engine oil OPEL 1900 1973 User Guide

lB- 16 1973 OPEL SERVICE MANUAL
8. Making sure that brush holder is aligned at right
angles to the
field frame, rivet brush holder to field
frame. See Figure
lB-14.
RIVET
Figure 18.14 Riveting Brush Holder to Frame i
Replacing Bushings
If sintered bronze bushings in. commutator ehd
frame and drive housing are worn, they must be
replaced. Soak new bushings in engine oil for at least
half an hour prior to installation. Press out old bush-
ings and press in new bushings. See Figure
lB-15.
Figure 18.15 Installing New Bushings
St& Assembly
1. Lubricate armature shaft. Install drive assembly
with pinion outward. 2. Slide pinion stop retainer down over shaft with
recessed side outward.
3. Place a new snap ring on drive end of shaft and
hold it in place with a hard
wood block. Strike block
with hammer to force snap ring over end of shaft,
then slide the ring down into groove in shaft. See
Figure
lB-16, view A.
7
(
I
I
E-.
Figure 1B-16 Pinion Stop Retainer and Snap Ring
Installation
4. Place thrust collar on shaft with shoulder next to
snap ring and move the retainer into contact with
ring. Using pliers on opposite sides of shaft, squeeze
retainer and thrust collar together until snap ring is
forced into the retainer. See Figure
lB-16, view B.
5. Lubricate drive housing bushing and install arma-
ture and drive assembly in housing.
6. Install solenoid thrust spring and solenoid.
Figure 1B-17 Applying Sealer to Starter

1 C- 18 1973 OPEL SERVICE MANUAL
IGNITIPN SYSTEM
CbNTENTS
Subject
DESCRIPTION AND OPERATION: Ignition System ..................................................................
Ignition
Switc,h....................................................................
Ignition Coil
..........................................................................\
Distributor
............................I...............................................
DIAGNOSIS: (Not Available)
MAINTENANCE AND ADJUSTMENTS: Contact PointReplacement ............................................
Dwell Angle Adjustment :
................................................
Ignition Timing Adjustment ..........................................
Ignition Wire Inspection :
..................................................
Check Ignition Output ......................................................
Check Distributor
..............................................................
Check Spark Plugs
............................................................
MAJOR REPAIR: Distributor Removal ..........................................................
Disassembly ........................
I...............................................
Reassembly
..........................I...............................................
Distributor Installation
....................................................
SPECIFICATIONS: /
Ignition
Coil ..........................................................................
Distributor
....‘........................i...............................................
Spark Plugs ........................................................................\
..
DESCRIPTION AND OPERATION
INGITION SYSTEM
The ignition system basically consists of an ignitipn
switch, ignition coil, distributor, battery and related
wiring. The ignition switch is located in the steering
column, the ignition coil is located left front inner fender
skirt and the distributor is located at the left
front of the engine.
IGNITION SWITCH
The combined ignition switch and steering lock ian
be switched to any one of the below listed positions.
Insert key with notch pointing upward.
Page No.
lC-18
lC-18
lC-19
lC-19
1 c-20
1 c-20
1 c-20
lC-21 r
lC-21
1 c-22
1 c-22
1 r-23
1 C-23
1 c-24
1 C-25
1 C-26
1 C-26
1 C-26
(Fully counterclockwise) Lock position. Ignition
locked, steering locked, only with key removed.
Electrical circuits disconnected except to main light-
ing switch and dome lamp. The
key can be removed.
0- (First position clockwise from lock) Garage posi-
tion. ‘The key and lock assembly must be pushed “in”
to reach this position from lock. The steering is un-
locked and the ignition is off. The electrical circuits
are the same as in lock position. The key cannot be withdrawn.
l- [Chposition.) All electrical circuits controlled by
ignition switch are completed through the switch.
The key cannot
be removed while switch is in drive
position.

IIIGNITION SYSTEMlC- 19
11. (Startx position.) The ignition key must be
released as soon as engine starts. The switch then
returns aujomatically to the on position.
IGNITION
GOILThe ignition coil consists of a laminated non- mag-
netic iron
(core enclosed by two coils; the primary
winding and the secondary winding.
The prim+y circuit consists of the power source
(battery), the ignition switch, the ignition coil pri-
mary winding, the distributor breaker points with
ignition condenser connected in parallel, and all con-
necting
lo& tension wiring.
The secondary circuit consists of the ignition coil
secondary ‘winding, the spark plugs, all connecting
high tens@ wiring, the distributor cap and the
ro-tor.
When the’ ignition switch is turned on and the
breaker pdints are closed, current flows through the
ignition
c&l primary winding and produces a mag-
netic field wound the coil windings.
When the breaker points are separated by the revolv-
ing distributor cam, the magnetic field collapses and
induces a high voltage surge in the secondary wind-
ing,
produ;cing a spark between the spark plug elec-
trodes. ,
The ignitidn condenser which is connected in paral-
lel with the breaker points, prevents arcing between
the
separa’ted breaker contacts, and current flow
after~ the breaker points have been separated, thus
causing a kery rapid collapse of the magnetic field
around th$ Ignition coil.
/
IGNITION ‘DISTRIBUTORThe ignitidn distributor breaks the primary current,distributeslthe high voltage surges induced in the coil
secondary winding to the spark plugs according to
the engin< tiring order and sets ignition timing in
relation to. engine RPM and load.
The housi+g of the distributor contains the centrifu-
gal advance mechanism and the movable breaker
plate with’s breaker lever and contact support. The
vacuum advance mechanism is attached to the
breaker plate and mounted on the outside of the
distributor, housing. See Figure lC-1.
The distributor shaft is driven by a helical gear on the
camshaft and in turn drives the engine oil pump. The
ignition condenser is mounted on the outside of the
housing. The engine output is to a large extent in-
fluenced b) the ignition timing. Maximum engine
performance is obtained when the combustion proc-
ess is well underway as the piston starts down on thepower stroke. The air-fuel charges are, however, not
burned instantly, so it is necessary to advance the
spark in relation to the piston top dead center as
engine speed increases or as engine load decreases.
If the spark is too far advanced, the engine knocks,
causing a drop in engine power output and overheat-
ing. If the spark is retarded, part of the energy deve-
loped during combustion is wasted which will result
in reduced engine power output, excessive fuel con-
sumption and overheating.
The ignition distributor has a double acting double
diaphragm vacuum unit. See Figure lC-1. The ad-
vance unit is supplied with “ported” vacuum. That
is, vacuum is supplied from a port in the primary
barrel of the carburetor located just above the closed
throttle valve. This port supplies no vacuum during
idling nor during closed throttle deceleration, but
supplies full intake manifold vacuum at all speeds
where the throttle valve is opened enough to uncover
the port.
Figure lC-1 Ignition Distributor
The retard unit is supplied with intake manifold
vacuum at all times by means of a line connected
directly to the intake manifold. During idling and
deceleration, when there is no vacuum to the ad-
vance unit, the retard unit will cause the timing to be
retarded 5 degrees. However, during part throttle
operation when there is vacuum to the advance unit,
the advance unit will overpower the retard unit so
that the retard unit has no effect on timing.
The purpose of the retard unit is to reduce hydrocar-
bon and carbon monoxide emissions during idling
and deceleration, where they are especially bad.
In order to avoid voltage losses for easier starting, a
plastic cover has been inserted in the distributor be-
low the rotor as a seperator to keep the inside of the
distributor cup free from condensation.

I
ilC- 201973 OPEL SERVICE MANUAL
There is also a plastic hood slipped over the distrivu-tar cap with an outlet for the ignition cables as an
added protection against moisture from the outside.
See Figure lC-2.
Figure lC-2 Ignition Distributor With Hood Installed
MAINTENANCE AND ADJUSTMENTS
CONTACT POINT REPLACEMENT
Removing Contact Points1. Remove contact support lock
,screw and remqve
contact point support. If condenser is to be replaced,
it will be necessary to replace condenser and
1eads;asan assembly.
Installing Contact Points1. Lightly lubricate distributor cam with high tein-perature cam and ball bearing lubricant. Excessive
lubricant will throw off into contact points.
:
,
2. Position support on breaker plate and install lock
screw leaving slightly loose for later adjustment..
3. Plug breaker arm wire in.
4. Adjust breaker point gap to ,016”.
/
DWELL ANGLE ADJUSTMENT
1. Connect dwell meter.
2. Remove distributor cap. Remove rotor. Loosen
breaker point set screw approximately
l/8 turn.
3. Insert screwdriver in notch of stationary breaker
point. Observe dwell meter while cranking engine.
Twist screwdriver as required to obtain a reading of
50 degrees plus or minus 3 degrees.4. Tighten breaker point set screw, then recheck
dwell.
5. Install rotor and cap.~Start engine and recheck
dwell. It is important that dwell be rechecked, as
instal~lation of rotor and cap will sometimes change
the dwell angle.
IGNITION TIMING ADJUSTMENT
Preliminary Timing (Engine Won’t Run)To time the ignition on any engine which will run,
use subparagraph b only. However, if the timing of
an engine is completely off, the following procedure
must first be used to get the engine to run.
1. With rocker arm cover removed, rotate crankshaft
in a clockwise direction until both valves for No. 1
cylinder are closed and the timing marks line-up.
(Valves are completely closed if rocker arms can be
“rocked” slightly.)
2. Install distributor in engine so that vacuum ad-
vance unit is in original position and notch in dis-
tributor rotor lines-up with notch in housing. See
Figure lC-3. If distributor does not seat in engine
block., turn distributor shaft so that rotor points
about 20 degrees clockwise from distributor timing
notch
(see Figure lC-18), then press lightly on dis-
tributor housing while cranking engine with starter.
After oil pump tang snaps into slot in distributor
shaft, start timing again from Step 1, leaving dis-
tributor installed.
Figure lC-3 Rotor Position for Filing No. 1 Cyliqder
3. Install distributor clamp and bolt, leaving bolt just
loose enough to permit movement of distributor. In-
stall distributor primary wire.L

IGNITION SYSTEMlC-214. Rota&distributor counterclockwise slightly until
contact pbints just start to open. This must be done
very carefully or engine will not start.
5. Install distributor cap. Make sure spark plug wires
are correctly installed in distributor cap, through clip
and on spark plugs.
Finish TimingIContact boint gap
(.016” at widest gap) or dwell 50
degrees plus or minus 3 degrees should always be
checked before adjusting ignition timing.
1. Connekt timing light to No. 1 spark plug.
2. Disconnect and plug vacuum advance unit and
retard u$it hoses.
3. Connect a tachometer from distributor side of coil
to
groun$l.4. Start dngine. Set idle speed to 900 RPM.
5. Rotate distributor as necessary to align timing
marks. T;ming mark is a steel ball embedded in the
flywheel and a pointer in a window in the right fly-
wheel housing. See Figure lC-4.:Figure lC-4 Ignition Timing Marks
6.
Tightq clamp bolt securely and recheck timing
mark ahgnment.
7. Reconnect vacuum hoses and adjust engine idle
speed
an: mixture.
IGNlTlOFj WIRE INSPECTION
1. The c$il and spark plug wires are of a specialresistance type. These secondary ignition wires
reduce television and radio interference.
2. Wipe ignition wires with a cloth moistened with
solvent and wipe dry. Bend wires to check for brittle,
cracked or swollen insulation. Defective insulation
will permit missing or cross-firing of spark plugs,
therefore any defective wires must be replaced.
3. If wire insulation is in good condition, clean any
terminals that are corroded and replace any termi-
nals that are broken or damaged. Terminals must tit
tight on spark plugs and in distributor cap.
4. Replace any hardened, cracked or loose cap nip-
ples or spark plug boots.
5. Check resistance of each wire from contact inside
distributor cap to spark plug or coil terminal. Re-
place any wire having over 10,000 ohms resistance
reading. See Figure lC-5.
Figure fC-5 Checking Ignition Wire Resistance
CHECK IGNITION OUTPUT
1. Disconnect secondary coil ivire so that engine will
not start. Connect a voltmeter from the battery side
of the coil primary to ground and check voltage
while engine is cranking. Reading should be 10 volts
or more. Low reading could be caused by a defective
battery, a discharged battery, high starter current
draw, a bad connection in the starter circuit or a bad
connection in the primary ignition circuit.
2. Connect an oscilloscope according to manufac-
turer’s instructions. Disconnect coil wire. Crank en-
gine and read coil output voltage. Reading should
exceed 20 KV (20,000 volts).

IGNITION SYSTEMlC- 23
9. Install:spark plugs using a 13/16 deep socket, an
extension and a torque wrench. Tighten to 22-29Ib.ft. 1
MAJOR REPAIRDlSTRlBtiTOR OVERHAULDistributbr Removal
1. Remove fuel pump. This is necessary because the
fuel
punp will block the distributor drive gear,
thereby preventing removal of the distributor. See
Figure lC-6.
2. Set No; 1 cylinder at firing point by turning engine
INOTCH IN STATIONARY& -.until cutout in distributor shaft (or rotor tip) points
to notch in distributor housing. See Figure
lC- 7.
3. Ball imbedded in flywheel should be approxi-
mately aligned with pointer in housing. See FigurelC-4.
4. Remove distributor hold-down clamp and remove
distributor. See Figure lC-8. Cover bore in timing
case to prevent foreign material from dropping into
engine. To make reinstallation of distributor easy, do
not rotate crankshaft or oil pump.
Disassembly
1. Remove distributor cap retaining spring clips, and
vacuum control units. See Figure lC-9.
Figure lC-9 Removing Retaining Clips
Figury lC-7 Aligning Shaft Cutout With Notch
Figure lC-8 Removing DistributorFigure lC-10 Removing Retaining Ring

lC- 261973 OPEL SERVICE MANUAL /
SPECIFICATIONSIGNITION COIL
Ignition Coil Number
.,.:.................................................................................................K12 V
Ignition Coil Current Draw, Amperes at 12.5 Volts
EngineStopped
...........:.........................._............................................................................3.8Engine Idling
....................................................................................................................2.3
DISTRIBUTORDistributor TypeNumber:
..................................................................................................JFU4
Total Advance (Centrifugal and Vacuum), Engine Degrees at 3600 R.P.M.
EngineRPM
..................................................................................................................29-37Centrifugal Advance, Engine Degrees and RPM
StartAdvance,atRPM
........................................................................................lOOO-1200MediumAdvance,DegreesatRPM
..............................................................7.5-15at1400Maximum Advance, Dkgrees at RPM
..........................................................28-32 at 3600
Vacuum Advance, Engine Degrees and
In. of Vacuum
Start Advance, at In. of Vacuum
................................................................-5 at 2.9-4.1 In.
Maximum Advance, Degrees at In. of Vacuum
........................................l-5 at 4.5-5.0 In.
VacuumRetard,EngineDegreesatClosedThrottle
............................................................-5CondenserCapacityinMicroFarads
...............................................................................15-.20Breaker Spring Tension in Ounces
..............................................................................14 to 19
Breaker Point Gap in Inches
..............................................................................................,016Dwell angle in Engine Degrees
....................................................................................50 + 3
Firing Order
....................................................................................................................l-32-2
SparkPlug or CoilCable,Max.Resistancti in Ohms
..................................................10,ooO
SPARK PLUGSMake and Model
-Production................I....................................................................AC42FS
Make and Model
- Replacement...................................................................................AC42FS
Ifcarbonfouling
occurs,use.....................................................................................AC43FS
SparkPlugTorqueinLb:Ft.
............................................................................................22-29Spark Plug Gap in Inches
...........................................................................................028-.03 1

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

3A- 21973 OPEL SERVICE MANUAL
FRONT SUSPENSION
CONTENTS
Subject
DESCRIPTION AND OPERATION:SuspensionDescription. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS:
FrontWheel
BearingAdjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Removal and Installation of Front Suspension . . . . . . . .Upper Ball Joint Removal and Installation
. . . . . . . . . . . . . .Lower Ball Joint Removal and
Installation
. . . . . . . . . . . . . .Upper Control Arm
Removal andInstallation
. . . . . . . . . .Lower Control Arm Removal and Installation
. . . . . . . .Steering
Knuckle
RemovalandInstallation. . . . . . . . . . . . . .Shock Absorber
RemovalandInstallation. . . . . . . . . . . . . . . .Front Spring Removal and Installation
. . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:Page No.
3A- 2
3A- 4
3A- 4
3A- 7
3A- 73A-103A-113A-133A-153A-15
Bolt Torque and Front End Alignment Specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3A-18
DESCRIPTION AND OPERATION
SUSPENSION DESCRIPTION
GTThe GT uses a maintenance-free independent front
wheel suspension and features unequal length con-
trol arms and a transverse three-leaf spring. The en-
tire front suspension is attached to the front cross
member and can be removed as a unit if so desired.
The engines installed in the GT are not supported by
mounting brackets but rest on a separate cross mem-
ber. The front suspension cross member is reinforced
in the area of the attachment to the frame. A one-
part damper plate is installed between cross member
and frame.
Ball joints are employed in the conventional manner
to provide pivoting joints between the control arms
and steering knuckles. Upward movement of the
control arms is limited by two large rubber bumpers
attached to the cross member.Road shock is dampened by the double direct acting
shock absorbers and a transverse double or triple
steel band spring. In addition, the shock absorber
limits downward travel of the control arms.
All moving parts, including ball joints, have no need
for lubrication as they have been pre-lubricated for
the life of the vehicle.
For distinguishing the individual front suspension
cross members,.a red label with black letters is stuck
onto the front side of the shock absorber support. See
Figure 3A-3.
Opel 1900. Manta
The front wheel suspension has coil springs and con-
trol arms of different length.
The stabilizer is designed to act as a tie strut. The end
is supported in a rubber bushing which is located in
a piece of tubing welded into the longer control arm.
To minimize brake torque, the horizontal shafts of

4A- 21973 OPEL SERVICE MANUAL
PROPELLER SHAFT AND CENTRAL JOINT
CONTENTS
Subject
DESCRIPTION AND OPERATION:
PropellerShaftandCentralJoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS: (Not
Applicable)
MAJOR REPAIR:
’Propeller Shaft Removal andInstallation
. . . . . . . ..-....Disassembly andAssembly of CentralJoint
. . . . . . . . . . . .SPECIFICATIONS:
Propeller Shaft and Central Joint Specifications . .
DESCRIPTION AND OPEqATlON
PROPELLER SHAFT AND CENTRAL JOINTDue to the use of both automatic and manual trans-
missions, propeller shafts of various lengths are re-
quired depending upon vehicle, engine, and
transmission (manual or automatic) application. The
propeller shaft is of a strong design due to increased
engine torque. It is also a one piece tubular shaft, but
it has two universal joints. See Figure 4A-1. The
front universal joint attaches to the transmission out-
put shaft by a splined slip joint. The rear universal
joint attaches to the pinion extension shaft flange by
Page No.
4A-2
4A-3
4A-3
4A-6two U-bolts. The splines of both propeller shafts are
lubricated internally with transmission lubricant. An
oil seal in the rear of the transmission extension pre-
vents loss of lubricant and entrance of harmful for-
eign material.
The torque tube which houses the drive pinion exten-
sion shaft is bolted to the differential housing. The
torque tube is pivoted in rubber elements of the cen-
tral joint support bracket which is bolted to the floor
panel. The support bracket and rubber parts of the
torque tube
arc termed the central joint. The front
end of the drive pinion extension shaft rides in a ball
bearing mounted in rubber in the central joint.
CENTRAL JOINT\REAR U-JOINT
FRONT U-JOINT
4A-1Figure 4R1 Propeller Shaft