door lock OPEL 1900 1973 User Guide

2D-161973 OPEL SERVICE MANUAL
2. Remove door lock knob.
3. Remove door inside handle.
4. Adjust sash window so that the main lever with
toothed segment are in alignment with the front re-
taining plate. See Figure 2D-9.Figure 2D-9 Aligning Main Lever With Front Retaining
Plate5. On Models 57, 57L and 57R, scribe position of
screw at the plastic support of window rail and un-SCRW.
6. Block sash window in door interior.
7. Scribe position of window lifter guide rail
screws.See Figure 2D- 10.
Figure 2D-10 Guide Rail Screws
8. Unscrew window lifter and let it down slowly.
9. Slide window upwards and block it.10. Remove window lifter through opening in inner
door panel upper part. See Figure 2D-11.
Figure
2D-1 1 Removing Window Lifter
Installation
1. Install window lifter through opening in inner
door panel tipper part. See Figure 2D-
11.2. Block window upwards.
3. Secure window lifter.
4. On Models 57 and 57R, secure plastic support of
window rail.
5. Install inside door handle.
6. Install door lock knob.
7. Install door trim pad.
REMOVAL AND INSTALLATION OF FRONT DOOR
LOCKRemoval
1. Remove door trim pad.
2. Remove door lock knob.
3. Remove door inside handle.
4. On lock side, scribe position of guide rail bolt,
unscrew bolt, push guide rail downwards, and
remove it through access hole. See Figure 2D-12.
5. Remove door lock and install new one. See Figure
2D-13.

DOORS2D-17
Figure ZD-12 Guide Rail Bolt
Figure 2D-13 Lock Retaining Screws
6. On Models 57, 57L and 57R, do not unscrew
window guide rail. Unscrew lock and, with actuating
lever engaged, remove lock from behind guide rail.
See Figure
2D-14.Installation
1. Install window guide rail, if removed.
2. Engage actuating lever and install lock. See Figure
2D-14.Figure 2D-14 Engaging Actuating Lever
3. Install guide rail through access hole and install
bolt and rail bolt. See Figure
2D-12.4. Install inside door handle.
5. Install door lock knob.
6. Install door trim pad.
REMOVAL AND INSTALLATION OF FRONT DOOR
LOCK CYLINDER
Removal1. Remove door trim pad.ZD-15
Figure 2D-15 Outside Door Handle Hex. Nuts

2D-18
1973 OPEL SERVICE MANUAL
2. With window closed, unscrew hex nut and remove
door outside handle. See Figure 2D-15.3. Clamp door outside handle in a vise provided with
protective jaws.
4. With ‘a screwdriver, lift cylinder lock ring out of
handle. See Figure 2D-16.
Figure 2D-16 Removing Cylinder Lock Ring Out of
Handle5. Pull lock cylinder out of door outside handle.InstalMion
1. Clamp outside door handle in a vise and protect
handle with pi&es of wood.
2. Install lock cylinder into outside door handle.
3. Install lock ring into handle. See Figure
2D-16.4. With window closed, install outside handle and
hex nut. See Figure 2D-15.
5. Install door trim pad.
REMOVAL AND INSTALLATION OF FRONT DOOR
WEATHERSTRIP1. From below, grind the peen off door check link pin
and drive out pin. See Figure
2D-18.2. Remove weatherstrip from front door.Figure 2D-17 Outside Handle
- Exploded View
Figure 20-16 Grinding
Peen Off Of Link Pin
3. Button in new weatherstrip in the door area and
push it in the metal profile in the area of the window
frame. See Figure
2D-19.4. Install door check link and rivet pin.
REMOVAL AND INSTALLATION OF FRONT DOOR
1. Remove door trim pad.
2. Remove lock knob.

Figure ZD-19 Installing Weatherstrip
3. Remove door inside handle.
4. Remove door belt reveal molding.
5. Remove window lifter.
6. Remove sash window guide rails.
7. Remove door lock.
8. Remove door outside handle,
9. Grind off door check link pin and remove door
check link./.-..&- _[I 2D-20
Figure ZD-20 Removing Door Weatherstrip10. Remove door weatherstrip, using a clip remover.
See Figure 2D20.
Il. Remove door rubber bumper.
12. Drive out upper and lower door hinge sleeve and
remove door, using Tool J-21688. See Figure
2D-21.Figure
ZD-21 Removing Hinge Pin
13. Install door and rivet door check link pin.
14. Reverse procedure for installation.
REMOVAL AND INSTALLATION OF REAR DOOR
SASH WINDOW
1. Remove and install door trim pad. See Figure
2D-22.Figure
ZD-22 Trim Pad Items
2. Completely open sash window and unscrew win-
dow guide rail in the places shown in Figure
2D-23.

2D-201973 OPEL SERVICE MANUAL
2. Remove door sash window.
Figure 2D-23 Guide Rail Screws
3. Pull guide rail towards the top out of door.
4. Position sash window so that cable retainer can be
unscrewed through access hole. Pull out sash win-
dow towards the top.
5. Push sash channel off window glass. See Figure2D- 24.Figure 2D-25 Cable and Pully Location
3. Loosen sheave adjustable bracket. Unscrew win-
dow regulator from inner door panel and remove
regulator and cable through access hole. See Figure
2D-26.Figure 2D-24 Sash Channel
6. Place new window glass and new filler into sash
channel.
REMOVAL AND INSTALLATION OF REAR
DOOR WINDOW REGULATOR
1. Remove door trim pad.Figure
213-26 Regulator Attaching Screws
Installation
- Left Door
In counterclockwise direction, wind cable onto pul-
ley up to the shoulder and clamp it behind lug. See
Figure 2D-27.

DOORSZD- 21
RIGHTLEFT ~-ZD-27
Figure ZD-27 Cables Wound On Regulators
Installation - Right DoorIn clockwise direction, wind cable onto pulley up to
the shoulder and clamp it behind lug. See Figure2D-27.
REMOVING AND INSTALLING
’
TAILGATE HINGES
Removal1. Remove screws securing hinge trim panel covering
tailgate binges and lift out trim panel. See Figure
2D-28.2. Disconnect battery, remove tail
te trun pad, and
withdraw wiring from tailgate.
u3. Mark position of tailgate hinges on tailgate,
remove bolts securing tailgate to hinges and lift off
tailgate.
,’HINGE TRIM
PANEL1IFigure ZD-28 Removing Tailgate Hinge Trim Panel
4. Release and remove torque rods. See Figure 2D-
29.Figure ZD-29 Tailgate Torque Rods
5. Remove bolts securing tailgate hinges to roof
panel and lift out tailgate hinges.
Installation1. Install tailgate hinges to roof panel and secure
with bolts.
2. Install torque rods. Installation of torque rods may
be facilitated by using vise-grip pliers to work torque
rod end over catch.
3. Install tailgate to tailgate hinges.
4. Install wiring to tailgate
5. Install tailgate trim pad and tailgate hinges panel
COVehg.6. Connect battery

2. Press off snap ring holding drive pinion in place
and remove drive pinion (see Figure 2F-10).
Installation1. Install drive pinion reverse of removal.
NOTE: If drive pinion is to be replaced, also replace
both cables to insure smooth operation of sun roof.
2. Rotate cable crank to its limit in a clockwise direc-
tion and install reverse of removal procedure.ROOF AND SUN ROOF2F-31
REMOVAL AND INSTALLATION OF FRONT AND
REAR WATER DRAINAGE HOSES
Removal of Front Water Drainage Hose
1, Remove sun visor from side of car which will have
drainage pipe taken out.
2. Partially detach pinchweld finishing strip from
door opening involved.
II2F-12L
Figure 2F-12 Sun Roof (Exploded View)

26-341973 OPEL SERVICE MANUAL
a 13/16 inch deep socket, and remove. See Figure2G-6.Figure
ZG-4 Seat to Underbody Hook
Figure
ZG-5 Seat Back Metal Tabs
3. Remove seat back towards the top.
REMOVAL AND INSTALLATION
OF GLOVE
COMPARTMENT DOOR LOCK
1. Unscrew nut of glove compartment lid lock, usingFigure ZG-6 Removing Glove Compartment Lock
2. Install new glove compartment lid lock.
REMOVAL AND INSTALLATION OF FRONT SIDE
PANEL TRIM PAD
1, Lift up door sill shield and pull off sealing strip up
to the instrument panel cover. See Figure 2G- 7.
Figure
ZG-7 Pulling Off Sealing Strip

2G-361973 OPEL SERVICE MANUAL
3. Install and align the remaining five listing wires.
If required, caulk retainers of 2nd and 5th listing
wires so that wires run in a straight line transversally
under the roof. See Figure
2G-9.Figure ZG-10 3rd. 4th and 6th Listing Wire
Attachment4. Lightly pull headlining towards the rear and ce-
ment to the rear roof frame cross member and then
to the rear quarter pillars using rubber cement.
When pulling headlining toward rear be sure that the
listing wires are not pulled out of line. A folded clothshould be used to smooth down cemented portions
of headlining.
5. Cut off surplus headlining along rear window, rear
quarter windows, and windshield, leaving enough to
tit under rubber channels.
6. Cement surplus material to pinchweld flanges.
7. Cut off excess headliner around door openings and
cement trimmed edge to pinchweld flange using rub-
ber cement.
Figure 2G-12 Quarter Window and Lock Pillar Sealing
StripFigure
2G-1 1 Lock Pillar Shield Attaching ScrewsFigure 2G-13 Trim Pad and Retaining Button

9A-i2 1973 OPEL SERVICE MANUAL
Check that air doors and water temperature control
valve are operating properly.
Check for plugged heater core-backflush heater core
as necessary.TROUBLEInadequate defrosting action.
CAUSE AND CORRECTIONExamine heater-defroster door for proper operation.
Adjust bowden cable so that door is fully closed in
FULL DEFROST position.
Check that air hoses connecting to defroster outlets
are secure.
Check for air leaks around edges of heater air dis-
tributor housing. Seal leaks, as necessary, with bodysea@. Check for body air leaks and seal, as neces-
sary, with body sealer.
TROUBLEBlower inoperative.
CAUSE AND CORRECTIONCheck blower fuse. Replace, if necessary, fuse posi-
tion 4
- amperage 15.
Check wiring for open circuit. Correct, as required.
Inspect for defective component, (i.e., blower switch
or blower motor)
- replace or repair as necessary.
MAINTENANCE AND ADJUSTMENTS
CONTROL CABLE ADJUSTMENTAdjustment of control cables is accomplished by po-
sitioning of the jacket or sheath of the control cable,
as held by the clamps on the control assembly and
heater case or by loosening screws and slidingbowden wire to obtain desired door or water valve
position.
MAJOR REPAIR
REMOVING AND INSTALLING HEATER HOUSING
Removal1. Unscrew hood lock together with ground wire(ground wire only on vehicles with radio interference
suppression). See Figure 9A-33.
Figure 9A-33 Hood Lock Attachments
2. Unscrew heater housing cover.
3. Pull hose of windshield washer system off jet and
take jet out of housing cover.
4. Unscrew bowden control wire from heater valve.
5. Unscrew heater housing from dash panel and pull
it off carefully. See Figure 9A-34.
Figure 9A-34 Heater Housing Attachments
6. Remove water hoses from heater core and pull
heater core out of heater housing. See Figure
9A-35.