service OPEL 1900 1973 Service Manual

REFRIGERANT COMPONENTS ALL MODELS9B- 87
SUCTION,011 INLET T”BE
REAR CYLINDER
’ REAR NEEDtE”q.PRESSURE RELIEF VALVE
THRUST BEARlNG
/IT DISCHARGE VALVE PLATE
fFRONT HEAD
,-SEAL SEAT O-RING
I,-SHAFT SEAL
~&SHELL TOHEAD O-RING
I,IPORTFRONT
CYLINDE<\., -I\,VALVE PLATE[SERVICE ONLYI(SERVICE ONLY1.TION VALVE REED DISC
Figure 96-l 64 Compressor Exploded View

98-88 1973 OPEL SERVICE MANUAL
Figure gB-165 Special Tools

System controls are the AIR knob controlling the
three speed blower motor switch and the TEMP
knob which controls the setting of the thermostatic
switch. When operating this system, the heater must
be off for maximum cooling.DIAGNOSIS
TROUBLE DIAGNOSIS GUIDE
Air Knob
Insufficient CoolingTurning the AIR knob clockwise operates the three-
speed blower motor.CHECK AIR FLOW9B-90 1973 OPEL SERVICE MANUAL
AIR CONDITIONER SYSTEM
OPEL 1900
- MANTA
CONTENTS
Subject
DESCRIPTION AND OPERATION:
General Description of System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...”Operation of Controls
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .DIAGNOSIS:
DiagnosisGuide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..“................... . . . . . . . . .MAINTENANCE AND ADJUSTMENT:
Adjustment of Thermostatic Switch
. . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Removal81InstallationBlowerSwitch. . . . . . . . . . . . . . . . . . . . . .Page No.
9B-90
9B-90
9B-90
9B-91
98-92Removal
& Installation Temperature Control Switch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal
& Installation Resistor Assembly. . . . . . . . . . . . . .Removal
& Installation Blower Motor Assembly . .
SPECIFICATIONS:
Specifications
.,...,,.,,..~.,.,..,,......,.,....,.,........,......,........ ,, . . . . . . .
98-92
98-92
98-92
98-96
DESCRIPTION AND OPERATION
GENERAL DESCRIPTION OF SYSTEMThe air conditioner is intended to give maximum
cooling comfort within the vehicle. To do this, care-
ful attention must be given to the following Sections.
The system operates on recirculated air only and is
entirely independent of the vehicle heater.
Temp KnobThis knob may be regulated to control the degree of
cooling desired. Fully clockwise provides maximum
cooling; however, turning the knob to the center de-
tent position provides adequate cooling for highway
operation.
When maximum cooling is required, outside air
should not be admitted to the car.
Recirculated inside air is drawn into the unit, passed
through the evaporator core and into the car through
the adjustable outlets in the evaporator case.
Operation of ControlsWhen the unit is set for maximum cooling and the
vehicle is being driven continuously at highway
speeds or at elevations of
4,OOC!ft. or more, there is
a possibility of the formation of ice on the evaporator
core fins.

98-92 1973 OPEL SERVICE MANUAL
MAJOR REPAIR
REMOVAL AND INSTALLATION OF BLOWER
SWITCH
Removal
I. Remove the face plate retaining screws and
remove the face plate assembly. See Figure 9B-172.
Figure SE-172 Face Plate Retaining Screws andcontrots
2. Remove the blower switch retaining screws and
remove switch.
Installation
1. Install the blower switch and retainer screws.
2. Install the face plate and secure with the retainer
screws. See Figure
9B-372.
REMOVAL AND INSTALLATION OF
TEMPERATURE CONTROL SWITCH
Removal
1. Remove the face plate retaining screws and
remove the face plate assembly noting the position of
the air sensing capillary so that it can be reinstalled
in the same location as when removed. See Figure
9B- 173.
2. Remove the temperature control switch retaining
screws and remove switch.
AIR SENSING CAPILLARY,yT,,ERMOSTATIC SWITCH
!IBUMPERBLOWER SWITCH98-136
Figure SB-173 Location of Air Sensing Capillary
Installation
1. Install the temperature control switch and secure
with the retaining screws.
2. Position the air sensing capillary in the exact
location as was noted when removing.
3. Install the face plate and secure with the retain-
ing screws. See Figure
9B-172.
REMOVAL AND INSTALLATION OF RESISTOR
ASSEMBLY
Removal
1. Disconnect the negative battery cable.
2. Remove the glove box assembly. 3. Disconnect the electrical plug from the resistor
assembly. See Figure
9B-176.
4. Remove two (2) screws and remove resistor as-
sembly.
Installation
1. Install the resistor assembly and secure with two
(2) screws.
2. Install the electrical plug onto the resistor assem-
bly. See Figure
9B-176.
3. Install the glove box assembly.
4. Connect the negative battery cable.
REMOVAL AND INSTALLATION OF BLOWER
MOTOR ASSEMBLY
REMOVAL
1. Remove the negative battery cable from the bat-
tery.

98.94 1973 OPEL SERVICE MANUAL
7. Remove 2 upper evaporator attaching nuts. See
Figures 9B-178 and 9B-181.
Figure 98-181 Location of Upper Evaporator
Attaching Bolt (Right Side)
8. Remove 2 attaching case mpunting bracket to
instrument panel screws. See Figure 9B-182.
Figure SB-182 Evaporator and Blower AssemblyBrackets and Attachments9. From underneath evaporator case, disconnect
two (2) drain hoses.lo. Carefully
PXIIOVS assembly from car. See Figure
9B-184.
11. Disconnect resistor electrical connector and
remove resistor assembly. See Figure
9B-184.12. Remove the blower case and blower motor at-
taching screws and remove assembly. See Figure 9B-
184.Installation
1. Install the blower motor assembly into caseFigure 98-183 Drain Hose
BLOWER MOTOR
Figcre 98.184 Assembly Removed
bracket with the electrical connector side of the mo-
tor to the right side ofthe bracket. Attach the mount-
ing strap.
2. Assemble the case halves and attach the cover
plate.
3. Install the resistor assembly and electrical con-
nector. Install blower motor connector. See Figure
9B-184.4. Install assembly into car carefully guiding
evaporator pipes up through cowl opening. See Fig-
ure 9B-185.
5. Install 2 upper evaporator attaching nuts. See
Figures 9B-178 and 9B-181.
6. Install 2 attaching case mounting bracket to in-
strument panel screws. See Figure 9B-182.

98.96 1973 OPEL SERVICE MANUALr DARK BLUE
LIGHT BLUE STRIPE
CUTOUT111111DARK GREEN DARK GREEN
,,
I
,\,\
BATTERYl LJ
\flu- +tL-2+- -7- -RESISTOR
A
EXlSilNG‘IWIRE
I
I
IFUSE BLOCK*,*,- I./SWITCH
r
ti‘WIREfIfI
1- IAAI
i$+.-lAC~,‘XESW WIRE
I I
TTEVAPO.RATOREVAPO.RATOR
BLACK WITH RED STRIPE BLACK WITH RED
Sl96-143
Figure 9B-188 Wiring Schematic‘RIPE96-143
Figure 9B-188 Wiring Schematic
SPECIFICATIONS
Blower Motor Type
......................................................................................................12 VDC
Blower Fan Type
..................................................................................................Squirrel Cage

98.98 1973 OPEL SERVICE MANUALDIAGNOSISTROUBLE DIAGNOSIS GUIDE
Insufficient Cooling
CHECK AIR FLOW
FAN DOES NOT RUN
- Correct electrical fault.
FAN RUNS
- Check air velocity.
NOT OK
- Clean evaporator inlets.
Clean evaporator core.
Clean evaporator outlets.
OK
- Check refrigeration (refer to Refrigeration
Diagnosis Guide).
MAINTENANCE AND ADJUSTMENTS
ADJUSTMENT OF THERMOSTATIC SWITCHThe system makes use of a thermostatic switch with
a self-supporting air sensing capillary. This capillary
controls the switch by sensing the temperature of the
air leaving the evaporator tins.
Checking for Proper Operation
1. Install the gauge set, and set up the vehicle as
described under FUNCTIONAL TESTING SYS-
TEM in Refrigerant Components Section.
2. Movement of the temperature control knob
should result in a definite change in suction pressure
and cycling of the compressor clutch.
3. If compressor continues to operate regardless of
the knob adjustment it indicates that the switch
points are fused, which will lead to evaporator
freeze-up. The switch should be replaced.
Adjusting Switch
If after the foregoing checks, the switch seems to be
operating correctly, adjust for proper setting if neces-
sary, as follows:
1. Set up car as described in FUNCTIONAL
TESTING SYSTEM in Refrigerant Components
Section.
2. The suction side of the system, read on the lowpressure gauge, should pull down to the pressure
shown in the chart in SPECIFICATIONS in Refrig-
erant Components Section.
3. Remove the duct assembly mtaining screws and
remove the duct assembly noting the position of the
air sensing capillary so that it can be reinstalled in
the same location as when removed. See Figure 9B-
190.Figure 98.190 Duct Assembly and Retaining Screws
Figure 9B-13 1 Duct Assembly
4. Remove the thermostatic switch retaining screws
and remove switch. Remove the non-metal end plate
from the switch to gain access to the switch adjusting
screw. Check the screw for stripped or otherwise
damaged threads.

gB-100 1973 OPEL SERVICE MANUAL
2. Remove the retaining screws from the duct as-
sembly. See Figure 9B-190.3. Lift up duct assembly and note the position of the
air sensing capillary so that it can be reinstalled in
the same location as when removed.
4. Remove the temperature control switch retaining
screws and remove switch.
Installation
1. Install the temperature control switch and secure
with the retainer screws.
2. Position the air sensing capillary in the exact
location as was noted when removing.
3. Install the duct assembly retaining screws.
4. Install the negative battery cable.
REMOVAL AND INSTALLATION OF RESISTOR
ASSEMBLY
Removal1. Remove the negative battery cable from the bat-
tery.2. Remove the luggage tray attaching screws and
lift out tray. See Figure 9B-194.
Figure 98-194 Luggage Tray3. Remove all evaporator cover attaching screws
and remove cover. See Figure
9B’-195.Figure 98.195 Evaporator Cover Assembly and
Attaching Screws
4. Remove the electrical plug connector from the
resistor assembly.
5. Remove 2 resistor attaching screws and remove
resistor assembly. See Figure 9B-197.
/98-147Figure 9B-196 Resistor and Blower Motor
Connections

98-102 1973 OPEL SERVICE MANUAL
2. Discharge system. Refer to DISCHARGING
SYSTEM in Refrigerant Components Section.
3. While system is discharging remove the luggage
tray attaching screws and lift out tray. See Figure9B-200.
4. Remove all evaporator cover screws and remove
cover. See Figure
9B-201.Figure
98.202 Evaporator Cover and Luggage Tray5. Remove the electrical plug connector from the
resistor assembly, and unplug blower motor connec-
tion and remove ground wire. See Figure
9B-203.6. From underneath evaporator housing, discon-
nect 2 drain hoses. See Figure 9B-204.
EVAPORATORFigure
98.204 Drain Hose
7. From under car remove 4 nuts securing evapora-
tor mounting bracket to floor. See Figure 9B- 205
and 9B-206.
Figure
98.203 Electrical Connections and Ground
WireFigure 98-205 Evaporator Mounting Bracket Bolts -Driver Side

98-104 1973 OPEL SERVICE MANUAL
the el&trical connector side of the motor to the right
side of the bracket.
2. Assemble the fan housing case halves and attach
the cover plate.
3. Install the resistor assembly.
4. Install the evaporator assembly into the car and
install mounting bracket. See Figure
9B-209.5. Untape the refrigerant lines and the inlet and
outlet pipes from the evaporator and install using
new o-rings on line fittings.
6. From under the car, install 4 nuts securing
evaporator mounting bracket to floor. See Figures9B- 205 and
9B-206.7. Evacuate system. Refer to EVACUATING SYS-
TEM in REFRIGERANT COMPONENTS Sec-
tion.
SPECIFICATIONS8. While system is being evacuated:
9. Connect 2 drain hoses underneath the evaporator
housing.
10. Plug in the resistor assembly electrical connector
plug and connect the blower motor connection and
install ground wire and 2 mounting bracket to case
screws using the rearward holes.
S’ee Figure 9B-209.11. Install the evaporator cover and all cover screws.
See Figure 9B-202.
12. Install luggage tray and attaching screws. See
Figure
9B-202.13. Connect the negative battery cable.
14. Charge system. Refer to CHARGING SYSTEM
in Refrigerant Components Section.