page 514: ...BLOWER SWITCH Removal i Remove instrument panel assembly Refer to Group 1 2 Unscrew switch assembly from panel Installation 1 Screw switch assembly to instrument panel 2 Install instrument panel asse...

Page 515: ...efer to Group 3 for this procedure 6 Remove two multiple wire plug connectors from steering column harness 7 Detach speedo cable 8 Remove dir ional signal flasher unit See Figure 9A 9 Figure 9A 9 Dire...

Page 516: ...Screws 14 Remove one bolt at top of heater blower case and two nuts from bottom of the case and remove heater blower and case assembly See Figure 9A 15 Figure 9A 12 Heater Control Screws and Support B...

Page 517: ...cover and attach through openings points A and B See Figures 9A 7 and 9A 8 11 Install right and left opening covers 12 Install the console shift cover between the seats using the following instruction...

Page 518: ...lve from hoses See Figure 9A 17 SPECIFICATIONS Engine Recommended Coolant __ __ _ __ Thermostat Opens At Degrees F __ ___ Installation 1 Install valve into heater hoses and install hose clamps 2 Conne...

Page 519: ...ntering the vehicle is regulated by the heater valve and the blower The distribution of this air is controlled by the heater air distributor housing under the instrument panel Moving the upper control...

Page 520: ...lets and or defroster outlets depending on the position of the lower con trol See Figure 9A 32 The heater valve regulates the flow of coolant through the heater core thereby varying t he temper ature...

Page 521: ...nt i e blower switch or blower motor replace or repair as necessary MAINTENANCE AND ADJUSTMENTS CONTROL CABLE ADJUSTMENT Adjustment of control cables is accomplished by po sitioning of the jacket or s...

Page 522: ...AND INSTALLING DEFROSTE l OUTLETS Removal 1 Pull out heater switch lever See Figure 9A 36 2 Remove instrument cover 3 Unscrew bowden control wires from heater valve and air distributor housing and pul...

Page 523: ...AND INSTALLATION OF HEATER CONTROL HOUSING Removal 1 Remove instrument panel cover refer to operat ion IRemoving and Installing Instrument Housing 2 Remove two sheet metal screws for control hous ing...

Page 524: ...42 4 In engine compartment attach bowden control wire to heater valve See Figure 9A 41 5 Install two 2 sheet metal screws for control hous ing attachment See Figure 9A 40 6 Install instrument panel c...

Page 525: ...ews See Figure 9A 46 2 Connect multiple plug on left side of shroud See Figure 9A 45 3 Seal shroud cover front and rear contacting areas with sealing cement See Figure 9A 47 4 Install shroud cover att...

Page 526: ...tion Compressor Opel 1900 Manta GT Removal and Installation Condenser Receiver Dehydrator Assembly GT Receiver Dehydrator Opel 1900 Manta GT Removal and Installation Evaporator and Expansion Valve Ope...

Page 527: ...bout controlling temperatures Figure 96 1 Transfer of Heat Transfer of Heat The only thing that will attract heat is a colder ob ject Like water which always flows down hill heat always flows down a t...

Page 528: ...hile in the old days the ice man 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...

Page 529: ...ing because if couldn t be located with a thermometer To best de scribe this disappearing heat scientists turned to Latin for the right word They chose the word la tent which means hidden Latent Heat...

Page 530: ...ea kettle on a stove No one would dare pick up the flask with his bare hands because even though boiling it would be so cold and it would be drawing heat away from nearby objects so fast that human fl...

Page 531: ...t in a vapor that way we increase the intensity of the heat or in other words we increase the tempera ture because temperature is merely a measurement of heat intensity And the most amazing part of it...

Page 532: ...t of the evaporator is very cold We know the liquid refrigerant boils at temperatures considerably below freezing and that the vapors arising from it are only a shade warmer even though they do contai...

Page 533: ...air in it would leak out through the puncture Abou t all you would be doing would be circulating nice fresh air through the tire 1Jnless you have something lo push against to block the tlow of air yo...

Page 534: ...e gas filled power ele ment body actuating pins seat and orifice At the high pressure liquid inlet is a tine mesh screen which prevents dirt tilings or other foreign matter from entering the valve ori...

Page 535: ...on the refrigerant Now let s find out how the temperature of the cooled air is con trolled METHOD OF TEMPERATURE CONTROL To achieve temperature control the compressor is run intermittently automatical...

Page 536: ...ge will register 70 psi pressure in a 100 degrees room the pressure will be 117 ps AIR CONDITIONING Because air conditioning has always been very closely allied with mechanical refrigeration most of u...

Page 537: ...rther advantage of air conditioning is that dust and pollen particles are trapped by the wet surfaces of the evaporator core and then drained off with the condensed moisture This provides very clean p...

Page 538: ...re basic and essential The desiccant or dehydrating agent and another chemical ingredient synthetic rubber makes it even more complex All of these ingredients have chemical properties which are entire...

Page 539: ...ich are suitable for use in refrigerating systems An ideal desiccant must have the following characteristics I High capacity 2 High eficiency 3 Low tendency to powder 4 Absorb moisture without reactin...

Page 540: ...o increased Any chemical reactions caused by contaminants al ready in the system are greatly accelerated as the temperature increases A 15 degree rise in tempera ture doubles the chemical action Even...

Page 541: ...re and dirt are responsible for many difficulties in refrigerating systems in most instances it is the presence of moisture in the system that accelerates these conditions It can be said themfore that...

Page 542: ...operate in a similar but opposite manner The discs are com posed of three reeds and function to open when the pistons are on the intake portion of their stroke downstroke and close on the compression...

Page 543: ...rt the shaft horizon tally and vertically 5 Needle Thrust Bearing and Races Two needle thrust bearings each sandwiched between two races are located on either side of the wash plate hub The front need...

Page 544: ...ront head 9 Discharge Tube The discharge tube is used to connect the discharge cavity in the front head with the discharge cavity in the rear head High pressure vapor discharge is channeled via the tu...

Page 545: ...ic clutch is actuated when the air conditioning temperature switch and the fan switch located on the evaporator cover assembly are closed When the switches are closed the coil sets up a magnetic field...

Page 546: ...ing the spring pressure and pushing the dia phragm against the operating pins see Figure 9B 34 This in turn will force the valve off its seat When the refrigerant low pressure gas flowing through the...

Page 547: ...et to the receiver dehydrator will cause high head pressures Outlet tube restrictions will be indicated by low head pressures Outlet tube restrictions will be indicated by low head pressures and littl...

Page 548: ...ck bottom of connections since Refrigerant 12 is heavier than air and will be more apparent at underside of fittings The flame color will turn yellow green when a small leak is detected Large leaks wi...

Page 549: ...rature Check expan sion valve If valve isn t permitting flow of liquid this will be indicated by a warm pipe out of the evaporator This may be caused by 1 Clogged or Plugged inlet screen in the expans...

Page 550: ...AND DISCHARGING SYSTEM Removal of any part in the refrigerant circuit will require discharging of the entire system Discharging the System 1 Remove caps from gauge fittings on the compres sor adapter...

Page 551: ...o compressor connect as follows A Close hand shut off valves on gauge set by turning clockwise B Remove caps from gauge fittings on the compres sor adapter fitting C Attach valve adapter J 5420 to end...

Page 552: ...injector J 24095 and open valve Flush J 24095 with refrigerant close valve and insert pick up tube into graduated container of clean refrigerant oil D Con ct J 24095 to suction fitting at the compres...

Page 553: ...n the system Air inlet temperature must be 70 degrees F or above to make an accurate check 8 When refrigerant has been installed continue to operate system and test for proper operation as ou tlined u...

Page 554: ...gh pressure gauge line to compressor high pressure gauge fitting 4 Turn high pressure hand shut off valve one turn clockwise and high pressure control one turn coun terclockwise open Crack open low pr...

Page 555: ...osition blower switch to Max Hi Operate for ten IO minutes at 2000 RPM to stabilize system 3 Observe the refrigerant through the sight glass cover of receiver dehydrator with the system operat ing IO...

Page 556: ...e oil content may result in dam age to compressor moving parts The refrigeration system will not require adding of oil unless there is an oil loss because of a ruptured line badly leaking compressor s...

Page 557: ...to keep the expansion valve from closing at the inlet source FLUSHING THE SYSTEM It is recommended that dry nitrogen be used as a flushing agent due to the low cost involved In addi tion dry nitrogen...

Page 558: ...e 9B 52 During removal maintain the compressor position so that the sump is downward Do not rotate compressor shaft 1 Support compressor from underneath and install into position from under car Insure...

Page 559: ...es to both ends of re ceiver dehydrator and tape closed open ends of re frigerant lines and also the open ends ofthe inlet and outlel pipes of the receiver dehydrator I Figure 98 54 Compressor Pulley...

Page 560: ...bably expended 1 Install receiver dehydrator Using new o rings during installation Lubricate o rings prior to instal lation using No 525 viscosity oil Figure 98 56 Pipes Hoses and Compressor Wire Loca...

Page 561: ...ch and disconnect the electrical wiring See Figures 9B 63 and 64 6 Remove evaporator inlet and outlet pipes re tainer and rubber grommet See Figure 9B 65 Figure 98 62 Glove Box Removed 4 Discharge ref...

Page 562: ...ining attaching screws and remove evaporator assembly See Figure 9B 70 Figure 98 70 Evaporator and Expansion Valve Assembly Opel 1900 Manta 14 Disconnect expansion valve capillary tube bulb attached t...

Page 563: ...tor 10 Install evaporator inlet and outlet pipes retainer and rubber grommet See Figure 9B 65 11 Connect vacuum cut off switch and electrical wiring making sure the delay restrictor and check valve ho...

Page 564: ...he circuit the system and or component must be Figure 98 75 Condenser Assembly Mounting Brackets Opel 1900 Manta flushed prior to installation Refer to FLUSHING THE SYSTEM 1 Install comjenser into car...

Page 565: ...rought to the necessary specific gravity by adding anti freeze Anti freeze added must have a glycol or glycerin base As the specific gravities of all anti freeze solutions having a glycol or glycerin...

Page 566: ...REFRIGERANT COMPONENTS ALL MODELS 9B 57 SUPPORT BRACE LARGE Figure 98 84 Compressor Installation GT...

Page 567: ...Figure 9B 84 2 Untape lines and ports and install compressor adapter fitting and bolt using new o rings See Figure 9B 82 3 Evacuate system Refer to EVACUATING SYSTEM 4 While system is being evacuated...

Page 568: ...age tray See Figure 9B 87 Figure 98 88 Evaporator Cover Assembly and Attaching Screws GT Figure 98 87 Luggage Tray 4 Remove all evaporator cover screws and remove cover See Figure 9B 88 5 Remove elect...

Page 569: ...gure 9B 90 Figure 98 93 Evaporator Mounting Bracket Bolts Passenger Side GT 0 RING OUTLET TUBE SEAL 9870 Figure 98 94 Inlet and Outlet Pipes and O Rings GT 11 Remove blower case and blower motor attac...

Page 570: ...ifficulties involved if the expansion valve is disassembled disaisembly of the valve is not recommended The valve may be cleaned by submerging it in a bath of trichlorethy lene alcohol or similar solv...

Page 571: ...nect 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 Battery needs only to be...

Page 572: ...tem Refer to CHARGING SYS T E M DISASSEMBLY AND REASSEMBLY OF CLUTCH DRIVE PLATE AND SHAFT SEAL It is not necessary to remove the compressor or dis connect refrigerant lines to remove or install clutc...

Page 573: ...ng motion remove the seal seat 96 82 Figure SE 108 Removing or Installing Ceramic Shaft Seal seat 8 Remove the seal assembly using Tool J 9392 Press tool downward on seal while twisting it clock wise...

Page 574: ...essor and connect gage charg ing lines as shown in Figure 9B 112 Pressurize suc tion side of compressor with Refrigerant 12 vapor to drum pressure Temporarily install the shaft nut and with compressor...

Page 575: ...into hub of clutch drive plate so that it projects out approximately 3 16 inch see Figure 9B 113 and position clutch drive plate onto shaft 10 Using drive plate installer J 9480 screw in staller on e...

Page 576: ...te 2 Using No 26 Truarc pliers J 6435 remove bear ing to head retainer ring see Figure 9B 116 Figure 9B 1 16 Removing or Installing Bearing to Head Retainer Ring 3 Place puller pilot J 9395 on hub of...

Page 577: ...in position with bearing to pulley retainer ring see Figure 9B 118 4 Drive pulley assembly onto hub of front head see Figure 99 l 19 Removing Bearing From Pulley Assembly Figure 9B 120 Removing or In...

Page 578: ...ositioned as shown in Figure 9B 123 Figure SB 122 Installing Pulley Assembly 6 Reassemble clutch drive plate DISASSEMBLY AND REASSEMBLY OF INTERNAL PARTS OF COMPRESSOR AND LEAK TESTING COMPRESSOR A cl...

Page 579: ...emoving Rear SfJction Valve Reed Disc Figure 98 127 Removing Oil Inlet Tube 2 Push shaft upward from front head and lift out cylinder assembly see Figure 9B 128 front suction valve reed disc and front...

Page 580: ...e reassem bly see Figure 9B 133 and separate cylinder halves using a hard rubber mallet or hammer and wood block SEALING Figure 96 131 Front Head Sealing Surfaces SUCTION PASS COVER Figure 98 132 Remo...

Page 581: ...front needle thrust bearing and races Figure 98 135 Piston Identification Ringless Examine shaft and wash plate assembly and replace as necessary 6 Wash all salvaged parts of cylinder assembly in bath...

Page 582: ...iston drive ball at the front of each piston Do not place shoe discs on rear piston drive balls Do not reassemble piston rings on pistons if service pis tons at this time Use lubricant in sufEcient qu...

Page 583: ...be tween 4 to 8 ounces pull the higher reading is desired To perform this step correctly feeler gage leaf leaves must be withdrawn straight out with a steady even motion and all surfaces involved mus...

Page 584: ...scale for checking distributor point setting may be used for this step c Reinsert feeler gage leaf leaves between rear needle thrust bearing and outer rear thrust race and draw leaf leaves out again t...

Page 585: ...roximately l 2 inch and lift out pis ton and related parts one at a time 15 Remove outer rear ero thrust race from shaft and set it aside for future gaging procedures 16 Remove previously selected out...

Page 586: ...over suction passage see Figure 9B 151 98 27 Figure SB 148 Service Replacement Discharge Tube 6 Liberally lubricate cylinder bores of rear cylinder with No 525 viscosity oil and reassemble rear cylin...

Page 587: ...d tap head lightly with mallet to seat on cylinder assembly 5 Place new shell to head 0 ring on shoulder of front head see Figure 9B 155 and liberally coat 0 ring and front head sealing surface with N...

Page 588: ...identified are in their origi nal location and then position oil pump outer rotor as shown in Figure 9B 157 5 Generously coat with No 525 viscosity oil new 0 ring and install in shell see Figure shell...

Page 589: ...gh pressure valve to charge high pressure side of compressor As soon as high pressure gage stabilizes reading close valve If high pressure gage drops back immedaitely when valve is closed an internal...

Page 590: ...ODELS 9B 81 ADAPTERS 91 I I n 1 II I II I DISCHARGE 11 1 COMPRESSOR USE LINE ONLY DURING COMPRESSOR SEAL T T GAGE I J 541 6 MANIFOLD AND GAGE SET J 5725 01 REFRIGERANl CYLINDER 99 129 Figure 96 160 Co...

Page 591: ..._ ___ 6 Approx Type of Refrigerant ___ _ __ Refrigerant 12 Refrigerant Capacity Fully Charged Opel 1900 Manta _ _ _ 2 Lbs GT __ __ 2 l 4 Lbs Functional Test Procedures 1 Place transmission in park for...

Page 592: ...NCTIIONAL TEST GT Temp of Air Entering Cond Engine RPM Camp Head Pressure Suction Press Discharge Air Temperature When compressor clutch disengages 70 80 90 100 110 2000 2000 2000 2000 2000 155 165 19...

Page 593: ...9B 84 1973 OPEL SERVICE MANUAL t COMPRESSOR CONDENSER EVAPORATOR q H P VAPOR q H P LIQUID q 1 p LIQUID q L P VAPOR q H P T X V POWER ELEMENT Figure 96 l 61 Cycle of Operation...

Page 594: ...ressor Shell 6 Piston Drive Ball 17 Pulley Bearing Retainer Ring 18 Pulley and Bearing Retainer Ring 29 Cylinder Assembh 30 Shaft Seal 7 Ball Seat Shae Disc 8 Piston 19 Clutch Hub and Drive Plate Asse...

Page 595: ...ER REAR NEEDtE q PRESSURE RELIEF VALVE T H R U S T BEARlNG IT DISCHARGE VALVE PLATE f FRONT HEAD SEAL SEAT O RING I SHAFT SEAL SHELL T O HEAD O RING I I PORT FRONT CYLINDE I VALVE PLATE SERVICE ONLYI...

Page 596: ...98 88 1973 OPEL SERVICE MANUAL Figure gB 165 Special Tools...

Page 597: ...ROL VALVE I WI 6A Gt ADAPTEK J 5453 GOGGLES J 24095 COMPRESSOR OIL INJECTOR J 6742 03 IHtRMOMETER D I A L TYPE 2S lZ5 J 2 2 1 3 2 0 2 I J 9 4 5 9 1 J 5 4 1 0 J 2 3 5 0 0 J 6 1 7 1 141 360 GAUGt C H A...

Page 598: ...IFICATIONS Specifications 98 92 98 92 98 92 98 96 DESCRIPTION AND OPERATION GENERAL DESCRIPTION OF SYSTEM The air conditioner is intended to give maximum cooling comfort within the vehicle To do this...

Page 599: ...system read on the low pressure gauge should pull down to the pressure shown in the chart in SPECIFICATIONS in Refrig erant Components Section 3 Remove the face plate retaining screws and remove face...

Page 600: ...emove switch AIR SENSING CAPILLARY yT ERMOSTATIC SWITCH I BUMPER BLOWER SWITCH 98 136 Figure SB 173 Location of Air Sensing Capillary Installation 1 Install the temperature control switch and secure w...

Page 601: ...ct refrigerant hose from evaporator outlet and pipe from evapora tor inlet and tape the open ends of the refrigerant lines and evaporator pipes See Figure 9B 178 5 Disconnect the delay restrictor and...

Page 602: ...ower case and blower motor at taching screws and remove assembly See Figure 9B 184 Installation 1 Install the blower motor assembly into case Figure 98 183 Drain Hose BLOWER MOTOR Figcre 98 184 Assemb...

Page 603: ...elay restrictor and check valve hose are installed correctly See Figure 9B 180 10 Install refrigerant hoses and pipes using new o rings on line fittings and evacuate system Refer to EVACUATING SYSTEM...

Page 604: ...RESISTOR A EXlSilNG I WIRE I I I FUSE BLOCK I S W I T C H r ti WIRE fI fI 1 I A A I i lAC XESW WIRE I I T T EVAPO RATOR EVAPO RATOR BLACK WITH RED STRIPE BLACK WITH RED Sl 96 143 Figure 9B 188 Wiring...

Page 605: ...must be given to the following sections The system operates on recirculated air only and is entirely dependent of the vehicle heater Temp Knob Recirculated inside air is drawn into the unit passed th...

Page 606: ...continues to operate regardless of the knob adjustment it indicates that the switch points are fused which will lead to evaporator freeze up The switch should be replaced Adjusting Switch If after th...

Page 607: ...switch removed from the evaporator assembly inaccurate readings will re sult Always replace the switch and duct assemblies before c ecking the system performance Removal MAJOFi REPAIR 1 Remove the ne...

Page 608: ...was noted when removing 3 Install the duct assembly retaining screws 4 Install the negative battery cable REMOVAL AND INSTALLATION OF RESISTOR ASSEMBLY Removal 1 Remove the negative battery cable fro...

Page 609: ...nnector 3 In l the evaporator cover and attaching screws See Figure 9B 195 4 Install the luggage tray and attaching screws See Figure B 194 5 Install the negative battery cable AIR CONDITIONER SYSTEM...

Page 610: ...orator Cover and Luggage Tray 5 Remove the electrical plug connector from the resistor assembly and unplug blower motor connec tion and remove ground wire See Figure 9B 203 6 From underneath evaporato...

Page 611: ...evapora tor See Figure 9B 208 SEAL 9870 Figure 98 208 Inlet and Outlet Pipes and O Rings 9 Lift off the mounting bracket and remove the evaporator assembly from the car 10 Remove the resistor assembly...

Page 612: ...ng bracket to floor See Figures 9B 205 and 9B 206 7 Evacuate system Refer to EVACUATING SYS TEM in REFRIGERANT COMPONENTS Sec tion SPECIFICATIONS 8 While system is being evacuated 9 Connect 2 drain ho...

Page 613: ...id to diagnosis Knowing whether the condition is intermittent or constant whether it occurs with engine off or running with car stationary or moving will help to pinpoint the problem Never turn on rad...

Page 614: ...nder The an tenna lead in wire is shielded and the shield should have good ground connection at the receiver and the antenna base c Check for other car wiring passing too close to radio receiver case...

Page 615: ...5 Using a 4mm socket remove hex head screw See Figure 9C 4 6 Remove tear lock bolts by first drilling a 3 16 inch pilot hole and using a l 4 inch bolt extractor remove bolts See Figure 9C 5 Figure 9C...

Page 616: ...substitute design Torque values must be used as specified during reassembly to assure proper reten tion of these parts Figure SC 10 Removing Radio Shaft Retaining Nuts 1 Install radio into instrument...

Page 617: ...of the radio problem as an aid to diagnosis Knowing whether the condition is intermittent or constant whether it occurs with engine off or running with car stationary or moving will help to pinpoint...

Page 618: ...mounting as in Step No 3b above 5 Radio is noisy only on dry days when car is mov ing Wheel and tire static will occur only during dry weather To check to see if noise is wheel static or tire static d...

Page 619: ...socket 2 Pull iubber grommet and antenna cable out of cowl pa See Figure 9C 17 3 Unscrew antenna from fender lnstallatipn 1 Install in reverse sequehce to removal Figure 9C 17 Antenna and Cable Under...

Page 620: ......

Page 621: ...r ZH 33 C B Balance Wheel and Tire 3G 62 Ball J t Upper 3A 7 Lower 3A 7 Battery Specifications lA 9 Testing lA 6 Charging lA 9 Trouble Diagnosis lA 4 Battery Test 421 l A 6 Belt Tensions 68 33 Blower...

Page 622: ...Procedure Transmission Opel 3Speed Automatic Frame Opel 1900 Manta Frame GT Opel SWVO Opel Xipeed Automatic Front Suspension Opel1900 Manta G T Front Wheel Alignment Front Wheel Bearing Adjustment All...

Page 623: ...on 7C 64 Oil Pan Engine 6A 10 Oil Pump Engine 6A 26 Oil Pump Transmission 7C 103 Oil Recommendations Engine OC 7 Oil Strainer Transmission 7C 99 Oil Viscosity Chart OC 7 Opel Emission Control System O...

Page 624: ...e Specifications Engine 6A 27 Turn Signal See Directional Signal Universal Joints 4A 3 Subject V Page Number V a c u u m M o d u l a t o r 7C 101 V a l v e B o d y Transmlssmn7C 99 V a l v e a n d S e...

Page 625: ...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...

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