service OPEL 1900 1973 Owner's Manual

lB- 14 1973 OPEL SERVICE MANUAL !
6. Remove shift lever shaft and: lift armature aid
shift lever assembly.
7. Drive back retaining ring on armature shaft. See
Figure
lB-5.
8. Take the lock ring, retaining ring, and
over&-
ning clutch and pinion off armature shaft. Cheqk
groove in shaft for burrs and remove with a soft tile.
Cleaning and Inspecting Parts
1. Clean and check all parts. Replace defective parts.
2. Turn down worn or burnt
cominutator on a good
precision lathe. Use a spindle
speed between 2,000
and 3,000 RPM. See Figure
lB-6. When turning
down commutator, adjust cutting depth of tool
so
that no more pits exist after this:operation. Do not
remove any more material than necessary, however,
because if commutator diameter
is less than 1 15/32
inches, armature must be replaced.
30166
Figure 1B-6 Turning Down Commutator
3. Undercut mica approximately ,020 below com-
mutator surface. Finish and thoroughly clean
corn-
mutator.
I
4. Check armature for short circuit on a
growler.
5. With a test lamp, check armature for ground.
Test
lamp must not light up. See Figure
IB-7.
Figure 1B-7 Testing Armature for Grounds
j
6. Check armature for an open circuit on a growler.
Considerable variation in readings between in-
dividual commutator bars would indicate an open
circuit.
7. Visually check
field coils. Replace burnt or
scorched
field coils.
8. With a test lamp, check
field coils for ground. See
Figure
IB-8. Test lamp must not light up. Replzice
grounded field coil.
Figure lB-8 Checking Field Coils for Ground
Replacing Field Coils
1. Mark locations of pole shoes to avoid incorrect
installation.
Figure 1B-9 Removing Pole Shoes

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.

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

lC- 22 1973 OPEL SERVICE MANUAL j
3. Start engine and disconnect a wire from a spark
plug. Read output voltage of disconnected spark
plug circuit. Reading should exceed 20 KV
(20,poO
volts).I
CHECK DISTRIBUTOR
!1. Clean distributor cap and inspect it for cracks or
tracking. Inspect inner segments for erosion and
outer sockets for corrosion.
2. Clean and inspect ignition wires. Make sure resist-
ance of each wire is less than 10,000 ohms. Replace
any defective spark plug boots or distributor
capnipples. See paragraph lC-12.
3. Inspect breaker points and replace if necessary.
Adjust breaker point gap to
,016 inch with rubbing
block on peak of cam lobe or check dwell and adjust
if not 50 degrees plus or minus 3 degrees. 4. Check
dwell variation by reading dwell at idle and at 3000
RPM. Dwell must not vary more than 3 degrees.
Excessive variation means distributor shaft, cam or
breaker plate are worn or damaged--overhaul dis-
tributor and replace defective parts.
5. Check distributor condenser for a minimum series
resistance and insulation leakage. Check for a
capacity between
.15 and .20 microfarads.
6. Check total advance (centrifugal and vacuum) at
2500 engine RPM using a timing light having a dial
for reading advance.
(a) The timing marks are aligned with both the
vacuum advance and the vacuum retard hoses dis-
connected and plugged.
Engine idle should be 900 RPM.
(b) Reconnect vacuum hoses. Run engine at
3600RPM and adjust knob until timing marks are
aligned. Read advance on dial. Maximum centrifugal
advance should be between 28-32 degrees.
7. If total advance is out of specifications, check
centrifugal advance only, at
2500 RPM. Discon+ectand plug all vacuum hoses. Maximum vacuum ad-
vance should be l-5 degrees at 4.5-5.0 in. hg.
8. Replace centrifugal or vacuum advance parts as
required to bring distributor total advance within
specifications.
9. Check operation of vacuum retard unit (rear unit)
by first making sure timing marks are aligned with
vacuum hoses disconnected and at slow idle (700
RPM). Then connect vacuum hose to vacuum retard
unit (rear unit). Timing ball should move in a retard
direction (upward).
CHEICK SPARK PLUGS1. Remove spark plugs. If electrodes are badly worn,
discard plugs. If inner or outer porcelain is cracked
or broken, discard plugs.
2. Note color and general appearance of inner end of
spark plug. Brown to grayish
- tan deposits and slight
electrode wear indicate correct spark plug heat
range. Plugs having this appearance may be cleaned,
regapped, tested and reinstalled.
3. Clean spark plugs in a sand blast type cleaner.
Clean only enough to remove deposits, not enough to
wear away porcelain. If deposits are too hard to
remove or if porcelain is glazed, discard plugs.
4. After cleaning spark plugs, clean tiring surfaces of
electrodes with a line file.
5. Test cleaned spark plugs on a pressure tester by
comparing spark of the used plugs with that of a new
plug. Install tested plugs, using new gaskets.
6. If removed spark plugs have excessive carbon foul-
ing and if the car will be driven mostly at low speeds
in city driving, it is advisable to replace plugs with
a hotter plug, AC43FS.
7. If removed plugs show rapid electrode wear or
inner porcelain breakage at low mileage. Check for
a vacuum leak such as a poor manifold to head fit.
8.
Clap spark plugs carefully (new or cleaned) using
a
,030 round wire feeler gage.IC6
Figure lC-6 Distributor Installation

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

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1 D- 301973 OPEL SERVICE MANUAL
6. Make sure all electrical accessories are turned (lff.
Start engine with battery post adapter switch closed;
open switch as soon as engine
iS: started.
7. Adjust engine speed to 2500 RPM.
8. Turn tester control knob to “LOAD” position
aid
adjust knob to obtain highest possible ammeter r&d-
ing. Output must be 30 amperes minimum. If
outcut
is okay, proceed to voltage regulator test below. j
/.9. If output is low, defect may be in alternator or m
regulator. To eliminate regulator, supply field &-
rent direct to cause full alternat,or output. Unplug
three-way connector from regulator and plug in a
jumper between the red and black leads. See Figure
lD-5. Retest as described in Steps 7 and 8. If output
is still low, generator is faulty and must be
remov&d.
301D5 :
Figure lD-5 Alternator Ouiput Check I
10. If output (using field jumper) is now okay, defect
is in the regulator or wiring harness. Check all wiring
connections. If all wiring is okay, try
replac/~g
regulator; if output now tests okay (without
uslpg
field jumper), you have found the trouble. Always
follow-up with a voltage regulator test.
Test and Adjust Voltage Regulator Setting
1. Always test alternator output first, as describedlin
subparagraph a above. Leave all test
instrumeqts
connected, but make sure field
jumper is removed; if
used.
2. With engine speed at 2500 RPM, turn tester con-
trol
knob to “l/4 OHM” position. Make sure ill
electrical accessories are turned off. After volt&e
reading stabilizes, any reading between 13.5 and 14.5
volts is okay.
3. If voltage reading is out of limits, remove regulator cover and adjust voltage regulator armature spring
tension to obtain a middle reading of 14.0 volts. If
reading fluctuates, voltage contacts are dirty.
4. Replace regulator cover and recheck voltage set- ting. A steady voltage reading between 13.5 and 14.5
volts means voltage regulator is okay.
5. Adjust engine speed to specified idle. Reseal volt-
age regulator cover carefully, using electrical tape.
MAJOR REPAIR
ALTERNATOR OVERHAUL
Always disconnect battery ground cable before mak-
ing any electrical repairs.
Alternator Removal
1. Disconnect battery ground strap.
2. Unplug wiring connector from alternator. 3. Disconnect battery lead from alternator.
4. Remove adjusting brace bolt, lockwasher, plain
washer and nut.
5. Loosen pivot bolt. Push alternator inward and
remove belt from pulley.
6. Drop alternator down and remove pivot bolt, nut,
lockwasher and plain washer.
7. Remove alternator.
Figure 1D-6 Removing Alternator Pulley

1 D- 32 1973 OPEL SERVICE MANUAL
12. Unsolder brushes, if they are worn to a length of
3/8 inch or less. Solder new brushes in place. To do
this, hold connecting wire in flat-nosed pliers to
pre:
vent
solder from flowing between wire strands, oth-
erwise the wire strands will become rigid and the
brushes unserviceable. See Figure
lD-15.
Figure 1D-12 Disconnecting Brush Connector
Figure 1 D-l 5 Soldering New Brushes
Note brush wire installation of correct assembly. See
Figwe lD- 16.
Figure 60.13 Removing Biush Holder
9. Unsolder diode connections and stator winding
ends. Clamp pliers on wire to transfer heat away
from diodes. Unsolder quickly using a very hot sol-
dering iron, as the diodes are very sensitive to heat.
See Figure
lD-14.
Figure 1 D-l 6 Brush Wire Installation
Figure 1 D-l 4 Unsoldering Connections
10. Remove stator assembly from housing.
Il. Remove two screws and negative diode support. 13. Test rotor windings and slip rings for a ground,
using a test light or an ohmmeter. Test light should
not light; ohmmeter should read near infinite resist-
ance end of scale. See Figure
lD-17.
14. Test rotor windings for a short by connecting an
ohmmeter between the two slip rings. Ohmmeter
should read between 4.0 and 4.4 ohms. See Figure
lD- 18.
15.
Test stator windings for a ground, using a test
light or an ohmmeter. Test light should not light;
ohmmeter should read near infinite resistance end of
scale. See Figure
lD-19.

1 D- 34 1973 OPEL SERVICE MANUAL!
I
one direction, but should not light at all in the otlier
direction. Diodes in each set of three should p&s
current and block current in the ‘same directions
Asthe others in the set. See Figure lD-21.
Removing Diodes/
Positive Diodes1. Press defective diode out of diode support, back-
ing-up support with a sleeve sliglitly larger than the
diode and pushing diode through with a shaft
slightly smaller than diode. See Figure lD-22.;
Figure 1 D-22 Removing Diode
Negative Diodes1. Clip lead from defective diode. Clip lead close
enough to diode so that tool will .function properly.
Figure 1 D-d3 Removing Diode2. Using Tool J-23526, press diode from support. See
Figure lD-23.
Installing Diodes
Positive Diodes1. Press new diode into diode support. See FigurelD-24.
Figure lD-24 Installing Diode
Negative Diodes1. Using Tool J-23526, press diode into support. See
Figure lD-25. Insert negative diode pigtail lead
through tool pilot.
Alternator Reassembly1. Clean and inspect all parts. Check brushes. Re-
place them if they have worn down to
3/8 inch.
2. Lubricate both bearings with special ball bearing
lubricant.
3. Press rear bearing on rotor shaft and install front
bearing into drive end frame.
4. Assemble stator together with windings into rear
end frame.
5. Install both diode supports.
6. Solder diode connections and ends of stator wind-
ings together. Since diodes are very sensitive to heat,
solder quickly using a very hot soldering iron.

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1 D- 361973 OPEL SERVICE MANUALI‘\
Figure 1 D-27 Alternator - Exploded View301D27