charging OPEL GT-R 1973 User Guide

CHARGING SYSTEMlD- 29
REGULAiOR DESCRIPTION
The regulator contains only one unit - a double con-
tact voltage regulator. See Figure
lD-2.
I Figure 1 D-2 Voltage Regulator
Since th< alternator field is grounded inside the alter-
nator, the voltage contacts are in series with the field.
Field
&rent is supplied from the D- terminal of the
alter”@, goes through a small red wire to the volt-
age contacts in the regulator, comes out of the
regulator through a brown wire, into the DF termi-
nal of the generator, and through the field winding to
grouqd inside the generator. See Figure lD-3.
:
,
!
/ I
’ A I
j
/ I
-
IF
O?
i 2
j
:
:
k
I
I
.i
A = REGULATOR
B = CHARGING
INDICATOR LAMP
C = BATTERY D = DIODES
E =STATOR
I
I F
=ROTOR301D3
kigure
lD-3 Charging Circuit Diagram
The diodes in the alternator, since they act like one-
way check valves, make a cutout relay unnecessary;
battery current can flow only as far as the diodes, but
cannot discharge 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 not necessary. Any alternator
is limited by its design in regard to maximum current
output. Regardless of current need, an alternator
cannot put out more than its rated current output
and, therefore, cannot overheat and damage itself
due to excessive output.
MAINTENANCE AND ADJUSTMENTS
ALTERNATOR AND REGULATOR TESTS
Test Current Output
1. Check alternator belt condition and tension. Ad-
just to 45 lbs. using Gauge J-23600.
2. Install a battery post adapter at the positive post
of the battery.
3. Connect ammeter leads to adapter with red lead
toward generator and black lead toward battery posi-
tive post. Connect ground
lead to battery negative
post. See Figure
lD-4.
BATTERY POST
ADAPTER
SOID
Figure lD-4 Connecting Ammeter Leads
4. Connect voltmeter across the battery: red lead at
generator side of battery post adapter and black lead
to battery negative post.
5. Connect a tachometer to ignition system.

CHARGING SYSTEMlD- 31
Alternator Disassembly1. Remove nut and alternator pulley. See Figure
lD-6. Remove pulley and fan from rotor shaft.
2. Mark ‘drive end frame,
stator and rear end frame
to
ensurd correct installation of parts on reassembly.
Remove drive end frame. See Figure
lD-7.
Figure lD-9 Removing Drive End Frame Bearing
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 end frame off rotor shaft. See Figure
lD-9. ,
5. With puller remove rear ball bearing from rotor
shaft.
S& Figure lD-10.
6.
Remove positive diode support. See Figure lD- 11.
Figure 1D-l 1 Removing Positive Diode Support
7. Disconnect brush connector from negative diode
support. See Figure
lD-12.
8. Remove brush holder. See Figure
lD-13.

CHARGING SYSTEMlD- 33
Figure lD-17 Checking Rotor for Ground
Eigure lD-18 Checking Rotor for ShortFibwe 1 D-l 9 Checking Stator for Ground16. Check stator windings for a short, using a low
reading ohmmeter. Check two phases at a time by
holding ohmmeter prods alternately on winding
ends. Ohmmeter should read between
.26 and .29ohms. See Figure lD-20.
301 D20Figure 1 D-20 Checking Stator for Short
17. Clean slip rings with fine emery cloth and polish
them. To avoid generating flat surfaces on slip rings,
spin rotor on a lathe when cleaning and polishing.
Slip rings that are not concentric can be turned down
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 output is low one or more
of the nine diodes may be defective. See Figure lD-3.
19. If a defective diode is suspected, test diodes.
Before testing diodes, disconnect them, otherwise it
is not possible to determine which diode is defective.
Use a test light supplied with a DC voltage of not
more than 24 volts.
20. To test a diode, place one test light prod on diode
connection and other on diode housing, then reverse
test light prods. Test light should light brightly in
,
CONNECTIONCONNECTION
I(ANODE)
(CATHODE)
IURRENTCURRENT ,I
CURREN’
FLOW+
+ HOUSING(CATHODE)HOUSING
(AN&E) 3lMD2Figure 1 D-2 1 Positive and Negative Diodes

CHARGING SYSTEMlD- 35
’Figure lD-25 Installing Diode
I
7. Instail rotor together with drive end frame intostator and assemble generator in reverse order ofdisasse+bly. Make sure marks made during disas-
sembly
+-ire aligned.
8. Insta!l pulley and fan. Tighten nut to 30 lb.ft.
9. Test benerator on test bench, if available. If not,
install alternator on car and test.
Alternator Installation
1. Hold /alternator in position and install pivot bolt,
plain washer, lockwasher and nut finger tight.
2. Install alternator belt.
3. Install adjusting brace bolt, lockwasher, plain
washer and nut finger tight.
4.
Posit& a belt tension gage such as Gage J- 23600Figure 1 D-26 Alternator Installation
on belt. Pull alternator outward until gage reads 45
Ibs., then tighten adjusting brace bolt.
5. Tighten alternator pivot bolt.
6. Connect battery lead to alternator.
7. Plug three-way wiring connector into alternator
and engage safety catch.8. Connect battery ground strap.SPECkICATIONS
ALTERNATOR
35, AMPAlternatorNumberRated
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kl 14V35AZOOutputinVolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14ContinuousRatedOutputinAmperes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Test Output in Amperes at
2000 Engine RPM. . . . . . . . ..__.._...........................................23 Min.RksistanceofFieldCoilinOhms
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4.4Resistanceof StatorWindingsinOhms
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-29AlternatorPulleyNutTorqueinLb.Ft.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
BfltTensioninPounds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
REGULATORRegulatorNumber
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ADl/14V
Regulator Setting in Volts at 2500 Engine R.P.M.
. . . . . . . . . . ..___................................14 f .5

:lG- 56 1973 OPEL SERVICE MANUAL
I
FUSEqOSlTlON
1
2
3
4
5
6AMPS.
5
5
8
15
15
8ClRClJlT$ PROTECTED
OPEL 1900
& ‘MANTA (51,53,54,57,57R)
LEFT PARkING LIGHT,
LEFTTAIL LIGHT, LEFTSIDE
MARKER LIGHTS
RIGHT PApKING LIGHT, RIGH TAIL LIGHT, RIGHT
SIDE MARKER LIGHTS, INSTRUMENT PANEL LIGHTS,
SHIFT GUADRANT LIGHTS, LICENSE PLATE LIGHT,
FOG LIGHTS (RALLYE ONLY)
IGNITION IKEY
WARNIN BUZZER, TRUNK LIGHT,
HAZARD WARNING FLA,SHER, COURTESY LIGHT, CLOCK
BACKUP L’IGHTS, BLOWER MOTOR, CIGAR LIGHTER; RADIO,
SAFETY BELT WARNING BUZZER AND LIGHT
WINDSHIELD WIPERS, WINDSHIELD WASHER (RALLYE
ONLY), HORN
STOP LIGtiTS,TURN
SlGsNAL AND INDICATOR LIGHT,
PARKING BRAKE WARNING AND BRAKE FAILURE LIGHT,
FUEL GAGE, TEMPERATURE GAGE, OIL PRESSUREINDICATGR LIGHT. CHARGING INDICATOR~LIGHT,
TACHOMETER AND OIL PRESSURE GAGE (RALLYE ONLY)
AIR CONDITIONING
- 20 AMP INLINE F:USE
8
5
16
5OPEL GT
(77)WINDSHIELD WIPERS, WINDSHIELD WASHER, HORN, BACKUP
LIGHT, SP;FETY BELT WARNING BUZZER AND LIGHT
STOP LIGHTS, TURN SIGNAL AND INDICATOR LIGHT,
PARKING BRAKE WARNING LIGHT (AUTOMATIC ONLY),
BRAKE FAILURE WARNING LIGHT, RADIO, TACHOMETER,
OIL PRESiURE GAGE
& INDICATOR LIGHT, FUEL GAGE,
TEMPERATURE GAGE, CHARGING INDICATOR LIGHT
CIGAR LIGHTER, BLOWER MOTORIGNITION~KEY WARNING BUZZER, COURTESY LIGHT, CLOCK,
HAZARD WARNING FLASHER
LEFT PARKING LIGHTS, LEFT TAIL LIGHT, LEFT REAR
SIDE MAdKER LIGHT
RIGHT PA’RKING LIGHTS, RIGHT TAIL LIGHT, RIGHT REAR
SIDE MAdKER LIGHT
INSTRUMENT PANEL LIGHTS, LICENSE PLATE LIGHT.
SHIFT QUADRANT LIGHT
AIR CON,DlTlONlNG
-A/C HAS A 20 AMP INLINE FUSE AND IS
CONNECTED TO THE HOTSIDE OF FUSE NO. 23OlG3

1 H- 581973 OPEL SERVICE MANUAL
/-FOG LIGHT SWITCH IRALLYEi
\HEADLIGHT HIGH BEAM INDICATOR
-HAZARD WARNINGFLASHERINDICATORSYSTEM WARN,NGLlGHT
LWINDSHIELD WIPER SWlTCH -1 LFUEL&,UGELHEATER-DEFROSTER CONTROL
CHARGING INDICATOR LlGHTHEATER’ TEMPERATURE CONTROLHEATED REAR GLASS SWITCH1
301H1Figure 1 H-l
- 1900 lnstrumellt Arrangement
INSTRUMENT PANEL
(GT)I
Headlight SwitchesThere are two headlight switches, one for turning on
the headlights and the other operates an indicator
light on the instrument panel. Both switches are
located behind the left headlamp assembly.
When the headlamp lever is @shed forward,’ the
operating mechanism rotates the headlights to open
position, tuins the headlight and instrument panel
indicator light switches on until the headlamps are
locked in full open position at which time the indica-
tar lamp switch is turned off.
Along with the headlights, the headlight switch,also
turns on the parking lights, taillights, license plate
lights and rear side marker lights.
Parking Light and instrument Panel Light SwitCh
AssemblyThe left switch of this assembly is the Parking Light
Switch. By pushing inward on the lower half of thisswitch, the parking lights, taillights, license plate
lights and rear side marker lights are turned on and
can be turned off by pushing inward on the upper
half of the switch providing the headlights are not
turned on.
The center portion of this switch assembly is inopera-
tive and controls nothing.
The switch on the right end of this assembly is the
Instrument Panel Light switch. By pushing inward
on the lower half of the switch turns on the instru-
ment panel lights. The brightness of the instrument
panel lights can be adjusted by movement of the
switch. If either the Parking Light or Instrument
Panel switch becomes defective, the switch assembly
must be replaced.
Combined Windshield Wiper, Electrically Heated
Rear Window and Heater Blower SwitchThis switch assembly is located to the right of the
cigar lighter. If any one of these switches should fail,
the complete switch assembly must be replaced.

1 J- 72 1973 OPEL SERVICE MANUAL
I
WIRING IDIAGRAMS
CONTENTS
Subject
1973 WIRING DIAGRAMS: Windshield Wiper and
Horn:- Opel 1900 -
Manta....................................I.............. ..............................
Windshield Wiper and Horn’- Rallye ..........................
Windshield Wiper
andHorn!-GT
..................................
Turn Signal and Hazard Flasher
-
Opel 1900 - Manta !
........................................................
Turn Signal and Hazard Flasher
- GT ..........................
Oil, Fuel,
Temp.: Tach, Stop and Brake
Warning Light
.GT........................................................
Blower Motor, Lighter and
Rackup Lights -
Qpel 1900.Manta ........................................................
Blower Motor and Lighter
.,GT....................................
Indicator Lights and Gauges
- Opel 1900 -
Manta ........................................................................\
........
Indicator Lights
andGauges.Rallye ..........................
Dome Light and Buzzer
- Opel 1900 - Manta..........
Dome Light, Buzzer and Clock - GT ............................
Headlamps
- Opel 1900 ’
....................................................
Headlamps
.Mantaj............................................................
Headlamps and Fog Lights
.Rallye ..............................
Headlamps, Parking, Tail and Instrument
PanelLighting.GT ........................................................
Left Parking and Tail Lights
- Opel 1900 -
Manta ..................................i.............................................
Right Parking and Tail Lights
- Opel 1900 -
Manta................. ..*............................................................
Starting, Ignition and Charging
-
Opel 1900.Manta..........i.............................................
Starting, Ignition and Charging
- GT ..........................
Instrument
Panel.GT ......................................................
A/C Generatorand Regulator
- All Models..............
Seat Belt Warning System (Manual Transmission)
-Opel1909-Manta ..........................
Seat Belt Warning System (Automatic Transmission)
.Opel 1900 - Manta..........................
Seat Belt Warning System (Manual Transmission)
- GT........................................................ Page No.
1 J-74
1 J-75
1 J-76
1 J-77
1 J-78
1 J-79
1 J-80
lJ-81
1 J-82
1 J-83
1 J-84
1 J-85
1 J-86
1 J-87
1 J-88
1 J-89
1 J-90
1 J-91
1 J-92
1 J-93
1 J-94
1 J-95
1 J-96
1 J-97
1 J-98

1 J- 92 1973 OPEL SERVICE> MANUALd5
Figure 1~19 Starting,
lgniiion and Charging Opel 1900 Manta

I
I
WIRING DIAGRAMSlJ- 93
I
Figure
lJ-20 Starting, Ignition and Charging GT

Figure 7C-1 Quadrant In Park Position -Opel 1900
and Manta7C- 381973 OPEL SERVICE MANUAL
R
- Reverse enables the vehicle to be operated in a
reverse direction.
N
- Neutral position enables the engine to be
started and operated without driving the vehicle.
D
- Drive range is used for all normal driving
conditions and maximum economy and has three
gear ratios. Downshifts are available for passing
by depressing the accelerator partially at lower
car speeds and through the “detent” at higher car
speeds.
S or 2
- Second range adds new performance for
hilly terrain. It has the same starting ratio as Drive
range, but prevents the transmission from shifting
above second gear to retain second gear for
acceleration or engine braking as desired. Second
range can be selected at any vehicle speed, but
should not be used above the speed shown m the
Owner’s Manual. This is to prevent over-speeding
the engine. The transmission will shift to second
gear immediately and remain in second until the
vehicle speed or the throttle position is changed
to obtajn first gear operation in the same manner
as in Drive range.
L or 1
- Lo range can be selected at any vehicle speed,
but should not be used above the speed shown in the
Owner’s Manual. The transmission will shift to low
(1st) gear immediately and remain in 1st gear regard-
less of vehicle speed or throttle position. This is par-
ticularly beneficial for maintaining maximum engine
braking.
PRINCIPLES OF OPERATION
Torque ConverterThe 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 certain conditions of input and output speed.
Figure
7C-2 Quadrant in Park Position - GT Models
The quadrant has six positions indicated in the fol-
lowing order: (Opel 1900 and Manta) P,R,N,D,S,
and L (Figure
7C-1); and (GT) P,R,N,D,2, and 1
(Figure 7C- 2).The torque converter used in the Opel three speed
automatic transmission consists of three basic ele-
ments: the pump (driving member), the turbine
(driven or output member) and the stator (reaction
member). See Figure
7C-3. The converter cover is
welded to the pump to seal all three members in an
oil tilled housing.
P
- Park position enables the transmission output
shaft to be locked
- thus preventing the vehicle
from roling either forward or backward. Because
the output shaft is mechanically locked by a
parking
paw1 anchored in the extension housing,
the park position should not be selected until the
vehicle has come to a stop. The engine may be
started in the Park position.Whenever the engine is running, the converter pump
turns at engine speed and acts as a centrifugal pump,
picking up oil at its center, adding energy, and dis-
charging the oil at its outer rim between the blades.
The shape of the converter pump shells and blades
cause the oil to leave the pump spinning in a clock-
wise direction toward the blades of the turbine. Asthere is no mechanical connection between converterpump and turbine, the oil is the only driving force
and strikes the blades of the turbine, transferring the