service OPEL 1900 1973 Repair Manual

2D-141973 OPEL SERVICE MANUAL
Figure 20.4 Position of Tool on Slide Lock Spring
2. Remove door inside handle escutcheon.
3. Remove lock knob.
4. Remove arm rest. See Figure 2D-5.
Figure 20-2 Door Striker
Figure 20-5 Removing Arm RestFigure 20.3
lnsarting Tool Between Handle and NylonDisc5. Remove door trim pad.
6. Prior to installation of trim pad, make sure that

2D-161973 OPEL SERVICE MANUAL
2. Remove door lock knob.
3. Remove door inside handle.
4. Adjust sash window so that the main lever with
toothed segment are in alignment with the front re-
taining plate. See Figure 2D-9.Figure 2D-9 Aligning Main Lever With Front Retaining
Plate5. On Models 57, 57L and 57R, scribe position of
screw at the plastic support of window rail and un-SCRW.
6. Block sash window in door interior.
7. Scribe position of window lifter guide rail
screws.See Figure 2D- 10.
Figure 2D-10 Guide Rail Screws
8. Unscrew window lifter and let it down slowly.
9. Slide window upwards and block it.10. Remove window lifter through opening in inner
door panel upper part. See Figure 2D-11.
Figure
2D-1 1 Removing Window Lifter
Installation
1. Install window lifter through opening in inner
door panel tipper part. See Figure 2D-
11.2. Block window upwards.
3. Secure window lifter.
4. On Models 57 and 57R, secure plastic support of
window rail.
5. Install inside door handle.
6. Install door lock knob.
7. Install door trim pad.
REMOVAL AND INSTALLATION OF FRONT DOOR
LOCKRemoval
1. Remove door trim pad.
2. Remove door lock knob.
3. Remove door inside handle.
4. On lock side, scribe position of guide rail bolt,
unscrew bolt, push guide rail downwards, and
remove it through access hole. See Figure 2D-12.
5. Remove door lock and install new one. See Figure
2D-13.

2D-18
1973 OPEL SERVICE MANUAL
2. With window closed, unscrew hex nut and remove
door outside handle. See Figure 2D-15.3. Clamp door outside handle in a vise provided with
protective jaws.
4. With ‘a screwdriver, lift cylinder lock ring out of
handle. See Figure 2D-16.
Figure 2D-16 Removing Cylinder Lock Ring Out of
Handle5. Pull lock cylinder out of door outside handle.InstalMion
1. Clamp outside door handle in a vise and protect
handle with pi&es of wood.
2. Install lock cylinder into outside door handle.
3. Install lock ring into handle. See Figure
2D-16.4. With window closed, install outside handle and
hex nut. See Figure 2D-15.
5. Install door trim pad.
REMOVAL AND INSTALLATION OF FRONT DOOR
WEATHERSTRIP1. From below, grind the peen off door check link pin
and drive out pin. See Figure
2D-18.2. Remove weatherstrip from front door.Figure 2D-17 Outside Handle
- Exploded View
Figure 20-16 Grinding
Peen Off Of Link Pin
3. Button in new weatherstrip in the door area and
push it in the metal profile in the area of the window
frame. See Figure
2D-19.4. Install door check link and rivet pin.
REMOVAL AND INSTALLATION OF FRONT DOOR
1. Remove door trim pad.
2. Remove lock knob.

2D-201973 OPEL SERVICE MANUAL
2. Remove door sash window.
Figure 2D-23 Guide Rail Screws
3. Pull guide rail towards the top out of door.
4. Position sash window so that cable retainer can be
unscrewed through access hole. Pull out sash win-
dow towards the top.
5. Push sash channel off window glass. See Figure2D- 24.Figure 2D-25 Cable and Pully Location
3. Loosen sheave adjustable bracket. Unscrew win-
dow regulator from inner door panel and remove
regulator and cable through access hole. See Figure
2D-26.Figure 2D-24 Sash Channel
6. Place new window glass and new filler into sash
channel.
REMOVAL AND INSTALLATION OF REAR
DOOR WINDOW REGULATOR
1. Remove door trim pad.Figure
213-26 Regulator Attaching Screws
Installation
- Left Door
In counterclockwise direction, wind cable onto pul-
ley up to the shoulder and clamp it behind lug. See
Figure 2D-27.

ZE-221973 OPEL SERVICE MANUAL’REAR COMPARTMENT LID
CONTENTS
Subject
DESCRIPTION AND OPERATION: (Not Applicable)
DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS: (Not
Applicable)
MAJOR REPAIR:
Removal and Installation
Weatherstrip
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lock Cylinder
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LuggageCompartmentLid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS: (Not Applicable)Page No.
2E-22
2E-22
2E-23
MAJOR REPAIRREMOVAL AND INSTALLATION OF LUGGAGE
COMPARTMENT LID WEATHERSTRIP
1. Detach old weatherstrip and clean sealing surface.2. Coat new weatherstrip and contacting surface
with rubber cement, and allow cement to dry for a
few minutes.3. Install new weatherstrip with rubber cement. See
Figure
2E-2.REMOVAL AND INSTALLATION OF LUGGAGE
COMPARTMENT LID LOCK CYLINDER
Removal
1. Remove luggage compartment lid lock. See Figure
2E-3.Figure
ZE-2 installing Luggage Compartment Lid2. With luggage compartment lid in almost horizon-Weatherstriptal position, unscrew lock cylinder nut, using a 13/16Figure
2E-3 Lid Lock Attaching Screws

2F-241973 OPEL SERVICE MANUAL
ROOF AND SUN ROOF
CONTENTS
,.,Subject
DESC,RIF?TION AND OPERATION: (Not Applicable)
DIAGNOSIS: Sun Roof Diagnosis
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND ADJUSTMENTS:Sun Roof Height Adjustment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . .
MAJOR REPAIR:
Removal and Installation
Sun Roof Panel andFrame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . .
Velvet Strip and Weather Strip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RearGuides andCables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . .
Drive Pinion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water DrainHoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . . . . .
Luggage Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS: (Not Applicable) Page No.
2F-24
2F-26
iF-27
2F-29
2F-29
2F-30
2F-31
2F-3i
DIAGNOSIS
SUN ROOF DIAGNOSIS
_ -
CONhTlONPAUSEI~C~RRECTI~X~
Sun roof does not operate
Transporter cable lengths
parallel. equal.Close sun roof, slide sun roof
frame to rear, remove.crank
handle
and cable crank. Check
that sun roof bears against sun
roof opening velvet strip and
that lifter’ portion of rear lifter
guides is positioned approximately
90 degrees to guide rails.
Turn
cable crank fully clockwise and
reinstall into cable box.
Transporter cables damaged
or worn. Replace cables. Both cables
must be replaced if either one
is damaged or worn.

2F-261973 OPEL SERVICE MANUALMAINTENANCE AND ADJUSTMENTSADJUSTING HEIGHT OF SUN ROOF PANEL
Adjust height of sun roof as follows:
1. Opel sun roof to half open position and pry apart
sun roof frame from sun roof panel (see Figure
2F-1).Figure
ZF-1 Separating Sun Roof Frame From SunRoof Panel2. Push detached sun roof frame rearward until it
contacts car roof stop.
NOTE: If difficulty is encountered when pushing
sun roof frame to rear due to the frame hooking into
the sun roof panel, close sun roof until lifters come
into operation. The sun roof frame should now easily
slide rearward.
ADJUSTMENT FRONT OF SUN ROOF
To adjust height of front of sun roof proceed as
follows:
1. Close sun roof.
2. Loosen screws securing front guides to front of sun
roof panel (see Figure
2F-2). Rotate height adjust-
ment ring until desired height is attained.
3. Readjust guides outward so that guides just touch
sides of rails and are not wedged or cocked against
rail sides and tighten screws. Recheck height adjust-
ment.
NOTE: The guides should lightly contact the guideFigure
ZF-2 Sun Roof Front Guide
rail and should have a clearance of no more than 0.02
inch.
ADJUSTMENT. REAR OF SUN ROOF
To adjust height of rear of sun roof proceed as fol-
lows:1. Completely close sun roof and check that the rear
sun roof lifter guides from approximately a 90 degree
angle with respect to the guide rail and that the lifter
contacts the guide stop (see Figure
2F-3). If this is
Figure
2F-3 Rear Sun Roof Lifter 90 Degrees toGuide Rail

2F-281973 OPEL SERVICE MANUAL
guides to height adjustment rings, loosen second
screw (see Figure 2F-6), and swing guides away from
guide rail.
NOTE: When swinging front guides inboard, be
careful not to change position of height adjustment
rings. It is suggested that the position of the height
adjustment rings be marked with a pencil prior to
loosening of front guide attaching screws.
5. Retighten remaining screw holding front guide in
position to prevent height adjustment rings from
turning.
6. Turn lifter guide tension springs 90 degrees in-
board and pull lifters out of sun roof panel brackets
(see Figure
2F-7).Figure
ZF-7 Pulling Rear Lifter Guide out of Sun RoofPanel BracketNOTE: Do not loosen lifter pin nut as this will
change height adjustment on rear of sun roof.
7. Lift out sun roof panel.
Installation of Sun Roof Panel1. Install sun roof panel onto guide rails and locate
panel evenly in stin roof opening.
2. Reposition front guides in original position on
guide rails. Be sure that they squarely contact guide
rails and are not cocked.
NOTE: To achieve proper clearance of front guides
to guide rail, the guides should lightly touch edge ofdshould have a clearance of no
3. Reconnect
riar lifter guides onto sun roof panel
brackets and reposition tension spring as shown in
Figure
2F-3.4. Crank sun roof fully closed and check that the rear
lifters are at approximately 90 degrees with respect
to guide rails and contact guide stops (see Figure
2F-3). If adjustment is required remove crank handle
and cable crank (see Figure 2F-4) and physically
reposition lifters to position described above. Rotate
cable crank to its fully clockwise limit and reinstall.
5. Pull sun roof frame forward and reattach to sun
roof panel.
6. Open and close sun roof several times and recheck
for smoothness of operation.
Removal of Sunlpoof Frame1. Remove sun roof panel.
2. Crank rear lifter guides to furthermost rear posi-
tion.
3. Remove screws securing upper corner plates in
position and lift out upper corner plates (see Figure
2F-8).Figure 2F-&Removing Upper Corner Plates
4. Remove scretii securing left und
r@t guide rai1%lift up front ends
of- guide rails and msert wedge
under forward g&de rail ends. Slide out sun roof
frame.

2F-301973 OPEL SERVICE MANUAL
3. Unscrew and remove upper and lower corner
plates (see Figure 2F-8).4. Unscrew and remove left and right upper cable
shields ans pull cable ends out of cable box.
5. Pull cable and rear lifter guides out of leftand
right guide rails.
Installation of Rear Guides and Cable1. Check both cables for wear or damage. If eigher
cable is defective, replace both cables.
2. Check pinion on cable crank (see Figure
2F-IO) for
wear or damage. If replacement of pinion is required,
also replace both cables.
Figure ZF-10 Cable Crank3. Install cables and rear lifter guides into guide rails
and work cables inward until they hit stops.
4. Unscrew and lift off cable box cover (see Figure
2F- 1 I).5. Insert cable ends into cable box and locate cable
ends in respective lower cable shields.
6. Install cable box cover, right and left upper cable
shields and right and left upper corner plates.
7. Temporarily install cable crank and crank handle.
Crank rear lifter guides to closed position. Remove
cable crank and crank handle.
8. Install sun roof panel and reposition frontguides
to original position on guide rails. Be sure frontFigure
ZF-1 1 Cable Box
guides squarely touch guide rails and are not cocked:
Also be sure sun roof panel is not cocked and is
evenly located in opening.
NOTE: To achieve proper clearance of front guides
to guide rail, the guides should lightly touch the edge
of guide rails and should have a clearance of no more
than 0.02 inch.
9. Reconnect rear lifter guides onto sun roof panel
brackets and reposition tension spring as shown in
Figure
2F-3.10. Push sun roof panel forward so that it contacts
roof panel velvet strip and manually raise rear lifters
to their 90 degree position. Sun roof panel will now
be fully closed.
11. Rotate cable crank to its limit in a clockwise
direction and reinstall.
NOTE: Be sure that drive pinion of cable crank
meshes with spirals of cable.
12. Reinstall cable crank and crank handle.
13. Pull sun roof frame forward and reattach to sun
roof panel.
14. Open and close sun roof several times to recheck
forsmoothness of operation.
REMOVAL AND INSTALLATION OF DRIVE PINION
Removal1. Position sun roof in fully closed position and take
off crank handle and cable crank.

2F-321973 OPEL SERVICE MANUAL
3. Carefully detach a portion of headlining around
window corner post involved.
4. Detach water drain hose from sun roof hose iit-
ting.
5. Remove cowl side kickpads.
6. Pull out from upper end front water drain hose.
Installation of Front Water Drain Hose
1. Insert from above water drain hose (wider end
upward) into door hinge pillar.
NOTE: Do not mistake front and rear water hoses.
The front hose is thinner than the rear hose and is
wider at the end which connects to hose fitting on
sun roof. The rear hose is uniform over its entire
length.
2. Work water drain hose downward through lower
half of door hinge pillar and be sure hose terminates
behind door sill flange at bottom of frbnt fender.
3. Cement upper portion of water drain hose to sun
roof hose fitting.
4. Cement detached portions of headlining into place
by use of rubber cement or nitrile vinyl trim adhesive
(3M Vinyl Trim Adhesive, Permalastic Vinyl Trim
Adhesive or equivalent).
5. Complete installation reverse of removal proce-
dures.
Removal of Rear Water Drain Hose1. Remove rear seat and rear seat back.2. Pry out plastic fasteners securing cardboard parcel
shelf in position and remove shelf.
3. Remove rear quarter trim pad.
4. Detach headlining only as required from area
around rear window pillar.
5. Pull out rear water drain hose.
Installation of Rear Water Drain Hose1. Install rear water drain hose in original position.
Insert hose from above and work downward. Ce-
ment both ends of hose in place.
2. Secure water drain hose in place along wheel-
house.3. Complete installation reverse of removal proce-
dures.
REMOVAL AND INSTALLATION
OF LUGGAGE
RACKAll 1973 luggage racks will be dealer installed, and
are held to the roof at the 4 corners. Removal and
installation is accomplished by removing the attach-
ing screw at each corner. See Figure
2F-14.Figure ZF-14 Luggage Rack