heater OPEL GT-R 1973 Owner's Guide

HEATER SYSTEM. OPEL 1900. MANTA9A- 15
Figure 9A-4 1 Bowden Wire Attachment
Figure SA-42 Control Wire
to Distribution? DoorAttachmentA
- Yellow Wire
B
- Grey Wire
C
- Brown Wire
6. Remove heater control housing.
Installation1. Install heater control housing,
2. Install wires onto blower switch. See Figure 9A-
53.Figure 9A-43 Blower Switch Wires
A
- Yellow Wire
B
- Grey Wire
C
- Brown Wire
3. Attach bowden control wire to air distribution
flap. See Figure 9A-42.
4. In engine compartment, attach bowden control
wire to heater valve. See Figure 9A-41.
5. Install two (2) sheet metal screws for control hous-
ing attachment. See Figure 9A-40.
6. Install instrument panel cover.
7. Adjust bowden control wires.
REMOVAL AND INSTALLATION OF HEATER
MOTOR
1. In engine compartment, remove five (5) shroud
cover attaching screws. See Figure 9A-44.
2. Carefully remove cover
3. Pull water hose off windshield wiper jet.
4. Disconnect wires to heater motor. For this pur-
pose, disconnect multiple plug connection on left
side of shroud. See Figure 9A-45.
5. Remove three (3) heater motor attaching screws.
See Figure 9A-46.
6. Take off motor.

9A-16 1973 OPEL SERVICE MANUAL
Figure 9A-44 Shroud Cover AttachmentsFigure 9A-46 Heater Motor Attaching Screws
Figure 9A-45 Heater Motor Wires
InstallationFigure 9A-47 Sealing Shroud
1. Install heater motor, attaching with three (3)
screws. See Figure 9A-46.
2. Connect multiple plug on left side of shroud. See
Figure 9A-45.3. Seal shroud cover front and rear contacting areas
with sealing cement. See Figure 9A-47.
4. Install shroud cover, attaching with five (5)
screws.SPECIFICATIONS
EngineRecommended Coolant
..........................................................................Ethylene-Glycol Base
ThermostatOpensAt(Degrees)
F.......................................................................................189Cooling System Capacity (With Heater)
..........................................................................6 Qt.
Blower Motor Type
......................................................................................................12 VDC
Blower Fan Type
..............................................................................................................Blade
Numberof FanBlades
..............................................................................................................7

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.

System controls are the AIR knob controlling the
three speed blower motor switch and the TEMP
knob which controls the setting of the thermostatic
switch. When operating this system, the heater must
be off for maximum cooling.DIAGNOSIS
TROUBLE DIAGNOSIS GUIDE
Air Knob
Insufficient CoolingTurning the AIR knob clockwise operates the three-
speed blower motor.CHECK AIR FLOW9B-90 1973 OPEL SERVICE MANUAL
AIR CONDITIONER SYSTEM
OPEL 1900
- MANTA
CONTENTS
Subject
DESCRIPTION AND OPERATION:
General Description of System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...”Operation of Controls
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .DIAGNOSIS:
DiagnosisGuide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..“................... . . . . . . . . .MAINTENANCE AND ADJUSTMENT:
Adjustment of Thermostatic Switch
. . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Removal81InstallationBlowerSwitch. . . . . . . . . . . . . . . . . . . . . .Page No.
9B-90
9B-90
9B-90
9B-91
98-92Removal
& Installation Temperature Control Switch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal
& Installation Resistor Assembly. . . . . . . . . . . . . .Removal
& Installation Blower Motor Assembly . .
SPECIFICATIONS:
Specifications
.,...,,.,,..~.,.,..,,......,.,....,.,........,......,........ ,, . . . . . . .
98-92
98-92
98-92
98-96
DESCRIPTION AND OPERATION
GENERAL DESCRIPTION OF SYSTEMThe air conditioner is intended to give maximum
cooling comfort within the vehicle. To do this, care-
ful attention must be given to the following Sections.
The system operates on recirculated air only and is
entirely independent of the vehicle heater.
Temp KnobThis knob may be regulated to control the degree of
cooling desired. Fully clockwise provides maximum
cooling; however, turning the knob to the center de-
tent position provides adequate cooling for highway
operation.
When maximum cooling is required, outside air
should not be admitted to the car.
Recirculated inside air is drawn into the unit, passed
through the evaporator core and into the car through
the adjustable outlets in the evaporator case.
Operation of ControlsWhen the unit is set for maximum cooling and the
vehicle is being driven continuously at highway
speeds or at elevations of
4,OOC!ft. or more, there is
a possibility of the formation of ice on the evaporator
core fins.

AIR CONDITIONER SYSTEM - GT96. 97
AIR CONDITIONER SYSTEM
GTCONTENTS
Subject
: DESCRIPTION AND OPERATION:
General Description of System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation of Controls
. . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS:
Diagnosis Guide
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAINTENANCE AND ADJUSTMENTS:
Adjustment of Thermostatic Switch
. . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Removal 8 Installation of Vacuum Switch.
Removal&InstallationBlowerSwitch. . . . . . . . . . . . . . . . . . . . . .Removal & Installation Temperature Control Switch
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . .
Removal&InstallationResistor Assembly. . . . . . . . . . . . . .Removal & Installation Blower Motor Assembly . .
SPECIFICATIONS:
Specifications
. . .
. . . . . . . . * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page No.
9BL 97
9Bi 97
9BL 98
98: 98
9B: 99
9B; 99
9B- 99
98~10098-101
9B-104
DESCRIPTION AND OPERATIONAir Knob
GENERAL DESCRIPTION OF SYSTEMTurning the AIR knob clockwise operates the three-
speed blower motor.
The air &mditioner is intended to give maximum
cooling comfort within the vehicle. To do this, care-
ful attention must be given to the following sections.
The system operates on recirculated air only and is
entirely @dependent of the vehicle heater.Temp Knob
Recirculated inside air is drawn into the unit, passed
through the evaporator core and into the car through
the adjustable outlets in the duct assembly.This knob may be regulated to cohtrol the degree of
cooling desired. Fully clock-wise provides maximum
cooling; however, turning the kndb to the center de-
tent position provides adequate cooling for highway
operation.
CONTROLSWhen maximum cooling is reqlired, outside air
should not be admitted to the car.
System c&trols are the AIR knob controlling the
three
spe&d blower motor switch and the TEMPWhen the unit is set for maximum cooling and the
vehicle is being driven continuously at highway
knob which controls the setting of the thermostaticspeeds or at elevations of 4,000 ft. or more, there is
switch. When operating this system, the heater musta possibility of the formation of ice on the evaporator
be off for maximum cooling.core tins.

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