crankshaft OPEL 1900 1973 User Guide

6A- 221973 OPEL SERVICE MANUALI. NO. I COMPRESSION - GAP IN FRONT
2. NO. 2 COMPRESSION - GAP IN REAR
3. UPPER STEEL BAND -
I - 2 IN.TOWARDS
THE LEFT OF INTERMEDIATE RING GAP
4. INTERMEDIATE RING - GAP IN FRONT
5. LOWER STEEL BAND -
I - 2 IN.TOWARDS
THE RIGHT OF INTERMEDIATE RING GAP.‘A” VERTICAL LINE FOR PISTON AND RINGS, FRONT
6A-36Figure 6A-36 Location of Piston Ring Gaps
With rings installed on piston, check clearance in
grooves by inserting feeler gages between each ring
and its Iower land. Any wear that occurs forms a
step at inner portion of the lower land. If the piston
grooves have worn to the extent that relatively high
steps exist on the lower lands, the piston should be
replaced since steps will interfere with the operation
of new rings causing ring clearances to become exces-
sive. Piston rings are not furnished in oversize widths
to compensate for ring groove wear.
When fitting new rings to new pistons, the side clear-
ance of the compression rings should be X024”
-
.1X34” (top) and .0013” - .OO24” (2nd), and the oil
ring clearance should be
.OO13” - .0024”.
Assembly of Piston and Connecting Rod
NOTE:Connecting rods may be out of alignment
due to shipping or
hand/i& Always check a new
rod before installing piston and pin.Inspect piston pin bores and piston pins for wear.
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 bore
gage or an inside micrometer. If clearance is in excess
of the
,001” wear limit, the piston and piston pin
assembly should be replaced.
1. Lubricate piston pin holes in piston and connect-
ing rod to facilitate installation of pin.
2. Install pin in following manner:
a. Position base support J-6047 on hydraulic press.b. Place tool J-23436-l in support J-6047 with small
diameter bore facing upward.
c. Place small end of tool J-23436-3 in bore of tool
J-23436- 1.d. Position piston, rod, and pin guide J-23436-3.
e. Line up pin on piston, and using tool J-23436-4
press pin into piston. See Figure 6A-37.
Ii-J-23436-4
J-23436-3--,J-23436-1
--cJ-6047
Figure 6A-37 Piston Pin Installation Tool Layout
- 1.9
Engine
3. Remove installer from connecting rod and piston
assembly and check piston for freedom of movement
on piston pin.
4. Make sure cylinder bores, pistons, connecting rod
bearings and crankshaft journals are absolutely
clean, then coat all bearing surfaces with engine oil.
5. Before installation of a piston and rod assembly in
its bore, position the crankpin straight down.
6. Remove connecting rod cap.
7. Make sure the gap in the oil ring rails and the gaps
of the compression rings are positioned correctly.
8. Lubricate the piston and rings and install in bore

ENGINE MECHANICAL AND MOUNTS6A- 231. NOTCH IN PISTON HEAD
POINTING TOWARD THE FRONT
2. OIL HOLE IN CONNECTING ROD
POINTING TOWARD THE RIGHT
(MANIFOLD SIDE)
3. NOTCH IN CONNECTING ROD
CAP POINTING TOWARD THE
REAR6A-36
Figure
6A-39 Piston and Rod Assemblyby oompressing the rings with a “wrap around” com-
pressor.9. Select a new connecting rod bearing, if necessary.
Otherwise install cap with bearing lower shell on rod
and tighten bolt nuts to 36
lb.ft. torque.
10. Install all other piston and rod assemblies in same
manner. When piston and rod assemblies are prop
erly installed, the oil spurt holes in the connecting
rods will be facing right.
11. Check end clearance between connecting rods in
each crankpin using feeler gages. Clearance should
be between
.0043” and .0095”.
12. Install cylinder head. Torque 10 cylinder head
bolts to 72 lb.ft (cold), and 2 cylinder head to timing
chain cover bolts to 17
lb.ft.13. Install new oil pan gasket by first installing flange
gasket with tabs 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 (Opel
1900 and Manta) front suspension
assembly. (GT) Install engine suspension cross mem-
ber.After installation of new pistons and rings, care
should be used in starting the engine and in running
it for the first hour. Avoid high speeds until the parts
have had a reasonable amount of break-in so that
scuffling will not occur.
TIMING CHAIN COVER AND TIMING CHAIN
Timing Chain Cover Removal
1, Support engine in vehicle as outlined under Engine
Oil Pan Removal and Installation.
2. Remove radiator and shroud assembly
3. Remove cylinder head.
4. Remove alternator belt and remove alternator
mounting bracket.
5. Remove fuel pump
6. Remove ignition distributor.
7. Remove chain tensioner assembly out of timing
cover.8. Remove crankshaft pulley bolt and remove pulley.
9. Remove water pump assembly.
10. Remove oil pan
11. Remove timing chain cover bolts. One bolt is
covered by the water pump. See Figure 6A-39.
12. Pull off sprockets with chain. Put a paint mark
Figure 6A-39 Bolt Behind Water Pump

6A- 24 1973 OPEL SERVICE: MANUAL
on front side of timing chain to permit reinstallation
in original position.
Timing Chain Cover and Timing
Chain installation
Reinstall timing chain cover by reversing removal
procedures, pay particular attention to the following
points.
1. Clean all parts, check for wear and replace as
required. The Parts Department supplies either the two sprockets complete with chain or the chain
alone. It is not permissible to replace sprockets alone.
The chain tensioner is, with the, exception of the
tensioner body, only available as a complete unit.
2. Turn crankshaft so that key for sprocket is on top
and vertical. Assemble chain’, with camshaft
sprocket, then put chain on crankshaft sprocket al-
ready installed. Be sure paint dot
on chain is in front
so that chain moves in same direction as prior to
disassembly.
3. Make sure camshaft sprocket mark is in alignment
with mark on support and chain in parallel with
damper block.
4. To install new timing case oil seal, drive out oil
seal from the rear using a drift. Coat circumference
of oil seal sparingly with suitable sealer and press seal
in, using tool J-22924. Take care not to damage tim-
ing case. See Figure
6A-40. 5. Inspect chain tensioner for 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 onto guide pin in upper left
corner of cylinder block and insert centering bolt
through timing chain cover into lower right corner
of cylinder block. See Figure
6A-40A. No sealing is
required.
SA-40.4
Figure 6A-40A Installing Timing Chain Cover
INSTALLER
Figure 6A-40 Installing Timing Cover Oil Seal onProtector
It is not necessary to use crankshaft bolt to install
seal when cover is off engine. 8. Install cylinder head
After sprocket has been attached to camshaft, re-
check alignment
LO see that chain has not slipped. At
this time both No.
1 and No. 4 pistons will be at TDC
position. No. 4 piston will be in tiring position and
No. 1 piston up on exhaust stroke. To time engine to
fire on No. 1 cylinder, rotate crankshaft 360 degrees.
This will position the timing mark 180 degrees from
original alignment of camshaft sprocket and support
bracket, and will completely close No. 1 intake and
exhaust valves. Also, the timing mark on the fly-
wheel
(ball) and cylinder block (pointer) will coin-
cide. See Figure
6A-41.
Replacing Timing Cover Oil Seal
(Engine Installed)
1. Remove fan belts.
2. Remove crankshaft pulley bolt and remove pulley. 3. Insert screwdriver behind seal and rest screw-
driver on crankshaft pin. Pry out oil seal.

ENGINE MECHANICAL AND MOUNTS6A- 251, CAMSHAFT SPROCKET
2. CAMSHAFT SPROCKET SUPPORT
3. LONG DAMPER BLOCK
4. CRANKSHAFT SPROCKET
5. CHAIN AND DAMPER BLOCK
IN PARALLEL
6. CRANKSHAFT KEY
7. PAINT MARK ON FRONT
8. TIMING CHAIN
9. MARK ON CAMSHAFT
SPROCKET SUPPORT
IO. MARK ON CAMSHAFT
SPROCKET
6A-41Figure 6A-4 1 Valve Timing Marks
Removal4. Lubricate new oil seal and place on installer
J-
22924.1. Remove cylinder head.
5. Place installer J-22924 on crankshaft. Using
crankshaft bolt and washer install seal into cover. See
Figure 6A-42.2. Loosen self-locking rocker arm nuts and swing
rocker arms off valve lifters.
6. Install crankshaft pulley, bolt and washer. Torque
bolt to 72
Ib.ft.3. Remove valve 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 left side andFigure 6A-42 Installing Timing Chain Cover Oil Seal
Replacing Distributor Drive Gear
On Crankshaft1. Remove fan belt.
2. Remove fuel pump. Plug end of fuel line with a
suitable stop.
3. Remove spark plug wires, distributor hold down
clamp. Remove distributor.
4. Turn crankshaft so key is on top.
5. Pry oil seal out of timing chain cover.
6. Insert a screwdriver through opening for fuel
pump and push out distributor drive gear, which has
a push tit on crankshaft, through oil seal seat in
timing cover.
7. Install new gear. Be sure key tits in
keyway. When
installing components, use new gaskets as required.
8. Install new oil seal.
9. Connect parts removed in steps 1 thru 3.
CAMSHAFT

6A- 28 1973 OPEL SERVICE MANUAL
Part
ConnectingRod Bolts..........................................................
Crankshaft Main Bearing Bolts
..........................................
FlywheeltoCrankshaft AttachingBolts..........................
Cylinder Head Attaching Bolts....Cold 72 -Warm 58
Camshaft Sprocket Attaching Bolts................................
Generator Bracket to Cylinder Block
Attaching Bolts ..................................................................
Generator Bracket to Timing Case Attaching Bolts
....
Crankshaft Pulley Attaching Bolts ....................................
Rocker Arm Stud in Cylinder Head ..................................
Spark Plugs ........................................................................\
....
Clutch Housing to Cylinder Block Attaching Bolts
......
Timing Case to Cylinder Block AttachingBolts ............
Water Pump to Timing Case AttachingBolts................
Engine Support to Cylinder Block Attaching Bolts
......
Rear Engine Suspension to Transmission Rear Bearing Retainer Bolts ....................................................
Transmission to Clutch Housing Attaching Bolts
........
Starter to ClutchHousing AttachingBolts....................
Support to Starter Attaching Nut
....................................
Intake and Exhaust Manifold to Cylinder Head Attaching Bolts ..................................................................
Unless Otherwise Noted:
10
@i Bolt (15 MM Hall.....................................................................- -
36
72
43
18
;i
72
29
30
36
14
11
40
22
29
40
4
33 ............30
8 MM Bolt (13 MM Head)........................................................................\
........................................................................\
........................................15
6 MM 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......................................................................................\
........................................................................\
........................................................................\
........................................
\fô\
²…..............7.6:1Octane Requirement........................................................................\
..........
Firing Order........................................................................\
........................
Regular - Lo;-?::
....................Cylinder Block Material....... ...............................................................................\
..............................................Cast Iron
Crankshaft Bearings Number and Type 5 Removable Steel Backed
In-Metal Babbitts
Bearing Which Takes End Thrust
........................................................................\
...................5
Connecting Rod Bearing Material
........................................................................\
..................
Steel Backed Tri-Metal Babbttts
Piston Material and Surface Aluminum Alloy, Lead Coated
Piston Pin Offset
........................................................................\
............,031 In. to the RightCompression Rings Material and Surface Treatment
No.
1....... ........... ............... ........ ............. ................Chrome-plated, Cast Iron
- Rectangular
No. 2
........................................................................\
..............................Cast Iron - Tapered
Oil Ring
........................................................................\
..................Chrome-plated, Cast Ir?n
Location of All Piston Rings
........................................................................\
Above Ptston Pm
Camshaft Material
........................................................................\
....................Alloy Cast Iron
Camshaft Drive........................................................................\
........................................Chajn
Number and Type of Camshaft Bearings 4 Steel-Backed Babbttt
Valve Lifter Type
..............................................................................................\
..........................................~..........Hydraulic
Oiling System Tvoe........................................................................\
Circulatmg High Pressure
Oil
&ppiied to: - .
Bearing Surfaces, Crankshaft, Camshaft and Connecting Rods............................Pressure
Piston, Pins
........................................................................\
............................................Vapor
Cvlinder Walls........................................................................\
..........................Nozzle Spray
Rocker Arms _,,,..,,....,._..___.,,..,,..............,,,,...,.......,..,,,.,.,,.....\
....,,...,.,.................~...... Pressure
Oil Reservoir Capacity
- Quarts .,,,...,,__.,,..,..,,..,...,..,,,...,,..............,,,... 3 l/4 With Dry Fdter
Oil Filter
- Type ,,....,__.,,...,....,....,,..,,,..,,...........,........................\
............ Throw Away Element

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.

7A- 61973 OPEL SERVICE MANUAL1. FIywheeI and Pressure PlateExamine friction surfaces of flywheel and pressure
plate for scoring or roughness. Slight roughness may
be smoothed with fine emery cloth, but if surface is
deeply scored or grooved the part should be re-
placed.
2.
CJutch Driven Plate
Inspect driven plate for condition of facings, loose
rivets, broken or very loose torsional springs.
If facings are worn down near rivets or are oily, the
plate assembly should be replaced. A very slight
amount of oil on clutch facings will cause clutch grab
and chatter. A large amount of oil on facings will
cause slippage. Removal of oil by solvents or by buff-
ing is not practical since oil will continue to bleed
from facing material when hot.
When oil is found on driven plate facings, examine
transmission drainback hole, pilot bushing, engine
rear main bearing and other points of possible oil
leakage.
Test the fit of driven plate hub on transmission main
drive gear for an easy sliding fit.
Regardless of whether the old plate or a new one is
to be installed, the plate should be checked for run-
out. Lateral run-out measured at disc circumference
should not exceed
.016 inch.
Inspect 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
crankshaft. If bushing is rough or worn it should be
Figure JA-3replaced. If replacement is necessary, remove bear-
ing with Tool J-21718 and Slide Hammer J-7004-1.
Install new bearing using J-21706. See Figure 7A-3
for removal procedure and Figure 7A-4 for installa-
tion.
\,,
Figure JA-4
Installation of Clutch1. Index alignment marks on clutch assembly and
flywheel. Place driven plate on pressure plate with
long end of splined hub facing forward toward the
flywheel. See Figure 7A-5.
2. Insert alignment Tool J-22934 through clutch
cover and driven plate.
3. Hold complete assembly against flywheel while
inserting end of Tool J-22934 into pilot bearing in
crankshaft.
4. Index the alignment marks and install four (4)
clutch cover to flywheel bolts finger tight. Complete
torquing bolts alternately and evenly one at a time.
5. Torque attaching bolts to 36 lb.ft. and remove
alignment tool.
6. Install release bearing.
7. Install flywheel housing and torque lower bolts to
36
lb.ft.8. Install flywheel housing lower cover.
9. Install clutch return spring and control cable.
10. Install transmission. See Manual Transmission
Section for procedure.
11. Adjust clutch control cable. Refer to paragraph7A-3.

Installation1. FLYWHEEL
2. CLUTCH ASSEMBLY
3. ASSEMBLY MARKS
4. CLUTCH ALIGNING
ARBOR J-229347A-51. Slide control cable ball end through eye in clutch
housing. Connect to lever and (on GT) install return
spring.
2. Replace washers and rubber grommet, slide cable
through retainer on dash panel, and connect to
clutch pedal. To adjust, refer back to Clutch Adjust-
ment paragraph
c or d.
Figure
7A-5 Clutch Installation
SPECIFICATIONS
GENERAL SPECIFICATIONSE-l
I-‘-J- : ,“/’‘~Clutch Specifications
Type. . . . . . . . . . . . . . . . . . . .
Pedal Lash
_ 3/4” to l-1/4”-. -..-.
.........Single Plate - Dry Disc
unvenFlareuamerer.....................................................................................................6-3/4”
Driven Plate Facings
......................................................................................Woven Asbestos
Number of Facings
....................................................................................................................
2Facing Attachment
........................................................................................................Riveted
Vibration Dampening
..................................................................................4 Torsional Springs
Bolt Tightening SpecificationsCLUTCH CONTROL CABLE REMOVAL AND
INSTALLATION
(SEE FIGURE 7A.6
OR 7A-7)
If a new cable was installed or the cable adjustment
was changed during an operation, x-adjust cable
afterwards.
Removal
1. Disconnect return spring and cable with ball end
from release lever. Slide control cable out of eye in
clutch housing.
2. With a screwdriver, pry E-ring out of groove in
control cable, at tirewall, and disconnect cable from
clutch pedal.
3. Pull cable out of retainer on dash panel and
remove washers and rubber grommet.
PartLocationTorque
Lbs.Ft..’
BoltFlywheeltoCrankshaft........................................................43
/BoltClutchCovertoFlywheel....................................................36
BoltTransmissiontoClutchHousing......................................32.36;:
BoltStartertoClutchHousing..................................................40
NutSupport to Clutch Housing................................................4IBoltIntake and Exhaust Manifold to Cylindei Head............33

7A- 101973 OPEL SERVICE MANUAL
Arrangement Of Clutch
1 Clutch release lever14 Clutch ossy. bolt, lockwasher
2 Slot in lever for control cable boll15 Hollow space under felt ring filled
endwith molybdenum disulfide paste
3Assembly marks
4Clutch assembly
5Flywheel
6 Flywheel ring gear
7Thrust pin
8Retaining spring
9Crankshaft
10 Clutch gear pilot bushing
11Oil seal
12Flywheel bolt
13Clutch housing
16 Felt ring
17 Clutch release bearing
18 Clutch gear ball beorirq
19 Clutch gear
20 Snap ring
21 Paper gasket
22 Clutch gear oil seal
23 Clutch release bearing sleeve
24 Clutch disc, long end of hub facing
forward.
?A-8Figure
7A-8 Arrangement of Clutch

causes the sprags to wedge and prevent rotation in
one direction, and to allow free rotation in the oppo-
site direction.7C. 441973 OPEL SERVICE MANUAL
The clutch is released by exhausting the oil from
behind the piston. The release springs push the pis-
ton to the released position, thereby removing the
force from the plates. See Figure 7C-16.Band
A band is used to hold one planetary member sta-
tionary with relation to the other planetary mem-
bers.
!See Figure 7C-19. The band is connected to the
SPR
7C-16Figure
7C-16 Sprag Cage Assembly
Sprag C(utchA sprag clutch is an overrunning clutch which allows
rotation in one direction only and consists of an inner
race, an outer race and the sprag assembly.
The sprag assembly itself consists of sprags, retainer
rings and a spring. See Figure 7C- 16. The sprags are
mounted at intervals between the two concentric re-
taining rings. The spring is located between the rings
and surrounds the ‘narrow portion of the sprags.
One diagonal dimension of each sprag is greater than
the distance between the inner and outer race, while
the other diagonal is less. See Figure
7C-17. This
\ \I’b+ SPRAG
DISTANCE AFigure
7C-17 Sprag Operational Schematictransmissio; case (stationary anchor) and is ope-
rated by a servo piston. One band is used in the Opel
Three: Speed Automatic Transmission and holds the
reaction sun gear and drum stationary in first and
second gear.
BAND\- D7uM
PRESSURE
STATIONARY
PASSAGE
yPlSfON
1 y””SERVO BODY RELEASE SPRING
7c19
Figure
7C-19 Band Application
COMPONENT OPERATION AND LOCATIONThe power flow and principles of operation of the
Opel Three Speed Automatic Transmission power
train are most easily understood when each unit is
considered separately with a part by part build up of
the unit.
The torque converter is connected to the engine by
means of a flex plate which is bolted directly to the
engine crankshaft and to the converter cover. The
converter cover is welded to the converter pump
member which provides a direct connection of the
engine to the converter. The converter pump hub tits
into the transmission oil pump driving the oil pump
whenever the engine is operating. See Figure
7C-20.The input shaft is splined into the hub of the turbine,
delivering the converter’s output torque to the trans-
mission gear train. See Figure
7C-21.