tire pressure OPEL GT-R 1973 Owner's Manual

98-32 1973 OPEL SERVICE MANUAL
inserting it in the connection. Another precaution -inspect the fitting for burrs which can cut the
“0”ring.
Restrictions
Restrictions may be due to powdered desiccant or
dirt and foreign matter. This may result in starved
evaporator and loss of cooling, or a seized compres-
SOT.When the amount of moisture in a system sufti-
ciently exceeds the capacity of the desiccant, it can
break down the desiccant and cause it to powder.
The powder passes through the dehydrator screen
with the refrigerant liquid and is carried to the ex-
pansion valve screen. While some of it may pass
through the valve screen into the evaporator, it may
quickly build up to cause a restriction.
Due to the fact that sufftcient oil can not be returned
to the compressor, it may seize.
Dirt
Dirt, which is any foreign material, may come from
cleaner residues, cutting, machining, or preserving
oils, metal dust or chips, lint or dust, loose rust,
soldering or brazing fluxes, paint or loose oxide
scale. These can also cause seized bearings by abra-
sion or wedging, discharge and expansion valve fail-
ure, decomposition of refrigerant and oil, or
corrosion of metal parts.
CorrosionCorrosion and its by-products can restrict valve and
drier screens, rough bearing surfaces or rapid fatigu-
ing of discharge reeds. This can result in high tem-
perature and pressure, decomposition or leaks. In
any event, this means a wrecked compressor.
From this, we can see the vicious circle that can be
produced in a refrigerating system to cause its fail-
ure. Corrosion can be the indirect cause of leaks, and
leaks can be the direct cause of corrosion. We can
also see the important role we as servicemen play in
maintaining chemical stability.
The major cause of corrosion is moisture.
Moisture
Moisture is the greatest enemy of refrigerating sys-
tems. Combined with metal, it produces oxide, Iron
Hydroxide and Aluminum Hydroxide. Combined
with R-12 it produces Carbonic acid, Hydrochloric
acid, and Hydrofluoric acid. Moisture can also cause
freeze-up of expansion valve and powdered desic-
cant.Although high temperature and dirt are responsible
for many difficulties in refrigerating systems, in most
instances it is the presence of moisture in the system
that accelerates these conditions. It can be said,themfore, that moisture is the greatest enemy of all.
The acids that it produces, in combination with both
the metals and the refrigerant, cause damaging
COT-
rosion. While the corrosion may not form as rapidly
with R-12 as with some other refrigerants, the even-
tual formation is as damaging.
If the operating pressure and temperature in the
evaporator is reduced to the freezing point, moisture
in the refrigerant can collect at the orifice of the
expansion valve and freeze. This temporarily re-
stricts the flow of liquid causing erratic cooling.
As previously mentioned, moisture in excess of the
desiccant’s capacity can cause it to powder.
YOU SHOULD KNOW AND REMEMBER..That the inside of the refrigerat,ion system is com-
pletely sealed from the outside world. And if that
seal remains broken at any point
- the system will
soon be destroyed. That complete and positive seal-
ing of the entire system is vitally important and that
this sealed condition is absolutely necessary to retain
the chemicals and keep them in a pure and proper
condition.
That all parts of the refrigeration system are under
pressure at all times, whether operating or idle, and
that any leakage. points are continuously losing re-
frigerant and oil.
That the leakage of refrigerant can be so silent that
the complete charge may be lost without warning.
That refrigerant gas is heavier than air and will rap-
idly drop to the floor as it flows from a point of
leakage.
That the pressure in the system may momentarily
become as high as 400 lbs. per square inch, and that
under such pressure the molecules of refrigerant are
forced out through the smallest opening or pore.
That the compressor is continually giving up some
lubricating oil to the circulating refrigerant and de-
pends upon oil in the returning refrigerant for con-
tinuous replenishment. Any stoppage or major loss
of refrigerant will therefore be fatal to the compres-
SOT.That the extreme internal dryness of a properly proc-
essed system is a truly desert condition, with the
drying material in the receiver holding tightly on to
the tiny droplets of residual moisture.

REFRIGERANT COMPONENTS ALL MODELS9s. 41
BIower Operating Normal Check for the following:Restriction or leakage in air ducts, A/C outlets not
opening.2. Do not carry cylinder in passenger compartment
of car.3. Do not subject cylinder to high temperatures.
MAINTENANCE AND ADJUSTMENTS4. Do not weld or steam clean on or near cylinder.
5. Do not fill cylinder completely.
GENERAL SERVICE INFORMATION AND SAFETY
PRECAUTIONS6. Do not discharge vapor into area where flame is
exposed or directly into engine air intake.
General InformationAll subassemblies are shipped sealed and dehy-
drated. They are to remain sealed until just prior to
making connections, and should be at room tempera-
ture before uncapping. This prevents condensation of
moisture from air that enters the system.
All precautions should be taken to prevent damage
to fittings or connections. Even minute damage to a
connection could cause it to leak. Any fittings with
grease or dirt on them should be wiped clean with a
cloth dipped in alcohol.
Do not clean fitting or hoses with solvents because
they are contaminants. If dirt, grease or moisture
gets inside the pipes or hoses and cannot be removed,the pipe or hose is to be replaced. Use a small amount
of clean refrigeration oil on all tube and hose con-
necting joints, and lubricate the
“0” ring gasket with
this oil before assembling the joint. The oil will help
in effectitig a leak-proofjoint and assist the
“0” ring
to slip into the proper location without being cut or
damaged. Always use new
“0” rings.
When tightening joints, use a second wrench to hold
the stationary part of the connection to prevent
twisting and to prevent hose kinking. Kinked hoses
are apt to transmit noise and vibration. Tighten all
connections in accordance with recommended
torques (see Division VI, Specifications).7. Do not expose eyes to liquid
- WEAR SAFETY
GOGGLES whenever discharging, charging or leak
testing system.
CHARGING AND DISCHARGING SYSTEMRemoval of any part in the refrigerant circuit will
require discharging of the entire system.
Discharging the System1. Remove caps from gauge fittings on the compres-
sor adapter fitting on the compressor.
2. With both valves on manifold gauge set (J-5725-
04) closed (clockwise), attach manifold to the com-
pressor adapter fitting on the compressor, using
J-5420 valve adapter at suction gauge fitting and
J-9459 valve adapter at discharge gauge fitting. See
Figure
9B-41.3. Fully open high pressure valve on manifold gauge
set to allow escape of refrigerant from system
through the manifold gauge set and out the center
fitting and hose. (Place end of hose in clean container
to collect oil loss due to rapid discharge of system).
4. When hissing ceases, indicating all refrigerant
has escaped, close high pressure valve on manifold
gauge set by turning valve clockwise.
Do not connect receiver-dehydrator assembly until
all other connections have been made. This is neces-
sary to itisure maximum moisture removal from sys-
tem.It is important that air conditioning hoses do not rest
on or contact body sheet metal except where neces-
sary. Because of the high frequency at which the
compressor operates, the passenger compartment is
susceptible to transfer of noise.
Evacuating the SystemWhen the refrigeration system is depressurized and
opened for service, some air will enter the lines, re-
gardless of how quickly openings are capped. In
or-der to remove this air and as much as possible of the
moisture it contains, the complete system must be
evacuated. Evacuating is merely the process of
removing all air from the system, thereby creating a
vacuum in the system.
Safety PiecautionsThe following safety precautions should always be
followed~,when servicing refrigerant charged compo-nents:Under no circumstances should alcohol be used in
the system in an attempt to remove moisture,
regard-less of the successful use of alcohol in other refrigera-
tion systems.
Preparations for Evacuating Complete System
1. Do not leave Refrigerant-12 cylinder uncapped.
1. Check the low pressure gauge for proper calibra-

98-48 1973 OPEL SERVICE MANUALCondition3. Compressor being
replaced with a ser-vice replacement
compressor major
oil loss evident.
Amount of Oil Drained
From Compressora. More than 4 oz.Amount of 525 Oil to Install
In Compressor
a.
Same amount as drained from
compressor being replaced.4. Compressor being
rebuilt or repaired
-no major oil loss
evident.b. Less than 4 oz.
a. More than 1
l/2 oz.b. Install 6 oz.
a. Same amount a.s drained from
compressor, plus
1 oz. additional.
5. Compressor being
rebuilt or repaired
major loss of oil
evident.b. Less than 1
l/2 oz.
a. More than 4 oz.b. Install 7 oz.
a. Same amount as drained from
compressor, plus 1
ozadditional.If foreign material is noted in oil drained from sys-
tem or evidence of moisture is obvious in the compo-
nents removed, it is recommended that the entire
system be flushed and the receiver-dehydrator be
replaced. A full oil charge of 10 oz. of 525 viscosity
refrigeration oil should be replaced in the system. It
should be noted that all service replacement com-
pressors will be supplied with 10 pz. of oil. In most
cases it will be necessary to drain oil from service
replacement compressor and refill it with amount as
specified in the Oil Replacement Table.filter screen on the expansion valve should be re-
placed. If the evaporator assembly is flushed while
installed in the car, the temperature bulb on the
evaporator outlet pipe must be disconnected to keep
the expansion valve from closing at the inlet source.
FLUSHING THE SYSTEMIt is recommended that dry nitrogen be used as a
flushing agent due to the low cost involved. In addi-
tion, dry nitrogen will not cause a temperature drop,
as in the case of refrigerant-12, which results in
thickening of refrigerant oil. Dry nitrogen has the
additional advantage of removing moisture from thesystem.Flushing of the system may involve all the compo-
nents of the system or individual components in the
system. The components may be flushed while
mounted in the engine compartment or may be
removed for flushing. When a component is not
removed, disconnect all refrigerant lines or hoses
attached to component. To perform flushing operat-
ion, connect a cylinder of refrigerant-12 to the com-
ponent to be flushed, ,then invert the cylinder and
open the cylinder valve so that the liquid refrigerant
pours out and through the component. When liquid
Refrigerant-12 reaches atmospheric pressure, it im-
mediately drops to minus 21.7 degrees F. Insure that
area immediately surrounding outlet of component is
clear of anything that may be damaged by contact
because of the sudden drop in temperature.MAJOR REPAIR
REMOVAL AND INSTALLATION OF
COMPRESSOR
- OPEL 1900 - MANTA
Removal
I. Remove negative battery cable from battery.
2. Remove air cleaner and heat pipe. Cover the
carburetor to keep out dirt etc.
3. Discharge system. Refer to DISCHARGING
SYSTEM.
In all cases where a complete system flushing operat-4. While system is discharging remove sheet metal
ion is performed, the receiver-dehydrator and thecover. See Figure
9B-50.

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