seat adjustment OPEL 1900 1973 User Guide

ENGINE MECHANICAL AND MOUNTS6A- 15New inlet valves must not be refaced or lapped with
grinding compound.The correct angle for the intake
and exhaust valve head is 44 degrees.10. Install cylinder head.
11. Adjust valve clearance. See MAINTENANCE
AND ADJUSTMENTS.
7. Inspect valve guides. Worn or pitted guides can be
reamed to accept valves with oversize stems. Over-
size valves are occasionally used in production.
Oversize valves are marked
’ 1 u “2” or “A” and are
stamped into the valve stem end and also stamped
near spark plug hole. See Figure 6A-22.
Replacing Rocker Arm Studs1. When replacing rocker arm studs become
neces-
sary, remove air cleaner, rocker arm cover and
rocker arm.
8. Reseat valve seats in cylinder head in the following
sequence:
Intake
NOTE:The rocker arm studs are screwed into the
cylinder head. A tapered part of the stem serves to
a void stud loosening.With 45 degrees cutter, remove burnt structure until
a metallic bright seat is obtained. Lightly coat valve
head with red lead, insert it into guide and turn it
under light pressure several times back and forth.
Thereby a contact pattern is obtained and the seat
width can be measured. If valve does not seat per-
fectly all around, lightly recut valve seat to the estab-
lished seat width of
,049” - .059” with 30 degrees
correction cutter.
ExhaustThe directions for reconditioning intake valve seats
apply in principle also to exhaust valve seat recondi-
tioning with the exception that the valve seat width
should be
.063-,073 in. and different cutters are em-
ployed.
NOTE:
: OTse new valve seals whenever
valves are reconditioned.9. Lube valves with engine oil and reinstall valves,
valve springs, caps and cap retainers using J-8062.
Install valve spring with closely wound coils toward
cylinder head. See Figure
6A-24.2. Attach vise grip pliers to stud being removed and
remove from cylinder head.
3. Screw in new stud. Seat tapered part of stud by
striking stud end with a rubber hammer.
4. Place two turned down rocker arm nuts on
threaded part of stud.
5. Torque stud into cylinder head to 29
lb.ft.
Valve Lifter ServiceThe valve lifters can be removed after removing
rocker arm cover and rocker arms.No oversize lifters have been released due to the
insignificant wear of the valve lifters and cylinder
head guides.
Amply oil respective parts and install in reverse se-
quence to removal.
Carry out hydraulic valve lifter adjustment as ou-
tlined in MAINTENANCE AND ADJUST-
MENTS.
VALVE
I SPRING
CLOSE
WOUND
COILS
TOWARD
HEAD6A-24
Figure 6A-24 Valve SpringCONNECTING ROD BEARINGSA connecting rod bearing consists of two halves or
shells which are alike and interchangeable in rod and
cap. When the shells are placed in rod and cap the
ends extend slightly beyond the parting surfaces so
that when rod bolts are tightened the shells will be
clamped tightly in place to insure positive seating
and to prevent turning. Theends of shells must never
be tiled flush with parting surface of rod or cap.
If a precision type connecting rod bearing becomes
noisy or is worn so that clearance on crankpin is
excessive, a new bearing of proper size must be se-
lected and installed since no provision is made for
adjustment. Under no circumstances should the con-necting rod or cap be filed to adjust the bearing
clearance.

ENGINE MECHANICAL AND MOUNTS6A- 17
seating and to prevent turning.The ends of she//s
must never be tiled flush with parting surface of
crankcase or bearing cap.Crankshaft bearings are the precision type which do
not require reaming to size. Shims are not provided
for adjustment since worn bearings are readily re-
placed with new bearings of proper size. Bearings for
service replacement are furnished in standard size
and undersizes. Under no circumstances should
crankshaft bearing caps be tiIed to adjust for wear in
old bearing.After removal of oil pan, pipe and screen assembly,
perform the following removal, inspection and in-
stallation operations on each crankshaft bearing in
turn so that the crankshaft will be well supported by
the other bearings.
If crankshaft has been removed to check straightness
the following procedure is suggested. Rest crank-
shaft on “V-blocks” at number one and number live
main bearing journals. Check indicator runout at
No. 3 main bearing journal. Total indicator reading
should not exceed
.C012”.1. Since any service condition which affects the
crankshaft bearings may also affect the connecting
rod bearings, it is advisable to inspect connecting rod
bearings
first. If crankpins are worn to the extent
that crankshaft should be replaced or reground, re-
placement of crankshaft bearings only will not be
satisfactory.
If replacement of cylinder block or crankshaft is re-
quired, always check main bearing clearance with
plastic-type gauge to obtain specified limits.
2. Remove one bearing cap, then clean and inspect
lower bearing shell and the crankshaft journal. If
journal surface is scored or ridged, the crankshaft
must be replaced or reground to insure satisfactory
operation with new bearings. Slight roughness may
be polished out with tine grit polishing cloth
thoroughly wetted with engine oil, and burrs may be
honed off with a tine stone.
3. If condition of lower bearing shell and crankshaft
journal is satisfactory, check the bearing clearance
with a plastic-type gauge.
4. When checking a crankshaft bearing with plastic-
type gauging material, turn crankshaft so that oil
hole is up to avoid dripping of oil on the gauge
material. Place paper shims in lower halves of adja-
cent bearings and tighten cap bolts to take the weight
of crankshaft
off the lower shell of beating being
checked.5. If bearing clearance exceeds
.C03”, it is advisable
to install a new bearing; however, if bearing is in
good condition and is not being checked because ofbearing noise, it is not necessary to replace the bear-
ing.6. Loosen all crankshaft bearing cap bolts
l/2 turn,
and remove cap of bearing to be replaced.
7. Remove upper bearing shell by inserting Bearing
Shell Remover and Installer J-8080 in oil hole in
crankshaft, then slowly turning crankshaft so that
the tool rotates the shell out of place by pushing
against the end without the tang. See Figure
6A-27.When turning crankshaft with rear bearing cap
removed hold oil seal to prevent it from rotating out
of position in crankcase.
8. The crankshaft journal cannot be measured with
an outside micrometer when shaft is in place; how-
ever, when upper bearing shell is removed the jour-
nal may be checked for out-of-round by using a
special crankshaft caliper and inside micrometer.
Figure 6A-27 Removing and Installing Crankshaft
Bearing Upper Shell
The caliper should not be applied to journal in line
with oil hole.
If crankshaft journal is more than
.M)12” out-of-
round, the crankshaft should be replaced since the
full mileage cannot be expected from bearings used
with an excessively out-of-round crankshaft.
9. Before installation of bearing shells make sure that
crankshaft journal and the bearing seats in crankcase
and cap are thoroughly cleaned.
10. Coat inside surface of upper bearing shell with
engine oil and place shell against crankshaft journal
so that tang on shell will engage notch in crankcase
when shell is rotated into place.
11. Rotate bearing shell into place as far as possible
by hand, then insert Installer J-8080 in crankshaft oil
hole and rotate crankshaft to push shell into place.
Bearing shell should move into place with very little

6E- 561973 OPEL SERVICE MANUAL
valve stop screw. Loosen the stop screw until the
valve is completely closed. Turn the screw in l/4turn from closed position, hold, and tighten lock nut.
This is done to insure that the throttle blade will not
stick closed. See Figure
6E-30.PUMPFigure 6E-30 Adjusting Secondary Throttle Valve Gap
24. Install accelerator pump connecting rod in lower
hole of primary throttle shaft lever and cotter pin in
outboard hole at accelerator pump actuating lever
end. Paying attention to proper arrangement of cot-
ter pin and washers. See Figure
6E-2.25. With throttle plate completely closed, there
should be no clearance between the pump levei and
the pump plunger rod.
26. If a clearance is present, loosen 4 accelerator
Figure
6E-31 Accelerator Pump CoverFigure 6C32 Accelerator Pump Cover
pump cover retaining screws and allow the
dia-’phragm spring to push plunger against lever so that
a zero clearance exists. Then retighten the screws.
See Figures
6E-3 1 and 6E-32.27. Insert accelerator pump discharge nozzle so that
the bent tube end points into suction channel of the
primary barrel.
28. Fill the bowl with fuel.
29. With fuel in bowl, slowly open the throttle and
observe the accelerator pump pressure relief valve
exhaust ports and where it seats into the bowl. See
Figure
6E-33. Fuel should not be bleeding back into
the bowl from the exhaust ports or where the relief
valve seats, but a steady stream of fuel should dis-
charge from the discharge nozzle.
30. With fuel in bowl, rapidly open the throttle atid
observe the exhaust ports of the pressure relief valve.
See Figure
6E-33. Fuel should~exhaust’from the ac-
celerator pump pressure relief valve exhaust ports.
3 1. If the pressure relief valve malfunctions, remove
it and replace with a new one.
32. No float adjustment is possible, so check position
of float arm by comparing with a new float of thesame carburetor type. If float arm is bent, replace
float.

CARBURETOR AND THROTTLE LINKAGE6E- 57
ACCELERATOR PUMP
PRESSURE RELIEF
VALVE SEAT
ALVE
VENT DISCHARGE
(AIR BUBBLES FROM THIS
HOLE
IS NORMAL)
PUMP INLET
VALVE EXHAUST
PORT
--6E-33
Figure 6E-33 Carburetor Fuel Bowl
33. Install float and pivot rod making sure rod is
seated in casting.36. Install new air horn gasket so that the holes in
the gasket coincide with the screw holes in carbu-
retor housing. See Figure
6E-35.34. Install leaf spring so that spring ends rest on float
spindle. See Figure
6E-34.37. On vent valve, pay attention to cotter pin position
and arrangement of washers.
3.5. Screw in float needle valve together with copper38. Basic adjustment of idle mixture adjusting screw
seal ring
(.08 in. thick).is 5 turns open.

7A- 21973 OPEL SERVICE MANUALDIAGNOSIS
CLUTCH TROUBLE DIAGNOSIS
ConditionPossible Cause
CorrectionFails to release (pedal
1. Improper cable1. Adjust cable.
pressed to floor
- shiftadjustment.
lever does not move
freely in and out of
“Reverse” gear.
2. Faulty pilot bearing.2. Replace bearing.
3. Faulty driven plate.3. Replace driven plate.
4. Yoke off ball stud.4. Install properly.
5. Clutch driven plate hub5. Repair or replace main drive
binding on main drive gear
gear.spline.
Slipping1. Improper adjustment (no1. Adjust cable.
lash).2. Oil-soaked driven plate.2. Install new driven plate and
correct oil leak at its source.
3. Worn facing or facing3. Replace driven plate.tofn from driven plate.
4. Warped pressure plate or4. Replace same.
flywheel.
5. Weak diaphragm spring.5. Replace cover assembly.
6. Driven plate not seated6. Make 20-50 normal starts.
in.7. Driven plate overheated.7. Allow to cool
- check lash.
Grabbing1. Oil on facing or burned1. Repair oil leak and install
or glazed facings.new driven plate.
2. Worn splines on main2. Replace transmission main drive
drive gear.gear.
3. Loose engine mountings.3. Tighten or replace mountings.
4. Warped pressure plate or4. Replace pressure plate or
flywheel.flywheel.
5. Burned or smeared resin5. Sand off if superficial, replace
on flywheel or pressureburned or heat checked parts.
plate.

MANUAL TRANSMISSION76.19
DIAGNOSIS
MANUAL TRANSMISSION DIAGNOSIS
ConditionPossible CauseNoisy in Forward Speeds1) Low lubricant level.
2) Incorrect lubricant.
3) Transmission misaligned or loose.
4) Front main bearing worn or damaged.
5) Mainshaft bearing worn or damaged.
6) Countergear or bearings worn or damaged,
7) Main drive gear worn or damaged.
8) Synchronizers worn or damaged.
Noisy in “Reverse”1) Reverse sliding gear or shaft, worn or damaged
Hard Shifting1) Clutch improperly adjusted.
2) Shift shafts, or forks worn.
3) Incorrect lubricant.
4) Synchronizers worn or broken.
Jumping Out of Gear1) Partial engagement of gear.
2) Transmission misaligned or loose.
3) Worn pilot bearing.
4) End play in main drive gear (bearing retainer
loose or broken, loose or worn bearings on
main drive gear and mainshaft).
5) Worn clutch teeth on main drive gear and/or
worn clutch teeth on synchronizer sleeve.
6) Worn or broken blocking rings.
7) Bent mainshaft.
Sticking in Gear1) Clutch not releasing fully.
2) Low lubricant level.
3) Incorrect lubrication.
4) Defective (tight) main drive gear pilot
bearing.
5) Frozen blocking ring on main drive gear cone.
6) Burred or battered teeth on synchronizer
sleeve and/or main drive gear.
MAINTENANCE AND ADJUSTMENTS
ADJUSTING REVERSE GEARSHIFT BLOCKER1. Engage second speed.
2. Adjust selector ring (a) so that ball on lower end
of shift finger has an equal clearance on both sides
when seated into the transmission case extension bolt
hole. See Figure
7B-7.3. Back off selector ring an additional
l/4 of a turn
and tighten lock nut (B). See Figure
7B-7.SERVICING GEARSHIFT LEVER
Removal1. Unscrew console from floor panel, on small con-
sole remove three (3) attaching screws, on large con-
sole remove four (4) attaching screws. The fourth
screw is accessible after removal of the ash tray. See
Figure
7B-8.2. Remove rubber bellows from cover plate and from
below unbutton protective cap arranged around in-
termediate shift lever.

AUTOMATIC TRANSMISSION 7C-1314. Bolt extension housing to rear of case. Torque to
20-30 Ibs. ft. See Figure
7C-221.
Figure 7C-22
1
Installation of Speedometer Driven Gear1. Install speedometer driven gear and housing into
extension housing. See Figure
7C-222.Figure 7C-222
2. Install speedometer driven gear housing retainer
into slot provided in speedometer driven gear hous-
ing. Bolt retainer to extension housing. Torque to
6-Slbs. ft. See Figure
7C-223.
installation of Detent Valve, Modulator Valve,
Modulator Assembly1. inspect detent valve sleeve oil seal and replace if
necessary.Figure 7C-223
2. Install detent valve, sleeve, spring, and spring seat
into case bore using liberal amount of transmission
fluid.
3. Depress detent valve spring and insert spring pin
to secure detent valve assembly. Detent valve sleeve
must be installed with slots facing oil pan. Care
should be taken so that spring pin is inserted into the
groove provided in sleeve and not into one of the oil
passage slots in the sleeve.
4. Install modulator valve and sleeve into case with
small end of modulator valve first.
5. Using new modulator assembly gasket, install
plunger and thread modulator into case and tighten
to
12-15 Ibs. ft. using tool J-23100. See Figure 7C-
224.
Installation and Adjustment of ServoAdjustment of servo can be performed with trans-
mission in vehicle.
1. Install servo apply rod, spring and piston into case,
using liberal amount of transmission fluid.
2. Compress servo piston spring using compressor
tool J-23075, lightly tapping servo piston while com-
pressing until piston is seated to avoid damage to the
oil seal ring.
3. Install servo retaining ring. See Figure
7C-225.Remove compressor tool J-23075.

REFRIGERANT COMPONENTS ALL MODELS96.61
CAPILLARY T”BEFigure 98.95 Evaporator and Expansion Valve
Assembly GT
valve from refrigerant lines, and tape closed open
ends of lines and inlet and outlet ports of expansion
valve.
Installation5. Install resistor assembly.
6. Install evaporator assembly into car and install
mounting bracket. See Figure
9B-96.Figure 98.96 Evaporator and Blower Assembly
- GT
If expansion valve or refrigerant lines have been ex-
posed to
,the atmosphere for any amount of time and
moisture may have entered the valve or the system,
flush the system and install new receiver-dehydrator
or valve as necessary.7. Untape the refrigerant lines and the inlet and
outlet pipes from the evaporator and install using
new o-rings on line fittings.
Due to the possible adjustment difficulties involved
if the expansion valve is disassembled, disaisembly of
the valve is not recommended. The valve may be
cleaned by submerging it in a bath of trichlorethy-
lene, alcohol, or similar solvent. Dry by blowing iil-tered compressed air through the outlet port of the
valve. The filter screen at the inlet port may be re-
placed. Remove screen by threading a lo-32 NF
screw intp 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.
3. Install blower motor assembly into case and se-
cure with attaching screws.
4. Install finger guard shields and fan housing case.Figure 98-97 Refrigerant Hoses and Hose Clamps
Under Car
- GT

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

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