manual transmission OPEL 1900 1973 Owners Manual

I4I
.7C.140 .1973 OPEL SERVICE MANUAL
J-7004-1SLIDE HAMMER
J-2291 3MAIN SHAFT ASSEMBLY TOOL
J-22929SPEEDOMETER DRIVEN GEAR
REMOVER AND INSTALLER
J-22922J-22926TRANSMISSION CASE EXTENSIONSPEEDOMETER DRIVEN
HOUSING SEAL INSTALLERGEAR PIN REMOVER
J-21715DETENT PIN PLUG REMOVER
J-22934CLUTCH PLATE ALIGNING ARBORTRWARC PLIERS
J-22923REVERSE IDLER SHAFT REMOVER
J-2291 I
J-21 684NEEDLE BEARING LOADER
BEARING PRESS PLATE7&56
Figure
7C-235 Special Tools. Manual Transmission

98.40 1973 OPEL SERVICE MANUAL
2. Interconnect manifold and gage set (J-5725-01),
gage charging lines (J-5418) and gage adapters
(J-5420) to air conditioning system as shown in Figure
9B-40.3. Place transmission in “Park” for automatics and
in neutral for manuals. Apply hand brake.
4. Turn blower switch to the “Hi” position.
5. Turn temperature switch to “Max” position.
6. Run engine at 2000 RPM for ten (10) minutes with
car doors and windows closed and the hood up. Place
a high volume industrial type fan in front of radiator
if head pressure should exceed 250 psi and also at
high ambients to bring the pressures to within the
limits specified in the Functional Charts in Division
V.In the case of the Opel 1900 and the Manta, a ther-
mometer should be placed in a position to read the
temperature of the air discharging from the right-
hand A/C outlet. In case of the GT, a thermometer
should be placed in a position to read the tempera-
ture of the air discharging from the left-rear A/C
outlet.
HEATER-AIR CONDITIONER REFRIGERANT
CIRCUIT TROUBLE DIAGNOSIS GUIDE
Insufficient Cooling (Check Air Flow)
Normal Air Flow (Inspect system for visual defects.
Run functional tests.)
Discharge Air
- Normal Temp Check for air leaks
through dash, car body, windows, or from heater or
ventilators.
Discharge Air
- High Temp Check sight glass for
foaming and compressor clutch for engagement.
No Compressor Clutch Engagement Check connec-
tions at clutch switch, harness connectors, and check
clutch switch.
No Foaming Compare evaporator pressure to that
on functional test table.
Foaming System is probably low on refrigerant.
Check for leaks, repair, evacuate, and charge. If
foaming still occurs, check for restriction in refriger-
ant lines between condenser and receiver dehydrator.
Evaporator Pressure Normal Compare head pres-
sure to pressure on functional test table.
Evaporator Pressure Low Ice may be forming on
evaporator. Low volume of air discharging at A/C
outlet after system has been running above idle con-dition
,for approximately 15-30 min.utes. Discharging
air gradually elevating in temperature. 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 expansion valve; 2)
Broken capillary line; or 3) Discharged temperature
bulb. If the valve is okay, the pipe out of the evapora-
tor will be cold.
Evaporator Pressure High Check the expansion
valve to determine if themobulb is making good con-
tact and is properly insulated. Operate engine at 2000
RPM with maximum air conditioning setting. If
evaporator pressure remains high, feel suction line.
If line feels frosty or extremely
(cold with relative
high ambient conditions, then partially cover the
condenser to obtain head pressures from 265 psi to
280 psi maximum. If evaporator pressure rises above
30 psi, change the expansion valve.
Also, check if compressor may be the cause due to
some internal or external mechanical trouble which
prevents reduction of pressure. Check for external
troubles, slipping belt, bad clutch and/or pulley, or
improper clutch engagement, before investigating
the compressor internally.
Head Pressure High Check for the following: Con-
denser air flow low, air in system, excessive refriger-
ant in system, restriction in condenser.Head.PressureLowRestriction in flow of refrigerant
to evaporator, or expansion valve plugged or defec-
tive.
Low Air Flow (Check blower operation and
evaporator. Check operation of controls.)
Ice BIocking Evaporator Run functional test. If
evaporator pressure is low, ice may form on evapora-
tor and reduce air flow.
Evaporator Pressure Low Ice may be forming on
evaporator. Low volume of air discharging at A/C
outlet after system has been running above idle con-
dition for approximately 15-30 minutes. Discharging
air gradually elevating in temperature. 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 expansion valve; 2)
Broken capillary line, or 3) Discharged temperature
bulb. If the valve is okay, the pipe out of the evapora-
tor will be cold.BlowerNot OperatingCheck for the following: Fuse
blown, blower switch defective, wire broken or loose
connection, poor ground connection, or blower mo-
tor defective.

96-54 1973 OPEL SERVICE MANUAL
valve. The filter screen at the inlet port may be re-
placed. Remove screen by threading a lo-32 NF
screw into old filter screen. With a washer and a nut
on the screw arranged to work as a puller screw, hold
the body of the screw and turn the nut. Insert the
new filter screen into the inlet port and lightly tap
screen only enough to seat.
1. Install expansion valve using new o-rings during
installation. Lubricate o-rings prior to installation
using No. 525 viscosity oil.
2. Install evaporator assembly and case attaching
screws. See Figure 9B-70.3. Install blower motor assembly into case and se-
cure with attaching screws. See Figure
9B-69.4. Install finger guard shields and fan housing case.
See Figure
9B-69.5. Install resistor assembly and electrical connector.
Install blower motor connector. See Figure
9B-69.6. Install assembly into car carefully guiding
evaporator pipes up through cowl opening. See Fig-
ure
9B-71.Figure 93-7 1 Inlet and Outlet Pipes and O-Rings
-Opel 1900 Manta
7. Install two (2) upper attaching evaporator at-
taching nuts. See Figures 9B-66 and
9B-67.8. Install two (2) attaching case mounting bracket
to instrument panel screws. See Figure
9B-67.9. Connect two (2) drain hoses underneath evapora-
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 checkvalve hoses are installed correctly. See Figures
9B-63and 64.
.gB-72 Delay Restrictor and Check Valve Hose.Assembly
12. Install refrigerant hoses and pipes using new
o-rings on line fittings and evacuate system. Refer to
EVACUATING SYSTEM.
13. While system is being evacuated, install in-line
fuse and left side of distributor duct. See Figure 9B-
61.14. Install glove box.
15. Install negative battery cable and charge system.
Refer to CHARGING SYSTEM.
REMOVAL AND INSTALLATION OF CONDENSER
ASSEMBLY -OPEL 1900. MANTA
Removal
1. Remove negative battery cable from battery.
2. Remove air cleaner.
3. Discharge system. Refer to DISCHARGING
SYSTEM.
4. While system is discharging, remove lower radia-
tor hose from radiator and drain coolant into a suita-
ble container.
5. Remove fan shroud.
6. On vehicles with automatic transmission, un-
screw oil lines from connectors on lower radiator
tank and plug lines. It is essential that no dirt enters
the oil lines. When unscrewing oil lines, hold connec-
tors on lower radiator tank with pliers to avoid leak-
ages. Ensure that no dirt enters oil cooler.
7. Remove upper radiator hose from radiator.
8. Remove lower attaching nut and slide radiator
upward and out of engine compartment.
9. Remove inlet and outlet hoses from condenser

r98-82 1973 OPEL SERVICE MANUAL
SPECIFICATIONS
Tightening Specifications
Part
Location
NutDrivePlateNut toCompressorShaft..............................
NutRear Head to Shell................................................................
CaPSchraderServiceValve......................................................
Compressor Specifications
Torque
Lb. Ft.
15
21
5Type
..............................................................................................Six Cylinder Axial Opposed
Make
............................................................................................................................Frigidaire
Effective Displacement (Cu. In.)
..........................................................................................
9.2Oil
..........................................................................................................................525 Viscosity
Oil Content (New)
....................................................................................................10 Fl. Oz.
Air Gap Between Clutch Drive Plate and Pulley
......................................0.022 to 0.057 In.
Clutch Type
................................................................................................................h4agnetic
Belt Tension
..............................................................................................1 lo-125 Lbs. Irritial
....................................................................................................................80 Lbs. Retension
Pipe and Hose Connection Torque Chart
Metal TubeThread andSteel TubingAluminum orNominal Torque
I
Outside Dia.Fitting SizeTorqueCopper TubingWrench Span
Lb. Ft.Torque
Lb. tit.
5-7
General SpecificationsThermostat Opening Temperature
.._.....,,,...__....,,.............................................................. 189
Capacity of Cooling System With Air Conditioner (Quarls)
.,,..___....___............... 6 (Approx.)Type of Refrigerant
.___,,,._...,.,,,.__.....,,,.......,,,,.......,,,...................,,,......,,,............ Refrigerant 12
Refrigerant Capacity (Fully Charged)
Opel
1900-Manta,,._....,,,,._...._.,,,,.......,,,........,,............................................................2 Lbs.
GT
,..__..,..,..__..,,,.......,,,,.......,,,........,,,.,......,,,,,......,,.,,........,,.......,,..........,,............... 2 l/4 Lbs.
Functional Test Procedures1. Place transmission in park for automatics and in
neutral for manuals. Apply hand brake.
2. Turn blower switch to HI position,
3. Turn temperature switch to MAX position-.
4. Run engine at 2000 RPM for ten (10) minutes with
car doors and windows closed and the hood up. Place
a commercial high volumn fan in front of condenser
if head pressure should exceed 250 psig.A commercial high volumn fan should be placed in
front of the condenser at high ambients to bring the
pressures to within the limits specified in the Func-
tional Charts. When testing the Opel 1900 and
Man& a thermometer should be placed in a position
to read the temperature of the air discharging from
the right-hand A/C outlet. When testing the GT, a
thermometer should be placed in a position to read
the temperature of the air discharging, from the left-
rear
,A /c outlet.

SubjectPage Number
Subject Page Number
A
Air Conditioning Refrigerant Components .................
98.17
Opel 1900
& Manta-In Car Components .....9B-90
GT.ln Car Components..................98-97
Alignment Opel 1900
& Manta .....................3C-22
GT-Opel ..............................
3C-22
Alternator Description ...........................
lD-28
Specifications. .........................1 D-35
Overhaul K-l..........................lD-30
Removal & Installation ..................lD-30
Testing...............................lD-29
Wiring Diagrams
Manta .............................
1 J-105
Opel 1900
..........................lJ-103
GT ................................
lJ-107
AM
Radio-GT............................9C-105
AM Radio-Opel 1900 &Manta ...............
9C-109
Antenna, Installation .......................
9C-111
Antenna Trimmer .........................
9C-110
Assembly of Transmission from Major Units Manual ...............................
78-23
3 Speed Automatic .....................
7C-103
Axle,
R&r, Disassembly ....................48~11
Bolt Torque Specifications
Engine ...............................
6A-27
Transmission. Manual ....................
78-33
3 Speed Automatic .....................
7C-136
Clutch ...............................
7A-7
Body ................................
2A-4
Brakes
Brake Drum, Shoes & Linings .............5C-28
Hydraulic Wheel Cylinder ................
5C-30
Hydraulic Master Cylinder ................
5A-2
Parking Brake Cables .....................
5C-33
Standard Brakes ........................
X-22
Disc Brakes...........................5B-10
Brake Booster and Vacuum
Coritrol Valve ....5A-5
Bumpers, Front and Rear ...................
ZH-33
C
B
Balance,,Wheel and Tire....................3G-62
Ball
J&tUpper .........................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 and Air Inlet Assembly, Removal and Installation
Owl 1900&Manta.....................9A-15
GT
.: ................................9A-5
Body Name Plate ............................
OA-1
Style’Numbers ......................... OA-2
Windows and Weatherstrips ...............
ZC-9
Doors ................................
ZD-13
Interior Trim and Headlining ..............
26-33
Seatsi................................26-33
Roof&d Sunroof-Opel 1900
& Manta ......2F.24 Camshaft,
1.9L
Engine .....................6A-25
Car Model Identification .......
.,............OA-1
Carburetor..............................6E-44
Trouble Diagnosis ......................
6E-49
Description ...........................
6E-44
Overhaul .............................
6E-53
Adjust ...............................
6E-50
Removal
& Installation ......,............6E-52
Specifications ..........................
6E-58
Charging
System
Description ..............
:............ 1 D-28
Specifications. ............
.,............lD-35
Testing..................:............lD-29
Wiring Diagrams
Manta .............................
lJ-105
Opel 1900 ..........................
lJ.103
GT ................................
lJ-107
Chart Lubrication ........................ OC-5
Chassis Springs, Front. ........
!............3A-15
Clutch, Second-Automatic Transmission .......
7C-103
Clutch Adjustment .........................
7A-4
Control Arm Front Upper ...................
:............3A-10
Lower ...............................
3A-11
Converter Checking Procedure ................
7C-125
Coolant Flow ............................
68-32
4 Speed Manual Transmission ...
!,...........7B-12
Cranking System. See Starting
SyStem
Crankshaft..............................6A-16
Cylinder Head ...............
:............6A-12
D
Description
3.Speed Automatic.....................7C-37

Subject
Page NumbelSubjectPage Number4.Speed Manual I..
Clutch
Detent Cable Adjustment
:Differential
Directional Signal Switch
Repair Opel 1900 & Manta
Repair GT
:Disassembly of
4.Speed Manual Transmission
DistributorFunction of Valves and Hydraulic Control Units
Opel
3.Speed Automatic.................
74-21
Fuse Chart..............................lG-56
Fusible Link.............................
lA-8Specifications.
Point Replacement..
..,78-127A-
17c-9148-73E-393E-4878.23
1C-26
1 c-20
GEGas Tank See Fuel Tank
General Specifications
Engine...............................6A-28
Opel 3.Speed Automatic
.................7C-134
Transmission, Manual.,
..................78-33
Clutch...............................7A-7
Body................................ZA-4
Governor Drive Gear
Opel
3.Speed Automatic.................7C-103
Grille
Opel 1900 & Manta.....................8A-7
GT..................................8A-6 Electrically Heated Rear Window
Engine
General Description
Cooling System
Lubrication System
Trouble Diagnosis
Exhaust Manifold
Exhaust System
Removal and Installation
External Oil Leaks,
Opel 3 Speed Automatic
FFast Idle Adjustment
..................
Filter-Engine Oil
......................
Fluid Checking Procedure Transmission
Opel 3Speed Automatic.............
Frame-Opel 1900 & Manta.............
Frame
GT-Opel......................
SWVOOpel Xipeed Automatic...........
Front Suspension
Opel1900&Manta.................
GT..............................
Front Wheel Alignment................
Front Wheel Bearing Adjustment
All Series.........................
Fuel Gauge
Trouble Diagnosis
Opell$OO&Manta...............
GT............................
Fuel Pump Operation..................
Fuel System
Fuel Tank (Opel 1900 & Manta)
.......
Fuel Lines (Opel 1900 & Manta)
.......
Fuel Tank
(GT)....................
Fuel Gauge Tank Unit
(GT)...........
Fuel Lines
(GT)....................
Fuel Tank Removal and Installation....
Cleaning Tank.....................
lH-576A-268-326A-46A-66A-126D-427C-816E-51
oc-77C~Bl2B-826-77c-1003A-23A-23C-223A-4
HHazard Warning Flasher
....................lG-55
Headlamp Aiming
.........................1 F-46
Headlamp Switch
Opel 190.0 & Manta
.....................1 F-46
Headlamp Mechanism GT
..................8A-2
Heater System Opel 1900 &Manta
Trouble Diagnosis
......................9A-11
Description and Operation
................9A-10
Adjustments and Minor Service............9A-12
Removal and Installation
.................9A-12
Specifications..........................$A-16
Heater System GT
Trouble Diagnosis
......................9A-4
Description and Operation
................9A-2
Adjustments and Minor Service
............9A-4
Removal and Installation.................9A-5
Specifications..........................$A-9Horn
Operation.............................lG-54
Hydraulic Operation
Opel
3.Speed Automatic.................7C-64
IIdentification Number Vehicle...............
OA-1ldle.Adjustment
..........................6E-51
Inflation Pressures, Tires.
...................36-62
Ignition Coil
Specifications.
.........................
lC-26Identification, Engine
......................
OA-1Ignition System
Timing...............................
lC-20Instrument Panel Parts Removal

SubjectPage Number
Subject Page Number
o,,e, 1900 & Manta .....................1H-59
GT..................................lH-63
intake Manifold, 1.9L Engine
..........:.....6A-12
R
Radiator
JRadiator All Models .,.
Radio
66-32
Joint,
Ball
adder.; ...............................3A-7
dower...............................3A-7
K
Antenna Trimmer Adjustment GT
Antenna Trimmer Adjustment
Opel 1900
& Manta
Removal and Installation Opel 1900
& Manta
Removal and Installation GT
Trouble Diagnosis GT
.,.
Trouble Diagnosis -Opel 1900 &Manta
Reverse Clutch
Rings, Piston,
1.9L Engine
Rocker Arm Assembly.
1.9L Engine..
9C-1 06
9C-1 10
Keys and Locks ..........................OA-1
L
Low Servo Cover .........................7c-100
Lubrication
Engine Oil Change Interval ................OC-7
Oil Viscosity Chart. .....................
OC-7
Fluid Capacities........................OC-5
Lubrication System, Engine .................6A-4
9C-1 11
9c-107
9c-105
9c-109
7c-103
6A-19
6A-12
s
M
Mainshaft Assembly 4.Speed
Manual Transmission ....................
78-26
Manifold
Intake ...............................
6A-12
Exhaust ..............................
6A-12
Master
Cdlinder, Brake.....................5A-2
Model
D&ignation (Body Style)
.............. OA-2
Mountings. Engine, GT ....................
28-6
Opel 1900 & Manta
.......................28-6
0
Oil Chan& Interval ........................OC-7
Oil Filter: Engine
.........................OC-7
Oil Flow Circuits, Automatic Transmission .....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
(OECS)
Specifications..........................6F-64
Service Procedures......................6F-63
Trouble Diagnosis ......................
6F-62
P
Parking Brake............................5C-33
Piston, Pin Rings ..........................
6A~lS
Planetary Gear Set ........................
7C-118
Power Unit Brake ........................
5A-5
Propeller Shaft ...........................
4A-2
Pump, Oil Engine........................
6A-26 Sequence for Transmission Diagnosis
..........
7C-81
Service ProceduresClutch..................7A~5
Shift Linkage Adjustments
4.Speed Manual ........................78-19
3.Speed Automatic .....................7C~93
Shock Absorber, Rear
All Series .............................
3F-51
Spark Plug Specifications ...........................
66-68
Clean &Adjust. ........................
lC-22
Installation............................lC-22
Wires................................lC~21
Specifications
Engine ................................
6A-27
Front Wheel Alignment ....................
3C~22
Speedometer Installation
Opel1900&Manta.....................1 l-68
GT..................................11-70
Spring
Rear SuspensionAll Series ..............
:............3F-52
Front Suspension
Opel 1900
& Manta ...................3A~l6
GTO Opel ..........................
3A15
Starting Motor
Description ............................
1 E-1 0
Specifications .............:............1 B-1 7
Repairs
..................:............18-13
Removal..............................1 B-l 3
Steering Columns
Service Procedures -Opel 1900 &Manta ....
3E-36
Service Procedures
- GT ...._............3E-44
Steering Gear Adjustment. .....
:............3D-27
Steering Gear Disassembly and
Redssembly.....3D-30
Steering Gear Removal and Install&ion ........
30-28
Steering Linkage ..........................
38-19
Suspension
Front................................3A-2
Rear .................................
3F-51
,

SubjectPage Number1
Throttle Linkage Adjustment........,:.......6E-51
Timing Chain Cover.......................6A-23
Timing Chain and Sprocket.........
':.......6A-23
Tires...................................36-55
Inflation.....................
.;.......3G-62
Rotation.............................36-57
Sizes.........................
........3G-62
Track Rod..............................3F-53
Transmission Oil Pan
Automatic Transmission.................7C-99
Transmission Reassembly
4 Speed Manual. 1.9.....................76-28Tranmission Removal and Installation
4 Speed Manual
Removal...........................7B-22
Installation.........................76-22
Auto&tic............................7c-94Tune’Up Procedure........................66-65
Torque Specifications. Engine...............6A-27
Turn Signal See Directional Signal
Universal Joints..........................4A-3Subject
VPage Number
Vacuum Modulator..7C-101
Valve Body Transmlssmn7C.99
Valve and Seat Reconditioning Engine6A-12
WWater Pump Engine1.9L Engine
Wheels
Wheel Alignment
Whee! Bearing, Adjustment,
Windshield Wiper and Washer:
Trouble Diagnosis:Description and Operation
Removal and Installation
Specifications
Wiring Diagrams Complete
Opel 1900 ._.
Manta
GT
1 E-37
1 E-37
1 E-38
1 E-43
1 J-l 03
1 J-l 05lJ-10768-3436-553C-223A-4