check oil OPEL GT-R 1973 User Guide

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

IGNITION SYSTEMlC-214. Rota&distributor counterclockwise slightly until
contact pbints just start to open. This must be done
very carefully or engine will not start.
5. Install distributor cap. Make sure spark plug wires
are correctly installed in distributor cap, through clip
and on spark plugs.
Finish TimingIContact boint gap
(.016” at widest gap) or dwell 50
degrees plus or minus 3 degrees should always be
checked before adjusting ignition timing.
1. Connekt timing light to No. 1 spark plug.
2. Disconnect and plug vacuum advance unit and
retard u$it hoses.
3. Connect a tachometer from distributor side of coil
to
groun$l.4. Start dngine. Set idle speed to 900 RPM.
5. Rotate distributor as necessary to align timing
marks. T;ming mark is a steel ball embedded in the
flywheel and a pointer in a window in the right fly-
wheel housing. See Figure lC-4.:Figure lC-4 Ignition Timing Marks
6.
Tightq clamp bolt securely and recheck timing
mark ahgnment.
7. Reconnect vacuum hoses and adjust engine idle
speed
an: mixture.
IGNlTlOFj WIRE INSPECTION
1. The c$il and spark plug wires are of a specialresistance type. These secondary ignition wires
reduce television and radio interference.
2. Wipe ignition wires with a cloth moistened with
solvent and wipe dry. Bend wires to check for brittle,
cracked or swollen insulation. Defective insulation
will permit missing or cross-firing of spark plugs,
therefore any defective wires must be replaced.
3. If wire insulation is in good condition, clean any
terminals that are corroded and replace any termi-
nals that are broken or damaged. Terminals must tit
tight on spark plugs and in distributor cap.
4. Replace any hardened, cracked or loose cap nip-
ples or spark plug boots.
5. Check resistance of each wire from contact inside
distributor cap to spark plug or coil terminal. Re-
place any wire having over 10,000 ohms resistance
reading. See Figure lC-5.
Figure fC-5 Checking Ignition Wire Resistance
CHECK IGNITION OUTPUT
1. Disconnect secondary coil ivire so that engine will
not start. Connect a voltmeter from the battery side
of the coil primary to ground and check voltage
while engine is cranking. Reading should be 10 volts
or more. Low reading could be caused by a defective
battery, a discharged battery, high starter current
draw, a bad connection in the starter circuit or a bad
connection in the primary ignition circuit.
2. Connect an oscilloscope according to manufac-
turer’s instructions. Disconnect coil wire. Crank en-
gine and read coil output voltage. Reading should
exceed 20 KV (20,000 volts).

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.

1F. 46 1973 OPEL SERVICE MANUAL
’
/
Headlight High-Low Beam Control and Passing:
SignalI
When the headlights have been switched on, high
and low beam selection is made by raising the direc-
tional signal lever toward steering wheel. Each
ti&the lever is raised, beam position, will change.
When the headlights are not on, a flashing headlight
signal may be given by raising and lotiering the di-
rectional signal lever. With the headlights on and
inlow beam position, raising and lowering the direc-
tional signal lever will also cause the headlights to
flash.
Fog Light SwitchAll Rallye models are equipped with two white f?g
lights mounted below the front bumper.
The fog light toggle switch is located on the
insty-ment cluster to the left of the temperature and
fuelgauge cluster.
/
The fog lights can be turned off at any time by the
toggle switch, but can only be tyrned on when: :
1. The ignition switch on or the
?gine running.!
2. The fog light toggle switch lower half is pushed
in.3. The parking lights and/or low beam headlights
are
OKThe fog lights are automatically turned off if the
ignition switch is on and the headlights are switched
to high beam position.
Courtesy LightThe courtesy light illuminates the interior of the Car
when any door is opened. The courtesy light can also
be turned on with all doors closed by tilting the l&s.
GT Headlamp MechanismThe concealed headlamps are moved mechanically.
Pushing actuating lever on left side of console opens
headlamps and pulling lever closes headlamps. Two
(2) meshing gear segments convert the movement, of
the lever to a rotation of 180 degrees. The pivots of
the headlamps lie below the centerline so that with
headlamps in closed position, the headlamp housing
is flush with front sheet metal. Refer to Group 110,
Section “F”, for service procedures on the GT head-
lamp mechanism.
A white indicator lamp in the instrument panel lights
if the headlamps are not completely opened lorclosed The switches of the headlamp electrical sys-
tem are located behind the left headlamp operating,
mechanism.
MAINTENANCE AND ADJUSTMENTSHEADLAMP AIMING
The headlamps must be properly aimed in order to
obtain maximum road illumination and safety that
has been built into the headlighting equipment. With
the Guide T-3 type sealed beam units, proper aiming
is even more important because the increased range
and power of this lamp make even slight variations
from recommended aiming hazardous to approach-
ing motorists. The headlamps must be checked for
proper aim whenever a sealed beam unit is replaced
and after an adjustment or repairs of the front end
sheet metal assembly.
Regardless of method used for checking headlamp
aim, car must be at normal weight, that is, with gas,
oil, water, and spare tire. Tires must be uniformly
inflated to specified pressure. If car will regularly
carry an unusual load in rear compartment, or a
trailer, these loads should be on car when headlamps
are checked. Some States have special requirements
for headlamp aiming adjustment, and these require-
ments should be known and observed.
Horizontal and vertical aiming of each seal beam
unit is provided by two adjusting screws which move
the mounting ring in the body against the tension of
the coil spring. There is no adjustment for focus,
since the sealed beam unit is set for proper focus
during manufacturing assembly.
MAJOR REPAIRHEADLIGHT SWITCH
- OPEL 1900. MANTA
Removal1. Remove instrument cluster cover panel. See Sec-
tion H.
2. Compress retaining springs and pull switch out.
See Figure 1 F-
1.3. Pull multiple socket off switch.
Installation
1: Plug multiple socket in switch and push switch in
panel until clips lock in place.
2. Replace instrument cover and secure with two (2)
screws.

dOORS2D-15
3. Unhook con&cting rod out of old support and
hook into new support and door lock.
the water deflector foil is inserted in lower door slot.See Figure
2D-6. Reverse procedure for installation.2D-i-
Figure
2D-7 Removing Support
4. Screw support onto door inner panel so that it canbe shifted in both holes. Adjust remote control so
that the connecting rod has a clearance at the door
lock of
.02 inch (0.5 mm).
5. Tighten support to door inner panel.
b. Install door trim pad
REMOVAL AND INSTALLATION OF FRONT
DOOR
BELT REVEAL MOLDING
1. Bend up ends of molding.2. With a wooden wedge, pry off molding towards
the top. See Figure
2D-8.Figure
2D-6 Installing Water Deflector
REMOVAL AND INSTALLATION OF FRONT
DOOR
INSIDEHANDLE WITH SUPPORT
1. Remove door trim pad.
2. Unscrew support and unhook connecting rod out
of door lock. See Figure
2D-7.Figure
2D-6 Removing Molding
3. Check retaining clamps in outer door panel for
proper position and tight seat. Push new molding
onto retaining clamps and bend both ends inwards.
REMOVAL AND INSTALLATION OF FRONT
DOOR
WINDOW LIFTER
Removal1. Remove door trim pad.

ROOF AND SUN ROOFZF-25ConditionCallseCorrectionSun roof lifts up on one
side only.Lifter wedge welded to under-
Remove sun roof panel and bend
side of sun roof panel doeslifter wedge so that it squarely hits
not run up ramp welded inramp. The only adjustment for
center of sun roof track.the ramp is the angle of the
rear portion. This should be
adjusted so that the wedge smoothly
rides up the ramp.
Transporter cable or drive
pinion damaged.If the transporter cable is worn
or damaged, replace both
cables. If drive pinion worn or
damaged, replace drive pinion and
also both transporter cables.
Sun roof scrapes on car roof
when closing sun roof.Lifters do not lie flat.Close sun roof, slide sun roof
frame to the rear and open and close
sun roof slightly noting operation
of lifters. Rework if necessary,plastjc lifter cushion with tile
to permit lifter to lie flat.
Sparingly lubricate lifter guide.
Sun roof frame becomes
detached.Attaching clips have lost
elasticity.Install new clips
Water enters car interior.
Water drain hoses blocked.
Bent water drain hoses
Rear water drain hoses have
been pulled out of rubber
grommets.
Velvet strips on front and
rear of sun roof do not seal
properly.Clean hoses with compressed air
or a flexible steel cable.
NOTE: To clear rear water
drain hoses, the sun roof panel
and frame must be removed.
Blowing out of rear drain hoses
from trunk compartment hose end
is not recommended due to
possibility of soiling car
interior.
Attempt to straighten drain
hoses by working a suitable
tube or cable through hose.
Replace hose if above corrective
action is not satisfactory.
Apply a small amount of rubber
cement to rear water drain
hoses and reinsert into rubber
grommet located in luggage
compartment floor panel.
Check sun roof for correct
height adjustment. If height
adjustment is correct, but a
tight seal does not exist,
relocate velvet strip upward
for better seal, or replace
velvet strip.

4B- 101973 OPEL SERVICE MANUAL
Figure 48-Z Removing Rear Axle Assemblyan equiva/entpart ifreplacement becomes necessary.
Do not use a replacement
part of lesser quality or
substitute design. Torque
values must be used as
specified
during reassembly to assure proper reten-
tion of these parts.1. Roll rear axle assembly under car on floor jack and
loosely attach lower control arms to rear axle hous-
ing.
2. Attach central joint support, to underbody with
bolts only finger tight.
3. Lower rear axle assembly, install lower damper
rings in spring seats, coil springs and upper damper
rings on springs. Make certain the damper rings and
springs are properly positioned.
4. Install track rod on axle housing.
5. On Opel 1900 and Manta, place a load of approxi-
mately 350
Ibs. in luggage conipartment or on the
GT, place a load of approximately 150 lbs. on drivers
seat and raise rear axle far enough for underbody to
clear jack stands.
6. Torque central joint support t$ underbody bolts to
36 lb.ft.
7. Torque lower control arm to
Axle housing bolts to
18
Ib.ft. on the GT and 22 lb.ft. dn the Opel 1900 and
Manta.
8. Torque track rod to rear axle attaching nut to
40lb.ft. on the GT and to 76
lb.ft. on the Opel 1900 and
Manta and remove added weight.
9. Install shock abosrbers and tighten nuts to 15
Ib.ft.on the GT and to 47
Ib.ft. on the Opel 1900 and
Manta.10. If car is equipped with stabilizer rod, connect
shackles to axle housing. Tighten to 25 lb. ft.
11. Connect brake hose to brake pipe and install
retaining clip.
12. Thread parking brake cable over exhaust system
and connect to lower control arm brackets, parking
brake actuating lever and brake backing plate. Install
brake drum.
13. Align mating marks and connect propeller shaft
to pinion flange. Tighten universal joint attaching
bolts to 11
Ib.ft. Bend respective lock plate tabs to
secure nuts or bolts.
14. Connect parking brake cable equalizer and return
spring to brake rod and adjust to specifications.
15. Bleed rear brake system and fill master cylinder.
16. Install wheel assemblies and tighten lug nuts to
65
lb.ft.17. Remove jack stands and lower car to the floor.
REMOVAL AND INSTALLATION OF AXLE SHAFT
ASSEMBLY
Removal1. Raise and support rear of car at jack brackets.
2. Remove wheel and brake drum as necessary.
3. Unscrew rear axle shaft retaining plate and with
axle shaft puller J-8805 coupled with slide hammer
J- 2619 on axle shaft flange, remove axle shaft.
4. For replacement of the bearing parts, first remove
retaining ring by cutting off with a chisel. See Figure4B-3.
5. Press off bearing, using rear pinion bearing
remover J-22912.
Installation
CAUTION: Fasteners in the following steps b are im-
portant attaching parts in that they could at&t
tee
performance of vital components and systems, and-
/or could result in major
repair expense.They must
be replaced with one of the same part number or with
an equivalentpart ifreplacement becomes necessary.
Do not use a replacement part of lesser quality or
substitute design Torque values must be used as
specified
during reassembly to assure proper reten-
tion of these parts.1. Check radial runout of axle shaft at ball bearing

REAR AXLE40- 11
Figure
48-3 Removing Axle Bearing Retaining Ring
seat and lateral runout of axle shaft flange near larg
est diameter.
Permissible radial runout is .002”, and permissible
“lateral runout is
.OO4”. An axle shaft which exceeds
these tolerances, or one which has been otherwise
damaged during removal, must be replaced.
2. Using installer ring J-21721-2, press on bearing so
that oil seal groove on bearing faces shaft splines.
3. Using installer ring J-21721-2, press on retainer
ring so that shoulder faces bearing.
Figure 48.4 Measuring for Axle Shaft Bearing Depth4. Check axle shafts end play as follows:
a. Using a depth gauge, measure depth of rear axle
bearing seat in axle housing (backing plate and gas-
kets in place). See Figure
4B-4.b. Measure width of bearing outer race. The differ-
ence between the two measurements indicates the
required thickness of the shims. The maximum per-
missible end play is .002”. If necessary to reduce end
play, add
,004” shims behind bearing as necessary. A
slight crush fit (up to ,006”) is desirable.
5. Coat rear axle shaft splines with hypoid gear lubri-
cant prior to installation.
6. Insert axle shaft into housing; using a mallet, drive
axle shaft completely into housing.
7. Install lock washers and nuts. Torque to 20
Ib.ft.8. Install brake drum and wheel assembly.
9. Remove supports and lower rear of car to floor.
DISASSEMBLY AND ASSEMBLY OF THE
DIFFERENTIALRemoval and installation of parts for service de-
scribed in the following sub-paragraph can be per-
formed with the rear axle assembly in the car. The
car must be raised and adequately supported to per-
mit access to the parts to be serviced.
Removal and Disassembly of Differential Case1. With car suitably supported at rear jack bracket
on each side, remove differential cover bolts and let
lubricant drain into suitable container.
2. Disconnect left end of track rod and wire to left
shock absorber.
3. Remove both rear wheels and brake drums.
4. Working through access holes in axle shaft flange,
remove four nuts and washers that retain the axle
shaft dust shield and brake backing plate to the axle
housing.
5. Unscrew rear axle shaft retaining plate.
6. Install axle shaft puller J-8805 coupled with slide
hammer J-2619 on axle shaft flange to remove rear
axle. In removing axle shaft, care should be exercised
to avoid damage to the oil seal. See Figure
4B-5.7. Remove differential cover and discard gasket.
8. Check and record ring gear backlash.

48. 16
1973 OPEL SERVICE MANUAL
protruding to install the pinion preload nut. Do
not use Installer J-22938 to adjust pinion preload.
See Figure 4B-20.
Assembly and Installation of Differential Case.
Opel 1900 and Manta1. Install side gears without thrust washers or shims.
BARREL SPLINE2. Lubricate and install pinion gears and thrust
washers between the side gears 180 degrees apart and
rotate the gears as an assembly until the pinion gear
bores are aligned with the pinion shaft bores in the
case.3. Install pinion shaft.
4. Install Special Tool J-24093 and, with the use of
a dial indicator, check end play clearance between
side gear and case as follows:
40-20a. Zero dial indicator on end of Tool J-24093. See
Figure 4B-22.
Figure 48.20 Installing Barrel Spline Sleeve
When the drive pinion end play is eliminated, the
preload specification is being approached. If this
specification is exceeded, replace the collapsible
spacer.10. Remove installer J-22938 and install washer and
pinion preload nut. Using Special Tool J-22932, hold
barrel spline and tighten preload nut until a preload
of 6-13
Ib.in. (9 Ibin. desired) with new bearings or
5-8
Ib.in. (6 lb.in. desired) with used bearings is re-
quired to rotate the drive pinion.
11. Use J-2293 1 to install a new pinion oil seal that
has been soaked in differential lubricant. See Figure4B-2
1.Figure 48.22 Zeroing Dial
lndicatotb. Using both hands, raise side gear until it bottoms
against case and record dial indicator reading. See
Figure 4B-23.
c. Measure the thickness of the concave thrust
washer by using a
0” to 1’ micrometer and subtract
this dimension from the dial indicator reading as
obtained in step b. Record dimension. See Figure
4B-24.
/INSTALLER J-22931d. After obtaining a dimension by subtracting con-48-21cave thrust washer thickness from dial indicator
reading, subtract an additional
,002 to obtain the
Figure 46.21 Installing Pinion Oil Sealcorrect shim thickness to be installed.

48. 221973 OPEL SERVICE MANUAL
9. Position
case assembly and outer races in the car-
rier. Use a soft-faced hammer to drive the case into
the carrier until the side bearing outer races bottom
in their bores.
10. Install side bearing caps in their original location
and torque the bolts to 33
lb.ft.IN. LB. TORQUL
11. Rotate case assembly several times to seat the
bearings. Check backlash and preload using a torque
wrench on a ring gear attaching bolt. See Figure 4B-
35. Torque required to turn case should be 20 to 30
Ib.in. for new bearings or 10 to 20 lb.in., for used
bearings. If torque is not correct, it will be necessary
to r&him the side bearings.
12. Insta!l torque tube assembly.
13. Install axle shafts.Figure 48.35 Checking Side Bearing
Preload
SPECIFICATIONS
DIFFERENTIAL SPECIFICATIONS
General SpecificationsRear Axle Type
.,,...,,,...,,_...._..,,...,,,...,,,....,,.,...,,.,,...,,..,,,........................ Semi-Floating Hypoid
Rear Axle Oil Capacity
..____,,...,,,...,.,..,............,,..,,..,,................................................. 2 l/2 7’.Ring and Pinion Gear Set Type
. . . . . . . . . . . . . . . . . .._................................................................Hypold
Axle Ratios