length OPEL 1900 1973 Service Manual

STARTING SYSTEMlB- 17
7. Seal area between solenoid and frame. See FigurelB-17.
8. With brushes and spring in housings held in place
with a 29 @llimeter socket, slide frame assembly in
position.
9. Install i+ulating sleeves in field frame.
10. Install knd frame and replace through bolts and
tighten bolts.
11. Install bolt holding field frame to solenoid.
SPEClFltjATlONS
Starter SpecificationsStarterNumber. . . .
.._.._..._...........................RatedVoltage
. . . . . . . . . . . . . . . . . . . . . . . . .No voad Test:
...............................................EF 12V0 .8 PS
.....................................................................12Volts
................................................................................................................................10.6Amperes
........................................................................................................................30-50RPM
......................................................................................................................7300-8500Cranking Amperes Test (InCar-Engine atOperating Temp.)
..................................175-205
Lock Test:
Volts
............................................................................................................................6 Min.
Amperes
....................................................................................................................280-320Volt$geRequiredtoCloseSolenoidContacts
....................................................................7.5MinimumDiameterof Commutatorin
Inches................................................................1.46Brush Spring Pressure in Ounces
....................................................................................40-46Minimum Length of Brushes in Inches...............................................................................2812. Check starter on bench before installing.
Starter Installation
1. Hold starter in position.
2. Install two bolts, one nut and lockwashers.
Tighten securely.
3. Install support bracket. To ensure a stress-freeintitallation, install bolt and two nuts only finger
tight. First tighten the bolt at the engine, then tighten
the two nuts at the starter end frame.

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.

WINDSHIELD WIPERSlE-41
Figurk 1 E-l 3 Cut Off Positive Brush Leads
i
Figure iE-14 Remove Negative Brush Retaining
S.X?WI
Cleaning apd Inspection of PartsWith the ekception of electrical parts and bushings,
clean all components in a cleaning solvent.
1. Check irmatare windings for ground, or open
circuit. If
b ground or open circuit is evident, the
armature must be replaced. If the armature checks
out, the c 2. Check brush springs. Spring pressure of new
brushes should be 6.35 to 8.47 ounces. Spring pres-
sure of worn brushes should be at least 3.5 ounces.
In case of /ower spring pressure, replace springs.
3. Check blushes for wear and replace if necessary.
Minimum brush length should be
.24’inch.4. Check d$ven gear for wear and replace if neces-
sary.
Assembly l/8inch layer’ of grease meeting GM Specification
02383. I
2. Install
d&en gear into housing3. Apply a small amount of grease to ball cavity of
driven gear and insert ball. See Figure lE-15.
Figure lE-15 Insert Ball into Driven Gear
4. Install transmission housing cover. See Figure
lE-
16.2. DRIVEN GEAR
3. CONTACT SPRINGS
4. TRANSMISSION
HOUSING COVER
Figure 1 E-l 6 Install Transmission Housing
Cover5. Solder positive brush lead(s) to brush holder(s).
Hold brush lead with needle nose pliers to prevent
solder from running up wire strands. See Figure
lE-
17.6. Install negative brush
7. Apply a small amount of grease to end of armature
shaft. Lightly oil armature shaft.
8. Insert brush springs and brushes into brush hold-
ers. Slide armature into housing, taking care not to
damage brushes.

WINDSHIELD WIPERSlE-43SPEhFlCATlONS
IGENEPAL SPECIFICATIONSiRated Voltage .
..__.,,,.,,,......................................,.,,... ~ __..__...__...._..................................... 12 VDC
,Test Voltage ___..................................................,...................,..,..................................... 13 VDC
Current Draw (Amps)
;No Load_, Low Speed
..__...__..__..,_,,..,,,.,,,,..,....................,,.................................................................. 1.5
I Hieh
SDeed .___,,...,,..,,._.._..............,...............................,,,..,,,.............................................. 2.2lLock:d
’
:Low Speed ___.,._,,,..,,,....................................,,.........,,..,,,.,,,,..................,,,........................... 16
,
High Speed . . . . . . . ..___.._........................................................................................................... 17
~Minimum Commutator Diameter __.................,,,,........................................................... .86 in.
‘Brush Spring Pressure
:New Brush
. . . . . . .._...__...................................................................................... 6.35 to 8.47 oz.Used Brush
..__,,,...,,.,,..................,...............................,,.,,,,.,,....................... 3.5 oz. minimum‘MinimumBrushLength
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24in.The windshield wiper motor instead of field coils has a permanent magnet
(oxide magnet). This motor design is sturdier and consumes less current.TORQirE SPECIFICATIONS
‘CrankArmtoMotorDriveShaft. . . . . . . . . . . . . . . . . . . . . . . . . .70to87in.lbs.iper Motor to Cowl
,
,.,,,.,,,,..,,............,..,,.,,.........................................14 to 17 in.lbs.

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-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

3A- 21973 OPEL SERVICE MANUAL
FRONT SUSPENSION
CONTENTS
Subject
DESCRIPTION AND OPERATION:SuspensionDescription. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS:
FrontWheel
BearingAdjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Removal and Installation of Front Suspension . . . . . . . .Upper Ball Joint Removal and Installation
. . . . . . . . . . . . . .Lower Ball Joint Removal and
Installation
. . . . . . . . . . . . . .Upper Control Arm
Removal andInstallation
. . . . . . . . . .Lower Control Arm Removal and Installation
. . . . . . . .Steering
Knuckle
RemovalandInstallation. . . . . . . . . . . . . .Shock Absorber
RemovalandInstallation. . . . . . . . . . . . . . . .Front Spring Removal and Installation
. . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:Page No.
3A- 2
3A- 4
3A- 4
3A- 7
3A- 73A-103A-113A-133A-153A-15
Bolt Torque and Front End Alignment Specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3A-18
DESCRIPTION AND OPERATION
SUSPENSION DESCRIPTION
GTThe GT uses a maintenance-free independent front
wheel suspension and features unequal length con-
trol arms and a transverse three-leaf spring. The en-
tire front suspension is attached to the front cross
member and can be removed as a unit if so desired.
The engines installed in the GT are not supported by
mounting brackets but rest on a separate cross mem-
ber. The front suspension cross member is reinforced
in the area of the attachment to the frame. A one-
part damper plate is installed between cross member
and frame.
Ball joints are employed in the conventional manner
to provide pivoting joints between the control arms
and steering knuckles. Upward movement of the
control arms is limited by two large rubber bumpers
attached to the cross member.Road shock is dampened by the double direct acting
shock absorbers and a transverse double or triple
steel band spring. In addition, the shock absorber
limits downward travel of the control arms.
All moving parts, including ball joints, have no need
for lubrication as they have been pre-lubricated for
the life of the vehicle.
For distinguishing the individual front suspension
cross members,.a red label with black letters is stuck
onto the front side of the shock absorber support. See
Figure 3A-3.
Opel 1900. Manta
The front wheel suspension has coil springs and con-
trol arms of different length.
The stabilizer is designed to act as a tie strut. The end
is supported in a rubber bushing which is located in
a piece of tubing welded into the longer control arm.
To minimize brake torque, the horizontal shafts of

FRONT SUSPENSION3A- 17Torque values must be used as specified during reas-
sembly to assure proper retention of these parts.1. Attach lower control arm to front spring eye.
Torque bolts to 18
lb.ft.2. Install spring compressor on spring and compress
spring to appropriate length.
3. Raise jack with spring compressor, spring and
control arm assembly into position under the car.
4. Install lower ball joints and torque nuts to 54
Ib.ft.Install new cotter pin.
5. Attach lower control arms to frame cross member
using new lock nuts.
6. Attach both shock absorbers. Torque bolts to 30
lb.ft.7. Remove spring compressor.
8. Install front wheels.
On replacement of the damper bushings on the front
springs, only the one-part damper bushing is in-
stalled for either the two-leaf or three-leaf spring.
For proper location of the marking lugs, see Figure3A-26.
Installation (Opel 1900. Manta)
CAUTION: Fasteners are important attachingparts in
that they
co&d affect the performance of vital com-
ponents and systems, and/or could result in major
repair expense. They must be replaced with one of
the same part number or with an equivalent part, if
replacement becomes necessary. Do not use a re-
placement part of
lesser quality or substitute design.
Torque values must be used as specified
during reas-
sembly to assure proper retention of these parts.1. Properly seat spring between lower control arm
and cross member.
2. Raise jack and place lower control into position.CROSS SECTION
SA-26Fig. 3A-26 Front Spring Damper Bushing.
3. Attach lower control ball joint to steering knuckle
and torque nut to 54
lb.ft.4. Tighten lower control arm to cross member bolt
to 43 lb.ft.
5. Attach stabilizer bar to cross member to body
support.
6. Install shock absorber and torque lower attaching
nut and bolt to 30
lb.ft.7. Install nuts on upper shock absorber attaching
studs. Tighten nuts until a distance from top of nut
to stud is approximately
l/2 inch.
8. Install front wheels and tighten nuts to 65
lb.ft.9. Remove stands and lower car.
SPECIFICATIONSBOLT TORQUE AND FRONT END ALIGNMENT

3E- 421973 OPEL SERVICE MANUAL
GT STEERING COLUMN ASSEMBLY
CONTENTS
Subject
DESCRIPTION AND OPERATION:
DescriptionofSteeringColumn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS: (Not
Applicable)
MAJOR REPAIR:
RemovalandInstallationofSteeringWheel. . . . . . . . . . . .Removal and Installation of Ignition Lock
Cylinder
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation of Steering Column
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation of Center Steering Shaft
Removal and Installation of Ignition Switch
and/or Steering Lock
.,~ ,........ ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation of Upper Steering
Bearing and/or Directional Signal Switch
. . . . . . . . . . . .Removal and Installation of Steering Column
Lower Bearing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:
Steering Column Torques
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page No.
3E-42
3E-44
3E-45
3E-45
3E-46
3E-46
3E-48
3E-49
3E-50
DESCRIPTION AND OPERATION
DESCRIPTION OF STEERING COLUMNThe Energy Abosrbing, Locking Steering .Column
assembly is used on the GT. This cohnnn is designed
to compress under impact. When an automobile is
being driven, the forward movement of the automo-
bile and the forward movement of the driver both
constitute a form of energy or force. When an au-
tomobile is involved in a frontal collision, the pri-
mary force (forward movement of the car) is
suddenly halted, while the secondary force (the
driver) continues its forward direction. A severe col-
lision generally involves these two forces
- the pri-
mary and the secondary forces. The secondaryjmpact occurs when the driver is thrust forward onto
the steering wheel and column.
The Energy Absorbing Column is designed to absorb
these primary and secondary forces to the extent thatthe severity of the secondary impact is reduced. Dur-
ing a collision, the steering column compresses and
thereby reduces its tendency to move rearward into
the driver’s compartment. A split second later when
the driver is thrown forward (the secondary impact)
his energy is also partially abosrbed by the compres-
sion characteristics of the column.
The Energy Absorbing, Locking Column assembly
may be easily disassembled and reassembled. The
serviceman should be aware that it is important that
only the specified screws, bolts and nuts be used as
designated during reassembly, and that they are
tightened to their specified torque. This precaution
will insure the energy absorbing action of the assem-
bly. Particular care should be exercised to avoid us-
ing overlength bolts as they may prevent a portion of
the assembly from compressing under impact.
Equally as important is correct torquing of all bolts
and nuts.
When the Energy Absorbing, Locking Column is

4A- 21973 OPEL SERVICE MANUAL
PROPELLER SHAFT AND CENTRAL JOINT
CONTENTS
Subject
DESCRIPTION AND OPERATION:
PropellerShaftandCentralJoint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS: (Not
Applicable)
MAJOR REPAIR:
’Propeller Shaft Removal andInstallation
. . . . . . . ..-....Disassembly andAssembly of CentralJoint
. . . . . . . . . . . .SPECIFICATIONS:
Propeller Shaft and Central Joint Specifications . .
DESCRIPTION AND OPEqATlON
PROPELLER SHAFT AND CENTRAL JOINTDue to the use of both automatic and manual trans-
missions, propeller shafts of various lengths are re-
quired depending upon vehicle, engine, and
transmission (manual or automatic) application. The
propeller shaft is of a strong design due to increased
engine torque. It is also a one piece tubular shaft, but
it has two universal joints. See Figure 4A-1. The
front universal joint attaches to the transmission out-
put shaft by a splined slip joint. The rear universal
joint attaches to the pinion extension shaft flange by
Page No.
4A-2
4A-3
4A-3
4A-6two U-bolts. The splines of both propeller shafts are
lubricated internally with transmission lubricant. An
oil seal in the rear of the transmission extension pre-
vents loss of lubricant and entrance of harmful for-
eign material.
The torque tube which houses the drive pinion exten-
sion shaft is bolted to the differential housing. The
torque tube is pivoted in rubber elements of the cen-
tral joint support bracket which is bolted to the floor
panel. The support bracket and rubber parts of the
torque tube
arc termed the central joint. The front
end of the drive pinion extension shaft rides in a ball
bearing mounted in rubber in the central joint.
CENTRAL JOINT\REAR U-JOINT
FRONT U-JOINT
4A-1Figure 4R1 Propeller Shaft