fuse chart OPEL 1900 1973 Service Manual

lG- 54 1973 OPEL SERVICE’ MANtiAL/SIGNAL SYSTEMSCdNTENTS
9Subject
DESCRIPTION AND OPERAT!ON:
Directional Signal Lever
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HazardWarning
Flasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BrakeSystemWarningLight
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS:
SignalSystem,.......................
i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAINTENANCE AND ADJUS,TMENTS:
MAJOR REPAIR:
Directional Signal Switch
:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HornRemoval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing Horn Contact
. . . . :.............................................
SPECIFICATIONS:
FuseChart. . . . . . I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page No.
1 G-54
1 G-54
1 G-55
lG-55 _1 G-55
1 G-55
16-551 G-55
1 G-56
DESCRIPTION AND OPERATION
DIRECTIONAL SIGNAL LEVERThe direction signal switch lever is a multi- purpose
lever controlling direction signals, passing signal,
and high and low beams. See Figure
lG-1.301Gl
Figure lG-1 Directional Signal Position for Headlamp
OperationThe direction signal lever is provided with a
two-step mechanism for operation of headlight high and
low beams, and passing signal (not in New Jersey).
With headlights off, moving the lever repeatedly to-
wards steering wheel flashes headlights as a passing
signal. With headlights on, moving the lever repeat-
edly towards steering wheel up to first stop also
flashes passing signal regardless whether or not the
direcl:ion signals are switched on. When the lever is
moved up to the second stop, the headlights are
changed from high to low beam
dr vice versa. On all
Rallye cars, when switching from low to high beam
position, with the fog lamp instrument panel switch
“ON” and ignition switch in “RUN” position, the
fog lights are automatically
switChed off. Direction
signals work in the normal manner; pushing the lever
up for right turn signal and pulling the lever down
for left turn signal.
The horn button is located in the center part of the
steering wheel. The horn is actuated by pushing
down on the ends of both spokes on Opel 1900 andManta’s or on the center horn button on the Rallye.
The button is provided with a spring-loaded plunger.See Figure
lG-2.

98.40 1973 OPEL SERVICE MANUAL
2. Interconnect manifold and gage set (J-5725-01),
gage charging lines (J-5418) and gage adapters
(J-5420) to air conditioning system as shown in Figure
9B-40.3. Place transmission in “Park” for automatics and
in neutral for manuals. Apply hand brake.
4. Turn blower switch to the “Hi” position.
5. Turn temperature switch to “Max” position.
6. Run engine at 2000 RPM for ten (10) minutes with
car doors and windows closed and the hood up. Place
a high volume industrial type fan in front of radiator
if head pressure should exceed 250 psi and also at
high ambients to bring the pressures to within the
limits specified in the Functional Charts in Division
V.In the case of the Opel 1900 and the Manta, a ther-
mometer should be placed in a position to read the
temperature of the air discharging from the right-
hand A/C outlet. In case of the GT, a thermometer
should be placed in a position to read the tempera-
ture of the air discharging from the left-rear A/C
outlet.
HEATER-AIR CONDITIONER REFRIGERANT
CIRCUIT TROUBLE DIAGNOSIS GUIDE
Insufficient Cooling (Check Air Flow)
Normal Air Flow (Inspect system for visual defects.
Run functional tests.)
Discharge Air
- Normal Temp Check for air leaks
through dash, car body, windows, or from heater or
ventilators.
Discharge Air
- High Temp Check sight glass for
foaming and compressor clutch for engagement.
No Compressor Clutch Engagement Check connec-
tions at clutch switch, harness connectors, and check
clutch switch.
No Foaming Compare evaporator pressure to that
on functional test table.
Foaming System is probably low on refrigerant.
Check for leaks, repair, evacuate, and charge. If
foaming still occurs, check for restriction in refriger-
ant lines between condenser and receiver dehydrator.
Evaporator Pressure Normal Compare head pres-
sure to pressure on functional test table.
Evaporator Pressure Low Ice may be forming on
evaporator. Low volume of air discharging at A/C
outlet after system has been running above idle con-dition
,for approximately 15-30 min.utes. Discharging
air gradually elevating in temperature. Check expan-
sion valve. If valve isn’t permitting flow of liquid,
this will be indicated by a warm pipe out of the
evaporator. This may be caused by: 1) Clogged or
Plugged inlet screen in the expansion valve; 2)
Broken capillary line; or 3) Discharged temperature
bulb. If the valve is okay, the pipe out of the evapora-
tor will be cold.
Evaporator Pressure High Check the expansion
valve to determine if themobulb is making good con-
tact and is properly insulated. Operate engine at 2000
RPM with maximum air conditioning setting. If
evaporator pressure remains high, feel suction line.
If line feels frosty or extremely
(cold with relative
high ambient conditions, then partially cover the
condenser to obtain head pressures from 265 psi to
280 psi maximum. If evaporator pressure rises above
30 psi, change the expansion valve.
Also, check if compressor may be the cause due to
some internal or external mechanical trouble which
prevents reduction of pressure. Check for external
troubles, slipping belt, bad clutch and/or pulley, or
improper clutch engagement, before investigating
the compressor internally.
Head Pressure High Check for the following: Con-
denser air flow low, air in system, excessive refriger-
ant in system, restriction in condenser.Head.PressureLowRestriction in flow of refrigerant
to evaporator, or expansion valve plugged or defec-
tive.
Low Air Flow (Check blower operation and
evaporator. Check operation of controls.)
Ice BIocking Evaporator Run functional test. If
evaporator pressure is low, ice may form on evapora-
tor and reduce air flow.
Evaporator Pressure Low Ice may be forming on
evaporator. Low volume of air discharging at A/C
outlet after system has been running above idle con-
dition for approximately 15-30 minutes. Discharging
air gradually elevating in temperature. Check expan-
sion valve. If valve isn’t permitting flow of liquid,
this will be indicated by a warm pipe out of the
evaporator. This may be caused by: 1) Clogged or
plugged inlet screen in the expansion valve; 2)
Broken capillary line, or 3) Discharged temperature
bulb. If the valve is okay, the pipe out of the evapora-
tor will be cold.BlowerNot OperatingCheck for the following: Fuse
blown, blower switch defective, wire broken or loose
connection, poor ground connection, or blower mo-
tor defective.

AIR CONDITIONER SYSTEM -OPEL 1900 - MANTA9B- 91FAN 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 fins.
Checking for Proper Operation
I. Install the gauge set and set up the vehicle as
described under FUNCTIONAL TESTING SYS-
TEM iti 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 ihe 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 low
pressure gauge, should pull down to the pressure
shown in the chart in SPECIFICATIONS in Refrig-
erant Components Section.
3. Remove the face plate retaining screws and
remove face plate assembly noting the position of the
air sensipg capillary so that it can be reinstalled in
the same location as when removed. See Figure 98.170. ,:Figure
98.170 Location of Air Sensing Capillary
4. Remove the thermostatic switch retaining screws
and remove switch. Remove the non-metal end plate
from the switch to gain access tq the switch adjusting
screw. Check the screw for stripped or otherwise
damaged threads.
5. If the low side pressure
was less than the pre-
scribed pressure at the end of each cooling cycle, turn
the adjusting screw a partial turn clockwise. See Fig-
ure
9B-171.Figure 9B-17 1 Adjusting
Thkmosfatic Switch
6. If the pressure was more than the prescribed
value, turn the adjusting screw counter-clockwise.
7. Reinstall switch end plate and install switch in
face plate. Install face plate on ,evaporator assembly
assuring that the air sensing
c&pillary has been re-
placed properly.
8. Check system performance. Fffurther adjustment
is needed, repeat steps 3 thru 7 until the correct
pressure is reached.
Do not attempt to run a performance test with the
face plate and switch removed
,from the evaporator
assembly
- inaccurate reading, will result. Always
replace the switch and face plate assemblies before
checking the system performance.

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.

Subject
Page NumbelSubjectPage Number4.Speed Manual I..
Clutch
Detent Cable Adjustment
:Differential
Directional Signal Switch
Repair Opel 1900 & Manta
Repair GT
:Disassembly of
4.Speed Manual Transmission
DistributorFunction of Valves and Hydraulic Control Units
Opel
3.Speed Automatic.................
74-21
Fuse Chart..............................lG-56
Fusible Link.............................
lA-8Specifications.
Point Replacement..
..,78-127A-
17c-9148-73E-393E-4878.23
1C-26
1 c-20
GEGas Tank See Fuel Tank
General Specifications
Engine...............................6A-28
Opel 3.Speed Automatic
.................7C-134
Transmission, Manual.,
..................78-33
Clutch...............................7A-7
Body................................ZA-4
Governor Drive Gear
Opel
3.Speed Automatic.................7C-103
Grille
Opel 1900 & Manta.....................8A-7
GT..................................8A-6 Electrically Heated Rear Window
Engine
General Description
Cooling System
Lubrication System
Trouble Diagnosis
Exhaust Manifold
Exhaust System
Removal and Installation
External Oil Leaks,
Opel 3 Speed Automatic
FFast Idle Adjustment
..................
Filter-Engine Oil
......................
Fluid Checking Procedure Transmission
Opel 3Speed Automatic.............
Frame-Opel 1900 & Manta.............
Frame
GT-Opel......................
SWVOOpel Xipeed Automatic...........
Front Suspension
Opel1900&Manta.................
GT..............................
Front Wheel Alignment................
Front Wheel Bearing Adjustment
All Series.........................
Fuel Gauge
Trouble Diagnosis
Opell$OO&Manta...............
GT............................
Fuel Pump Operation..................
Fuel System
Fuel Tank (Opel 1900 & Manta)
.......
Fuel Lines (Opel 1900 & Manta)
.......
Fuel Tank
(GT)....................
Fuel Gauge Tank Unit
(GT)...........
Fuel Lines
(GT)....................
Fuel Tank Removal and Installation....
Cleaning Tank.....................
lH-576A-268-326A-46A-66A-126D-427C-816E-51
oc-77C~Bl2B-826-77c-1003A-23A-23C-223A-4
HHazard Warning Flasher
....................lG-55
Headlamp Aiming
.........................1 F-46
Headlamp Switch
Opel 190.0 & Manta
.....................1 F-46
Headlamp Mechanism GT
..................8A-2
Heater System Opel 1900 &Manta
Trouble Diagnosis
......................9A-11
Description and Operation
................9A-10
Adjustments and Minor Service............9A-12
Removal and Installation
.................9A-12
Specifications..........................$A-16
Heater System GT
Trouble Diagnosis
......................9A-4
Description and Operation
................9A-2
Adjustments and Minor Service
............9A-4
Removal and Installation.................9A-5
Specifications..........................$A-9Horn
Operation.............................lG-54
Hydraulic Operation
Opel
3.Speed Automatic.................7C-64
IIdentification Number Vehicle...............
OA-1ldle.Adjustment
..........................6E-51
Inflation Pressures, Tires.
...................36-62
Ignition Coil
Specifications.
.........................
lC-26Identification, Engine
......................
OA-1Ignition System
Timing...............................
lC-20Instrument Panel Parts Removal