instrument cluster OPEL 1900 1973 User Guide

lti- 64 1973 OPEL SERVICE MANUALj
Removal of Cigar Lighter GT/
1. Remove instrument housing.I
’ 2. Disconnect electrical wire.
3. Remove hex nut on back of cigar lighter
base’.’4. Remove cigar lighter base.
Installation1. Install cigar lighter base.
2. Install hex nut on back of lighter base.
3. Connect wire to lighter.
4. Replace instrument cluster.

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GAUGES1 I- 67I
I Condition
Car
&s out of gas with
gauge indicating fuel in
tank. 1
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IPossible Cause
1. Tank unit misadjusted
2. Defective voltage
stabilizer.Correction
1. Follow corrective action as
stated above (obtain empty
reading on dash)
1. See corrective action above.
Temperature gauge not1. Loose dash gauge1. See corrective action above.
Iattaching nut.
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I2. Defective temperature1. Install 40 ohm resistor
Isending unitbetween temperature sneding
Iunit and ground (disconnect
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from unit). If dash unit reads
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full scale, replace temperature
Isending unit.
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I3. Open wiring.1. Follow corrective action as
Istated above (connector socket
Iwith blue wire).Tempkrature gauge indicates
hot when engine temperature1. Incorrect temperature1. Check for correct sending unit
sending unit
normal.(white porcelain) replace if
incorrect.
2. i>efective temperaturesending unit.1. See corrective action above.
3. Dkfective voltage
stabilizer.
1. See Corrective action above.
GAS
GdUGE TROUBLE DIAGNOSIS - GT4. Disconnect the tank unit lead wire (light blue with
black tracer) from the tank unit.
An inoperative gas gauge reading can normally be
found to result from a poor grounding condition
within the circuit. Using the procedure as outlined
below may lead to the correction of the inoperative
reading without replacement of either the tank unit
or the
dph unit.5. Connect ihe stock tank unit; ground unit, and
operate manually.
6. If the dash unit shows a correct reading, then
replacement of the tank unit is required as the cor-
rection.
1. Makelcertain the gas tank (ground) strap is prop-
erly secured.A correct reading will be one which resembles the
movement of the manually-operated tank unit.
2. Make’certain the ground wire (brown in color) for
gasoline/ and temperature gauges is properly con-
nected tb the windshield wiper motor and is secured.
(This
gl?ound wire is also common for the heater
blower
etor.)7. If the dash unit does not show a correct reading,
then its replacement is necessary.
If the adove procedure does not produce a satisfac-
tory gaube reading, an attempt to isolate the defec-
tive
par<, i.e. tank or dash unit should be made.
3. Rem&e a tank unit from parts stock.MAJOR
AEPAIR
OPEL 1900. MANTA
Removing Voltage Stabilizer1. Remove instrument cluster housing assembly.

1 I- 68 1973 OPEL SERVICE MANUAL
2. Pull voltage stabilizer of back of printed circhit.
See Figure
11-l.
!
L-_ -~~---,~. _^__, _-_~
Figure 1 l-3 - Speedometer Attaching Screws
Figure
11-l -Voltage Stabilizer
installation
2. Install six (6) screws holding instrument cluster
lens in housing.
3. Replace cluster housing.
1. Install voltage stabilizer on
back of printed circuit.
2. Install instrument cluster
ho*sing assembly. j
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Removing Speedometer I
1. Remove instrument cluster housing.:
2. Remove six screws shown in Figure
11-2 and
remove both instrument
cluster’lens.
Figure 1 l-2 - Removing Instrument Cluster Lens
3. Remove three speedometer attaching screws. L&X
Figure 11-3.
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Installation
1. Replace speedometer in cluster with three (3) at-
taching screws.
Removing Electric Clock or Tachometer
1. Remove instrument housing.
2. Remove six screws and remove both instrument
cluster lens, as shown in Figure
11-2.
3. Remove three screws, as shown in Figure 11-4, and
remove clock or tachometer.
L-u-.------ _._- -----G1.-A-... -.
Figure 1 l-4 - Removing Electric Clock or Tachometer
1. Install clock or tachometer in instrument cluster
with three (3) attaching screws.
2. Install six (6) screws holding instrument cluster
lens.

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IGAUGES1 I- 69
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3. Replace instrument housing.InstallationFiemoving~Temperature Indicator or Fuel Gauge
1. Remov+ instrument cluster housing.
2. Remov; six screws and remove both instrument
cluster
le+ See Figure 11-2.3. Pull v&age stabilizer off printed circuit and
remove fohr instrument attaching screws, as shown
in Figure
111-5.Figure
11-5 Removing Four Instrument Attaching\SCWWS
4. Take temperature or fuel gauge out of clusterlnstallatidn
1. Install itemperature or fuel gauge in cluster.
2. Replack voltage stabilizer on back of printed cir-
cuit. I
3. Replack both instrument cluster lens.
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4. Install /instrument cluster housing.
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IRemwind Rallye Gauges
1. Removt glove compartment.
2. Remo?e radio, if equipped.
3.
Remoje screws holding instrument carrier frominstrumejf
pane!.4. Disconpect wres from instrument gauge.
5.
Removal attaching nuts from gauge and remove.I1. Replace gauge with attaching nuts on panel.
2. Hook up wires to gauges.
3. With holding screws, attach gauge cluster to in-
strument panel.
4. Replace radio.
5. Replace glove compartment.
Removal of Temperature Sending Unit
1. Drain and collect coolant.
To drain radiator, remove end of lower radiator hose
that is connected to radiator.
2. Remove wire from temperature sending unit.
3. Unscrew temperature sending unit from thermo-
stat housing. See Figure
11-6.Figure
11-S -Temperature Sending Unitlnstalletian
1. Screw temperature sending unit into thermostat
housing after sealing unit with non-hardening per-matex.
2. Install wire on sending unit.
3. Replace coolant.

lb 70 1973 OPEL SERVlCE!MANUAL
Removing Oil Pressure Sending Upit1. Disconnect wire from sending
Fit.2. Unscrew oil pressure sending
u?it from block. St&Figure
11-7./
Figure
11.7 - Oil Pressure Sending Unit
Installation1. Replace oil pressure sending unit into block.
2. Connect wire to unit.
Figure 1 l-8 Rear View of SpeedometerI
Removal of Speedometer1. Remove instrument housing.
2.Remove speedometer. See Figure 11-9 1.
Installation
1.Install speedometer.
2.Install instrument housing, paragraph 11-71.per
Removal of Tachometer1. Remove instrument housing.
2.Remove tachometer.
3.Disconnect electrical wires. See Figure 11-9.
Figure
11-9 Rear View of Tachometer
Installation1. Connect wires.
2. Install tachometer.
3. Install instrument cluster.
Removal of Temperature Indicator and Fuel GaugeDash Unit
1. Remove instrument housing.
2. Remove temperature indicator and fuel gauge
dash unit.
3. Disconnect electrical wires. See figure
11-10.

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IGAUGESll- 71
Figure 1
IL10 Rear View of Temperature Indicator and
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IFuel Gauge Dash Unit
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Install&m1. Connekt wires and install unit.
2. Install! instrument cluster housing.
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Removal
\of Electric Clock
1.
Remoie instrument housing.
Figuy 1 I-1 1 Rear View of Electrical Clock
I2. Remove electrical clock.
3. Disconnect electrical wires. See Figure
11-I I.
Installation
1. Install clock and connect wires.
2. Install instrument cluster housing.
Removal of Ammeter and Oil Pressure Gauge
1. Remove instrument housing.
2. Remove ammeter and oil pressure gauge.
3. Disconnect electrical wires. See Figure
11-12.Figure 1 I-1 2 Rear View of Ammeter and Oil Pressure
GaugeInstallation
1. Connect wires to ammeter and oil pressure gauge
and install.
2. Install instrument cluster housing.

9A-6 1973 OPEL SERVICE MANUAL
b. Remove retaining screw in headlamp lever handle
and remove handle.c. Console cover is held in place by four push button
type studs, unsnap studs by prying cover up and
work cover upwards over shift lever and rubber shift
lever boot.
5. Remove left cover and right plug in instrument
panel cover and through openitigs remove instru-
ment panel attaching screws (points A and B). See
Figures 9A-7 and 9A-8. At this point it will be neces-
sary to lower the steering column, refer to Group 3
for this procedure.6. Remove two multiple wire plug connectors from
steering column harness.
7. Detach speedo cable
8. Remove
dir&ional signal flasher unit. See Figure9A-9.
Figure
9A-9 Directional Flasher Unit
9. Remove 6 instrument cluster retaining screws. See
Figure 9A-10.
Figure
9A-7 Instrument Panel Cover Screw Cover and
Plug LocationsFigure SA-10 Removing Instrument Cluster detaining
SCWWSFigure
SA-8 Location of Hidden Screws10. Grasp instrument cluster and pull straight back,
being careful of wires, etc. See Figure 9A-11.
11. Unscrew heater controls (A) and support bracket
(B). See Figure 9A-12.
12. Disconnect heater and defroster duct
hoses’frominstrument panel. See Figure 9A-13.

HEATER SYSTEM - GT9A. 7
13. Remove all screws from instrument panel pad-
ding and remove it from instrument panel. Arrow in
Figure
9A-14 show location at left side of dash panel
and windshield. Screws are located in same areas on
right side.
Figure 9A-1 1 Removing Instrument Cluster
Figure
9A-14 Instrument Panel Padding Screws
14. Remove one bolt at top of heater blower case and
two nuts from bottom of the case, and remove heater
blower and case assembly. See Figure
9A-15.
Figure 9A-12 Heater Control Screws and SupportBracket
Figure 9A-13 Heater and Defroster Duct Hoses Figure
9A-15
Location of Heater blower Case Boltand Screws
15. On removed heater assembly check relative posi-
tion of mixed air door so that on installation of unit hand control levers can be positioned according to
unit settings, either opened or closed position.

9A-8 1973 OPEL SERVICE MANUAL
Installation
1. Install heater blower and case assembly, securing
with one (1) bolt at the top and two (2) nuts from the
bottom. See Figure
9A-15.
2. Install instrument panel padding and connect
heater and defroster duct hoses, making sure hoses
are properly positioned and connected. See Figure
9A-16.
Figure 9A-16 Heater and Defroster Duct Hoses
3. Install support bracket (B) and heater control (A).
See Figure
9A-12.
4. Carefully push cluster back into instrument panel
housing, making sure electrical wires, etc., are not
pinched.
5. Install six (6) cluster retaining screws. See Figure
9A-10.
6. Install directional signal flasher. See Figure
9A- 9.
7. Attach speedometer cable.
8. Attach two (2) multiple wire plug connectors in
steering column harness.
9. Install steering column. Refer to Group 90.
10. Install instrument panel cover and attach
through openings (points A and B). See Figures
9A-7
and 9A-8.
11. Install right and left opening covers. 12. Install the console shift
cover
between the seats
using the following instructions:
a. Install console cover over shift lever and rubber
shift lever boot.
b. Install cover by pushing down until cover snaps into the four (4) push button type studs.
c. Install two (2) screws under ash tray opening and
install ash tray. 13.
In engine compartment, install hood lock control
cable to lock bar using retaining clip. See Figure
9A-
6.
14. Attach return hoses (B) and coolant feed hoses
(A) to heater core. See Figure
9A-5.
15. Attach lower radiator hose and add collected
coolant.
16. Check for proper operation and leaks in system.
REMOVAL AND INSTALLATION DEFROSTER
OUTLET
Removal
1. Remove instrument panel cover assembly. Refer
to Group 1.
2. Remove screws securing outlet to cover assembly.
Installation1. Install defroster outlet, securing with screws.
2. Install instrument panel cover assembly. Refer to
Group 1.
Figure 9A-17 Heater Valve

RADIO - GT9c. 107mer screw and rotate screw until maximum volume
is achieved.
MAJOR REPAIR
REMOVING AND INSTALLING RADIORemoval
1.
Disc&ect battery.
2. Remove access trim plug from right side of con-
sole. See Figure
9C-1.Figure
9C-3 Location of Access Trim Cover3. Using a 8mm socket, remove hex head screw. See
Figure
9C-2.4. Remove access trim cover on left side of console.
See Figure
9C-3.5. Using a 4mm socket, remove
hex head screw. See
Figure
9C-4.6. Remove tear lock bolts by first,drilling a 3/16 inch
pilot hole and, using a
l/4 inch bolt extractor,
remove bolts. See Figure
9C-5.Figure
9C-5 Drilling Pilot HoleIn\, Tear Lock Bolts7. Disconnect ignition (white) and direction signal
(black) wire set plugs.
8. Support steering column assembly and remove
both hex head bolts.
9. Disconnect speedometer
cabI&10. Remove 6 instrument cluster retaining screws.
See Figure
9C-6.Figure SC-4 Location of Hex Head Screw and Flasher
UnitFigure SC-6 Removing Instrument Cluster Retaining
screws