length OPEL GT-R 1973 User Guide

5C- 321973 OPEL SERVICE MANUAL
Never use copper tubing because copper is subject to
fatigue cracking which would result in brake failure.2. Cut tubing to length. The correct length may be
determined by measuring the old pipe using a cord
and adding l/8” for each double lap flare.
To make up a brake pipe assembly, proceed as fol-
lows:3. Double lap flare tubing ends, using a suitable flar-
ing tool such as J-8051. Follow the instructions in-
cluded in the tool set. Make sure fittings are installed
1. Procure the recommended tubing and fittings of
the correct size. (Outside diameter of tubing is used
to specify size.)before starting second flare.
4. Bend pipe assembly to match old pipe.
SPECIFICATIONS
BRAKE SPECIFICATIONS
Torque Specifications
Use a reliable torque wrench to tighten the parts listed to insure proper
tightness without straining or distorting parts. These specifications are for
clean and lightly-lubricated threads only; dry or dirty threads produce in-
creased friction which prevents
accurage measurement of tightness.
PartName
TorqueNut
BoltBrakeHose to Front WheelBrake Cylinder
Brake Backing Plate to Steering Knuckle(Uccer
Bolts)Lb&.
22
22...BoltBrake Backing’Plate to Steering Knuckle and
SteeringArm(Lower
Bolts)............................................
BoltBackingPlatetoRearAxleHousing................................
NutMaster Cylinder Actuator Rod to BrakePedal
..............
BoltWheelBrake Cylinder to Brake Backing Plate
..............
General Specifications47
43
5
5OperatingMechanism,ServiceBrakes
....................................................................Hydraulic
Parking Brakes
..........................................................................................Lever and Cables
Operation of Service Brakes Independent of
ParkingBrakes
..................................................................................................................Yes
WheelBrakes,Service
......................................................................................FrontandRear
Parking.
..................................................................................................................Rear Only
BrakePedalHeightAdjustment......................................................................................None
Static Pressure in Hydraulic System When Brakes
are Released
- Drum Brakes................................................................................4 psi Min.
Static Pressure in Hydraulic System to Rear
BrakesOnly
-DiscBrakes..................................................................................
4psiMin.
Brake Master Cylinder (for Drum Brakes) Bore
............................................................13/16
Wheel Cylinder Size
- Rear - All.......................................................................................: 5/8
Approved Hydraulic Brake ,Fluid
..........................................GM or Delco Supreme No. 11
Fluid Level in Reservoir
..........................................................................Fill to “Max.” Level
BrakeDrumRebore,Max&urnAllowable Inside
Diameter........................................
9.090Max. Allowable Out-of-Round
...........................................................................................CKl4Rear Brake Drum Size. New
............................................................................................
9.060

6A. 61973 OPEL SERVICE MANUALDIAGNOSIS
EXCESSIVE OIL CONSUMPTION
ConditionCorrectionExternal Oil Leaks at:Tighten attaching bolts. If leaks
Rocker Arm Coverspersist, remove cover (or pan),
Crankcase Front Covercheck sealing surfaces for burrs
Oil Pan and Gasketor scoring, replace gasket, and
seal bolts with silastic sealer or
equivalent. Make sure oil level
,is not overfull.
Improper Reading of Dip-Car may not be level when taking r
StickInsuffIcient oil “drain-back” time
after stopping engine (three
minutes must be allowed). Dip-
stick may not be completely pushed
down against stop. Dipstick may
be bent.
Oil Viscosity Too LightUse recommended SAE viscosity for
prevailing temperatures.
Continuous High-SpeedAt speeds above 60 mph, increased
Drivingsumption can be expected with any
Inform customer of this fact.
High-Speed DrivingWhen principal use of automobile i
Following Normal Slowcity driving, crankcase dilution f
Speed City Drivingcondensation occurs. High speed a
temperatures will remove water,
resulting in what appears to be
rapid lowering of oil level.
Inform customer of this fact.
Piston Rings NotAllow engine to accumulate at leas
“Broken In”
4,OCO miles before attempting any
engine disassembly to correct for
oil consumption.
NOISY VALVES AND LIFTERSIf the preceding check indicates valve mechanism is
abnormally noisy, remove the rocker arm cover so
that the various conditions that cause noise may be
The noise level of the valve mechanism cannot bechecked. A piece of heater hose of convenient length
properly judged where the engine is below operatingmay be used to pick out the particular valves or valve
temperature when the hood is raised, or when thelinkages
thit are causing abnormal noise. With the
valve rocker arm covers are removed.engine running at a speed where the noise is pro-
nounced; hold the end of hose to an ear and hold
Before attempting to judge valve noise level, the en-other end about
l/2 inch from point of contact be-
gine must be thoroughly warmed up (at least 20tween rocker arm and valve stem. Mark or record the
minutes of operation at
1200 to 1500 RPM) to stabil-noisy valves for investigation of following causes:ize oil and coolant temperatures and bring all engine
parts to a normal state of expansion. When the
en-1. Sticking, Warped, or Eccentric Valves, Worngine is warmed up, listen for engine noise while
sit-Guides Sticking valves will cause irregular engine
ting in the driver’s seat with the hood closed. Run theoperation or missing on a low speed pull and will
engine at idle and at various higher speeds.usually cause intermittent noise.

6A- 161973 OPEL SERVICE MANUALInspection of Connecting Rod Bearings and
Crankshaft JournalsRemove oil pan.
After removal of oil pan, disconnect two connecting
rods at a time from crankshaft and inspect the bear-
ings and crankpin journals. While,tuming crankshaft
it is necessary to
t&porarily reconnect the rods to
crankshaft to avoid possibility of damaging the jour-
nals through contact with loose rods.
If connecting rod bearings are chipped or scored they
should be replaced. If bearings
are in good physical
condition check for proper clearance on crankpins as
described under, checking clear$nce and selecting
replacement connecting rod beartngs.
If crankpin journals are scored or ridged, the crank-
shaft must be replaced, or reground for undersize
bearings, to insure satisfactory life of connecting rod
bearings. Slight roughness may be polished out withfine grit polishing cloth thoroughly wetted with en-
gine oil. Burrs may be honed off with a fine oil stone.
Use an outside micrometer to check crankpins for
out- of-round. If crankpins are mpre than
,002” out-
of- round, satisfactory life of new ,bearings cannot be
expected.
Checking Clearance and Selecting Replacement
Connecting Rod BearingsService bearings are furnished in standard size and
several undersizes. The clearance of connecting rod
(and crankshaft) bearings may be checked by use of
Plastigage, Type PG-1 (green), or equivalent, which
is soluble in oil.
1. Remove connecting rod cap with bearing shell.
Wipe off oil from bearing and crankpin journal, also
blow oil out of hole in crankshaft.
2. Place a piece of the plastic-type gauge material
Figure 6A-25 Checking Bearing
Cleatance WithPlastic-Type Gaugelengthwise along the bottom center of the lower bear-
ing shell (Figure 6A-25, view A), then install cap
with shell and tighten nuts to 36 lb. ft. Do not turn
crankshaft with gauge type material in bearing.
3. Remove bearing cap with bearing shell, the flat-
tened piece of gauge will be found adhering to either
the bearing shell or the crankpin. Do not remove it.
4. Using the scale printed on the envelope, measure
the flattened piece of gauge at its widest point. The
number within the graduation which closely corre-
sponds to the width of the gauge, indicates the bear-
ing clearance in thousandths of an inch. See Figure6A-25, View B.
5. The desired clearance with a new bearing is.0006”- .0025”. If bearing has been in service it is
advisable to install a new bearing if the clearance
exceeds .003”, however if bearing is in good condi-
tion and is not being checked because of bearing
noise, it is not necessary to replace the bearing.
6. After the proper size bearing has been selected,
clean off the gauge, oil thoroughly, reinstall cap with
bearing shell and tighten nuts to 36 lb. ft.
CRANKSHAFT BEARINGS AND SEALS
Replacement of Crankshaft BearingsA crankshaft bearing consists of two halves or shells
which are identical and are interchangeable in cap
and crankcase. All crankshaft bearings except the
rear main bearing are identical. The crankshaft end
thrust is taken up the rear (No. 5) main bearing.
Figure 6A-26 Engine Crankshaft Bearings
When the shells are placed in crankcase and bearing
cap, the ends extend slightly beyond the parting
sur-faces so that when cap bolts are tightened the shells
will be clamped tightly in place to insure positive

6A. 201973 OPEL SERVICE MANUAL
diameter at the right angle to the piston pin is greater
than the diameter parallel to the piston pin. When a
piston is checked for size, it must be measured with
micrometers applied to the skirt at ,points 90 degrees
to the piston pin. See Figure
6A-32. The piston
should be measured (for fitting p&poses) 2
l/2 in-
ches below the top of piston.
MEASURE AT
Figure 6A-32
Measuring,PistonInspect bearing surfaces of piston pins. Check for
wear by measuring worn and unworn surfaces with
micrometers. Rough or worn pins should be re-
placed. Check fit of piston pins in piston bosses.
Occasionally pins will be found tight due to gum or
varnish deposits. This may be corrected by removing
the deposit with a suitable solveni. If piston bosses
are worn out-of-round or oversize, the piston and pin
assembly must be replaced. Oversize pins are not
practical because the pin is a press fit in the connect-
ing rod. Piston pins must tit the piston with
0X4”to
.OCHl7” clearance.
Examine all piston rings for scores, chips or cracks.
Check compression rings for tension by comparing
with new rings. Check gap of compression rings by
placing rings in bore at bottom of ring travel. Meas-
ure gap with feeler gage. Gap should be between
,011” and .02.1”. If gaps are excessive (over .021”) it
indicates the rings have worn considerably and
should be replaced.
No attempt should be made to cut down oversize
pistons to fit cylinder bores. This practice
will de-
stroy the surface treatment and affect the weight.
The
sma/Jest possible oversize service pistons shouId
be used and the cylinder
bores should be honed to
size for proper clearance.1. Before installing piston, piston rings, or reboring
cylinders, observe the following:Cylinder bores may not be the same size. Standard
replacement piston sizes are in the midpoint of the
cylinder bore size range. Therefore, it may be neces-
sary to hone cylinders for correct piston tit. Out-of-
round on cylinder bore must not exceed
.ooO5”maximum with a taper of not over
.OilO5”.Before the honing or reboring operation is started,
measure all new pistons with micrometer contacting
at points exactly 90 degrees to piston pin (Figure6A-32) then select the smallest piston for the first
fitting. The slight variation usually found between
pistons in a set may provide for correction if the first
piston has excessive clearance.
If wear of cylinder does not exceed
.005” honing is
recommended for truing the bore. If wear or
out-of-round exceeds these limits, the bore should be trued
up with a fly cutter boring bar and then finish honed.
When reboring cylinders, all crankshaft bearing caps
must be in place and tightened to proper torque to
avoid distortion ofbores in final assembly. Always be
certain the crankshaft is out of the way of the boring
cutter when boring each cylinder. When making thefinal cut with boring bar, leave
,001 w on the diameter
for finish honing to give the required clearance speci-
fied.When honing cylinders, use clean sharp stones of
proper grade for the required amount of metal to be
removed, in accordance with instructions of the hone
manufacturer. Dull or dirty stones cut unevenly and
generate excessive heat. When using coarse or
medium grade stones use care to leave sufficient
metal so that all stone marks may be removed with
the fine stones used for finishing in order to maintain
proper clearance.
When finish honing, pass the hone through the entire
length of cylinder at the rate of approximately 60
cycles per minute. This should produce the desired
45 degree cross hatch pattern on cylinder walls
which will insure maximum ring life and minimum
oil consumption.
It is of the greatest importance that refinished cylin-
der bores have not over
.0005” out-of-round or ta-
pered. Each bore must be final honed to remove all
stone or cutter marks and provide a smooth surface.
During final honing, each piston must be fitted in-
dividually to the bore in which it will be installed and
should be marked to insure correct installation.
After final honing and before the piston is checked
for fit, each cylinder bore must be thoroughly
washed to remove all traces of abrasive and then
dried. The dry bore should then be brushed clean
with a power-driven iibre brush. If all traces of abra-
sive are not removed, rapid wear of new pistons and
rings will result. Fit new pistons in the following
manner:

ENGINE MECHANICAL AND MOUNTS6A- 29
Cooling System - Type ,._...___..___..___........................... Liquid Cooling With Circulating Pump
Filler Cap Type
- Pressure _,._.,,._.,,...,,.........,..,.....,.,.................,,......................... 13.2-15.2 PSI
Water Temperature Control
._,..__,,._.,,__.,,...,.,.,,.,,.,,.,...............,,...,,,... Thermostat and Bypass
Thermostat Open At
._,,.,,.......,__.,.........,,...,...,,..,.,,.,,...................................................... 189 F.
Cooling System Capacity
. . . . . . . . . . . . .._...__..............,,.,,.,,..,...................................,,................6 Qts.
Fan Drive
.,,...,,,....,,.,..,..,,........,..,,..,,,.............,..,,.,..,,.................,,............... Water Pump Shaft
ENGINE DIMENSIONS AND FITS
Cylinder, Crankcase, Pistons, Cylinder Head, Valves
Cyg;te; Bore Limits for Standard Size Pistons:3.659-3.660 In.
Size 23.661-3.663 In.Size 3
3.664-3.668 In.Cylindey Bore Limits for Oversize Pistons,
.02 In.Oversm
. .._............,..,,...,................................,,.,,.,,.........................................3.679-3.681 In.
Max.PermissibleCylinderBoreOut-of-Roundness
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..~.OOO5In.Max.Permissible Cylinder Bore Taper
,.., ,.,, ,.,._,__. ,_, ,.. .__... ..__. ,__. .____. ..__. .._..0005In.Piston Clearance, Nominal (on skirt bottom)
_..__,,_.,.___.__.._...........,.......................... .0014 In.No. 1 Compression Ring Side Clearance in
Piston Groove
,...,,,.,,,.,,...,__..........,,..,,...,,...,..,.,,.,,..,,..,,..,,..................,,,..,,,..., .0024-.0034 In.
No. 2 Compression Ring Side Clearance in
Piston 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 Ring
,...,,...,___.___.._..................,,,..,..,,..,,.,,,..,,,.,,..,,,..,,,...,,,,..,,,...,.... ,015.,055 In.
Piston Pin in Connecting Rod
..____.___..._,,__.,,,,,..,,.,,..,.................,,............................... Press Fit
IntakeExhaust
Valve Spring Pressure
Valve Closed
_______........___..,,,,,,............1.57 In. at 93 Lbs.1.36 In. at 97
Lbs.
ValveOpen. . . . . . . . . . . . . . .1.18 In. at 182 Lbs..96 In. at 180
Lbs.
Valve Stem Diameters
Standard
Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3538-.3543 In..3524-.3528 In.,003 In. Oversize
____.....__.._..,,,,,,.........3567-.3572 In..3553-.3559 In..0059 In.
Oversze .__......_______...............3597-.3602 In..3583-.3588 In.
.O 1 18 In. Oversize
_._...._._____...............3656-.3661 In..3642-.3647 In.
Valve Length, Nominal
..___.............4.843 In.4.92 In.
Valve Head Diameter
___.......____...,,,........1.574 In.1.34 In.Valve Guide Bores in Cylinder Head (Intake and Exhaust)
Standard Size
,,...,,...,,..,,..,,,..,,....................................,..,,...,,.,,,,..,,,,..,,...,,,,.., .3553-.3562 In.003 in Oversjze
.,..__,,._.,__..___....,,...,,..,,...,,,,,,.,,.,,..,................,.....,................. .3582-.3592 In.
,006 in Overslze
..,...,,..,,.......................................,.........................................3615-.3622 In.
.0118 in Oversize ,._.,,..,............,,...,,........................................,,.................... .3671-.3681 In.
Valve Stem Clearance
Intake .
.._........___..___.....,............,...,,..........................................,,...................... .OOl-.0029 In.
Exhaust
._.,,........,,...,,..,,...........,,...,................,..,,..,,................,,.....,.,........................ 0039 In.
Max. Permissible Head to Stem Runout
Intake
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..OO16In.Exhaust
.,...........,,...,...,.,,...........,,...,....,....,.,,,..,,.,,,........................................,.......... .0019 In.

GA. xl1973 OPEL SERVICE MANUAL
Valve Seat and Correction Angle in Cylinder Head
Intake
Valve Seat Angle ..,._,..__....,,..,,,..,.,.,.,..............,............................................................... 45”Outer Correction
.,,,.,,._.,._..___,,,.,,,,,.......,,.,..,...,,..,..,,..,,..,,,.............................................. 30”
Exhaust
Valve Seat Angle
,,,.,,.__,.__..___.,..,,..,...,,....,..,..,..,,..,..,...,..,,,...,,......................................... 45”
Outer Correction
.,,..,,...,._.,.__....,,,.....,,,........................................................................... 30”
Valve Face Angle
,,..,,,..,.__..__.._..,,,..,,...,,......,.,..,..,..,,.,,,..,..,,,..,,,..,,,...,,................................ 44”Valve Seat Width in Cylinder Head
Intake
. . . . . . . . . . .._..._._.................,,..,.....,,..,............,...,..,,,..,,..,,...,,...,,,..,..................049-,059 In.
Exhaust
.,..,,,..,,.___..,,..,,...,..,,,..,,...,,...,,...............,,..,,..........,,....,,...,..................... .063-,073 In.Valve Head Contact Area
,,..,,,..,,___.__.,,..,,..,.,,..........,...,,..,,............,,,...,....... Aim at Centricity
Valve Clearance at 176°F. Coolant and 140°F. to 176”
Oil Temperature
Intake and Exhaust
_.,,..,,,,,,..,,....,...,,,.,.,,,.,..........................,,,..,,,,.... Zero Plus One Turn
Cranking MechanismMax. Permissible Out-of-Roundness of Connecting Rod Bearing
Journals
.....................................................................................................................OC02 In.
Max. Permissible Taper of Connecting Rod and Crankshaft Bearing
Journals
.....................................................................................................................ooO4 In.
Max. Permissible Radial Runout of Center Main Bearing
JournalsWhenSupportedinEndBearings
...........................................................0012In.Max. Permissible UnparalYelism of Connecting Rod Bearing
Journals When Crankshaft 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.
MainBearingClearance
.....................................................................................ooO9-.@I25In.Connecting Rod Bearing Clearance
.................................................................ooO6-.0025 In.
Connecting RodEnd PlayonBearing Journal
...............................................0043-.0095In.Connecting Rod Bearing Length
.......................................................................7785-.7992 In.
CrankshaftThrustBearingLength
..............................................................................1.08In.
Valve MechanismCamshaft Bearing Clearance
.................................................................................OOl-,003 In.
Camshaft End Play
...............................................................................................004-038 In.
Max. Permissible Radial Runout of Camshaft Center Bearing
- Camshaft Supported in Outer Bearings................................................................,001 In.
ValveLifter Clearance in Cylinder HeadBore
...............................................0003-.OOl3In.
Engine Lubricating SystemOil Pump Gear Backlash
......................................................................................0%.008 In.
Oil Pump Gear End Play in Housing
........................................Gears Protruding Over Edge
of Housing: Not More Than
,004 In.
Clearance of Spindle in Bore of Oil Pump Driven
Gear
...............................................................................................................OCO3-.0015 In.
Clearance Between Oil Pump Drive Gear and
Bushing
.........................................................................................................00035-.OOl5 In.
Oil Pump Relief Valve Spring Pressure at a Spring Length
of
.8 In..................................................................................................................44-.66 Lbs.

CARBURETOR AND THROTTLE LINKAGE6E- 51
water, adjust the throttle stop screw to read 6 inches
of water (3 inches down and 3 inches up).
4. Disconnect manometer and reconnect the vacuum
advance hose.
5. Adjust idle air speed screw and mixture screw to
obtain maximum idle at 850 to 900 R.P.M. (auto-
matic transmission) or 900 to 950 R.P.M. (manual
transmission).
6. Make final adjustment by turning idle mixture
screw in to reduce idle speed 50 R.P.M.
7. Install red plastic caps over the air speed screw
and idle mixture screw. Replace plastic cap over the
throttle valve stop screw and secure in place with
Loctite.
Fast Idle Speed Adjustment
1. Remove air cleaner cover.
2. With engine off, open the throttle halfway and
close the choke valve, release the throttle, then re-
lease the choke.
3. Start engine without moving the throttle. Adjust
to 3200 to 3300 R.P.M. using 2 nuts on fast idle rod.
See Figures 6E-13 and
6E-14.Figure
6E-13 Decreasing Fast Idle Speed
CARBURETOR LINKAGE ADJUSTMENT
GT Series1. Remove air cleaner.
2. Have helper depress accelerator pedal to floor and
check to see if wide open throttle is reached at carbu-
retor.
3. If adjustment is necessary, proceed as follows:
6E-14Figure
6E-14 Increasing 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 is obtained at the carburetor when ac-
celerator pedal is
l/4” - l/2” from floor mat.
(d) Reinstall rod, lock spring and pedal return
spring.
Opel 19W and Manta SeriesThe carburetor bowden control wire is properly ad-
justed if, with correctly-adjusted engine idle speed,
engine at operating temperature and accelerator
pedal at an angle of 25 degrees to the vertical plane,
the ball (A) of the carburetor bowden control wire
rests against the accelerator pedal lever. See Figure
6E-15.
1. Position accelerator pedal at an angle of 25 degrees
to the vertical plane. To do this, loosen lock nut of
adjusting bolt (c) and unscrew adjusting bolt a few
turns.
Squeeze a 1 3/S” wood block (D) between accelera-
tor pedal and dash panel. See Figure
6E-15.Screw in adjusting bolt until the accelerator pedal
lever releases the wood block (D). Tighten lock nut.
2. Adjust bowden control wire at adjuster. See Figure
6E-16. Prior to doing this, adjust engine idle speed
with engine at operating temperature.
Set carburetor bowden control wire adjuster at the
bracket so that the ball (A) of the control wire rests
against part (B) of the accelerator pedal lever and the
wire core between bracket and segmental disc is not
sagging.

7A- 41973 dPEL SERVICE MANUALConditionPossible CauseCorrectionHeat-blued driven plate
and pressure plate
assembly.
1. Improper pedal1. Replace only driven plate, and
adjustment.adjust clutch pedal and cable.
Grab and chatter with
oil present on clutch
assembly.1. Oil leak.1. Correct oil leakage, clean
pressure plate in solvent, replace
driven plate and adjust pedal lash.
MAINTENANCE AND ADJUSTMENTS
CLUTCH LASH ADJUSTMENT
GTPedal lash, free pedal travel must be adjusted occa-
sionally to compensate for normal wear of the clutch
facings. As the driven plate wears thinner, pedal lash
decreases. Adjust clutch pedal free travel only with
ball stud located on right side of clutch housing if
cable length is not to be changed. To adjust pedal
lash proceed as follows:
1. Loosen lock nut on ball stud end located to the
right of the transmission on the clutch housing. Posi-
tion ball stud so that the outer end protrudes 3/4
inches out of housing and finger tighten lock nut. See
Figures
7A-1 and 7A-6.
2. Adjust ball stud, pivoting clutch release fork, to
obtain 3/4 to
l-1/4 inches pedal lash, free pedal. See
Figure 7A-6.
Opel 1900 and MantaThe clutch actuation works without clutch pedal free
travel. A readjustment of the clutch is only required
if the indicator lamp at the instrument panel lights
up.In synchronism with the gradual wear of the clutch
linings the clutch pedal travels from its basic adjust-
ment position upwards,
ie., towards driver. If the
clutch lining wear has reached such an extent that
the clutch pedal rests against switch, the indicator
lamp at the instrument panel lights up.
This is an indication that the clutch 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.
1. If the parking brake is provided with an indicator
lamp, the parking brake has to be disengaged, other-wise the same indicator lamp as for the clutch lights
UP.2. Carry out adjustment only with ball stud on clutch
housing whereby the distance (Item 20, Figure 7A-7)
between clutch housing contacting surface and
clutch release lever has to be adjusted in the rear to
4
l/4 inches.
Clutch Control Cable Adjustment(Only on
Installation of a New Clutch Disc or
Bowden
Control Wire)
GT1. Adjust ball stud so that outer end protrudes ap-
proximately 3/4 inches out of clutch housing.
2. Adjust distance between release lever and clutch
housing face at eye for control cable to approxi-
mately 4
l/4 inches. See Figure 7A-6. Hold cable in
this position and place E-ring two grooves ahead of
washer on rubber grommet. Clutch pedal free travel
is now between 3/4 and 1
l/4 inches and clutch
release bearing has proper clearance from pressure
plate.
Opel 1900 and Manta1. Adjust ball stud on clutch housing to basic dimen-
sion of approximately 3/4 inch. With lower end ofbowden control wire unhooked, push clutch release
lever towards the front so that the clutch release
bearing rests against clutch spring. Now, adjust ball
stud so that the dimension (Item 20, Figure
7A-7)between clutch housing contacting surface and
clutch release lever amounts in the rear to 4
l/4
inches.2. Pull reattached bowden control wire out of dash
panel so that clutch pedal rests against switch (in-
dicator lamp lights up).
3. In this position, install lockwasher at upper con-
trol wire attachment three grooves towards the front,
thereby completing control wire adjustment.

AUTOMATIC TRANSMISSION 7C- 93
(on Manta models, turn adjuster) until ball end of
cable rests firmly against lever.
2. At this point, measure length of exposed detent
inner cable. Depress accelerator pedal fu/fy, and
again measure inner cable. If correctly adjusted, de-
tent cable should move approximately 3/S inch.
Servicing Selector Lever1. Unscrew console from floor panel, on small con-
sole remove three (3) attaching screws and
on large
console remove four (4) screws. The fourth screw is
accessible after removal of ash tray. See Figure 7C-
88.Figure
7C-88Figure
7C-892. Unplug cigar lighter and lamps from console and
remO”e co”sole.
3. From below vehicle, remove selector rod from
intermediate selector lever.
4. Remove neutral start switch (A) and remove sup-
port housing attaching bolts. See Figure
7C-89.5. Remove support housing and, from the underside
of support housing, remove three (3) support attach-
ing bolts. See Figure
7C-90.Figure
7C-906. Remove intermediate selector lever (B) from shaft
and remove assembly from support housing. See Fig-
ure 7C-92.7GB2
Figure
7C.92

8A-2 1973 OPEL SERVICE MANUAL
HOOD, FENDERS, AND GRILLE
CONTENTS
Subject
DESCRIPTION AND OPERATION:
GTHeadlampOperation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS
GTHeadlampMechanism
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Removal and Installation
Hood (1900
- Manta). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fender(1900-Manta). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlamp Covering (1900
- Manta). . . . . . . . . . . . . . . . . . . . . . . .Headlamp Assembly
(GT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlamp
CableAssembly(GT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grille
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS: (Not Applicable)
DESCRIPTION AND OPERATION
DESCRIPTION AND OPERATION OF GT
HEADLAMP MECHANISMThe concealed headlamps are moved mechanically.
Pushing actuating lever on left side of console opens
headlamps, pulling lever closes headlamps. Two
meshing gear segments convert 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 sheet metal.
A white indicator lamp in the instrument panel lights
if the headlamps are not completely opened and
locked. The switches of the headlamp electrical sys-
tem are located behind the left headlamp operating
mechanism.
MAINTENANCE AND ADJUSTMENTS
ADJUSTMENT OF HEADLAMP MECHANISMBoth headlamp assemblies must operate in unison in
order to lock in either the open or closed position.
Page No.
8A-2
8A-2
8A-3
8A-3
8A-4
8A-4
8A-6
8A-61. Adjust headlamps to be parallel in any position by
changing length of right headlamp operating rod.
For adjustment loosen clamp bolt (A). See Figure
8A-1.Figure
8A-l Headlamp Operation Adjustments