OPEL GT-R 1973 Service Manual

I4I
.7C.140 .1973 OPEL SERVICE MANUAL
J-7004-1SLIDE HAMMER
J-2291 3MAIN SHAFT ASSEMBLY TOOL
J-22929SPEEDOMETER DRIVEN GEAR
REMOVER AND INSTALLER
J-22922J-22926TRANSMISSION CASE EXTENSIONSPEEDOMETER DRIVEN
HOUSING SEAL INSTALLERGEAR PIN REMOVER
J-21715DETENT PIN PLUG REMOVER
J-22934CLUTCH PLATE ALIGNING ARBORTRWARC PLIERS
J-22923REVERSE IDLER SHAFT REMOVER
J-2291 I
J-21 684NEEDLE BEARING LOADER
BEARING PRESS PLATE7&56
Figure
7C-235 Special Tools. Manual Transmission

HOOD,
FENDERS,
AND
GRILLEGROUP 8I ISectionI IPage No.1
8A1 Grille’. 1 814-2 (Hood Fenders, and

8A-2 1973 OPEL SERVICE MANUAL
HOOD, FENDERS, AND GRILLE
CONTENTS
Subject
DESCRIPTION AND OPERATION:
GTHeadlampOperation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS
GTHeadlampMechanism
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Removal and Installation
Hood (1900
- Manta). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fender(1900-Manta). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlamp Covering (1900
- Manta). . . . . . . . . . . . . . . . . . . . . . . .Headlamp Assembly
(GT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlamp
CableAssembly(GT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grille
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS: (Not Applicable)
DESCRIPTION AND OPERATION
DESCRIPTION AND OPERATION OF GT
HEADLAMP MECHANISMThe concealed headlamps are moved mechanically.
Pushing actuating lever on left side of console opens
headlamps, pulling lever closes headlamps. Two
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 head-
lamps in closed position the headlamp housing is
flush with front sheet metal.
A white indicator lamp in the instrument panel lights
if the headlamps are not completely opened and
locked. The switches of the headlamp electrical sys-
tem are located behind the left headlamp operating
mechanism.
MAINTENANCE AND ADJUSTMENTS
ADJUSTMENT OF HEADLAMP MECHANISMBoth headlamp assemblies must operate in unison in
order to lock in either the open or closed position.
Page No.
8A-2
8A-2
8A-3
8A-3
8A-4
8A-4
8A-6
8A-61. Adjust headlamps to be parallel in any position by
changing length of right headlamp operating rod.
For adjustment loosen clamp bolt (A). See Figure
8A-1.Figure
8A-l Headlamp Operation Adjustments

HOOD, FENDERS, AND GRILLE8A- 3
2. Adjust headlamps to lock or unlock simultane-
ously by adjusting lock nut (B). See Figure EA-1.3. Adjust headlamp assembly in opening as follows:
a. To align front of assembly vertically or horizon-
tally, loosen bolts indicated (A) in Figure 8A- 2.
b. To align front of assembly longitudinally, loosen
lock nut (B) in Figure 8A-2 and bolts marked (B) in
Figure
8A-3.c. To align rear of assembly vertically loosen bolts
indicated (A) in Figure
8A-3.MAJOR
REPAIR
REMOVAL AND INSTALLATION OF HOOD1. With a pencil, mark hinge positions on engine
hood. See Figure
SA-4.Figure EA.2 Headlamp Assembly Front Adjustment
LocationFigure
CIA-3 Headlamp Assembly Rear AdjustmentLocationFigure
CIA-4 Marking Hinge Position
2. Unscrew engine hood bolts from hinges. Hood
must be aligned so that the distances to the
adjacent surfaces are almost equal all around.
REMOVAL AND INSTALLATION OF FENDER
(OPEL 1900. MANTA)
1. Remove and install front bumper.
2. Remove and install radiator grille.
3. Remove and install headlamp covering.
4. Remove and install side panel trim pad.
5. Remove and install hood catch.
6. Remove and install rubber bumper (hood rest).
7. If required, remove and install direction signal
lamp.
8, Unscrew attaching bolts at fender circumference
and remove fender. See Figure
8A-5.

8A.41973 OPEL SERVICE MANUAL
Figure SA-5 Location of Fender Attaching Bolts
9. Fit new fender and apply a sealing compound, as
required, to joint. See Figure
SA-6.Figure 8A-6 Sealing Location
10. Coat fender inside with a dampening compound.
REMOVAL AND INSTALLATION OF HEADLAMP
COVERING (OPEL
1900. MANTA)
Removal1. Remove radiator grille.2. In engine compartment unscrew headlamp cover-
ing.
Se:e Figure SA-7.Figure 8A-7 Headlamp Covering Attaching Bolts
Installation1. Install headlamp covering. See Figure
SA-7.2. Install radiator grille.
REMOVAL AND INSTALLATION OF HEADLAMP
ASSEMBLY
(GT)1. Move headlamp to open position and remove
headlamp cover. See Figure
SA-8.Figure EA.8 Removing Headlamp Cap

HOOD, FENDERS, AND GRILLEBA- 5
2. Remove headlamp assembly and remove multiple
plug from wire set.
3. Disconnect Bowden control wire(B). Loosen link-
age at the clamp screw (A) and disconnect linkage in
direction of arrows. See Figure SA-9.Figure EA.9 Disconnecting Linkage
4. Mark support plate at its circumference and
remove it. The marking facilitates the adjustment on
reinstallation. See Figure
SA-2.5. Mark swivel plate at its circumference and remove
it. See Figure
8A-3.Figure EA.10 Removing Headlamp Assembly6. To avoid damage cover headlamp upper and lower
edges with tape.
Turn headlamp 90 degrees and carefully remove
headlamp housing in direction of arrow. See Figure
8A-10.7. Through access hole on fender underside, remove
the two attaching screws and the screw at the upper
deflector panel. See Figure
8A-11.Figure EA.1 1 Locking Mechanism Attaching Screws
8. Prior to removing, mark the individual single
plugs (left headlamp only) and remove lock assem-
bly. See Figure
8A-12.Figure EA.1 2 Headlamp and Headlamp Indicator
Switches

8A-61973 OPEL SERVICE MANUAL
9. On installation make sure that the gaps between
headlamp housing in closed position and headlamp
opening is equal all round and housing is flush in its
height with the body.
REMOVAL AND INSTALLATION OF HEADLAMP
CABLE ASSEMBLY
Removal1. Remove cotter pin. See Figure
EA-13 “CL”2. Remove trunion block and nut. See Figure SA-13
“D.”
3. Remove outer adjusting nut and pull cable
through bearing. See Figure 8A-13 “B.”
4. Pull cable through front chassis support.
5. Hoist car.
6. Remove wire clip and unsnap ball seat at control
lever. See Figure 8A-14 “A.”
7. Remove ball-socket and lock nut. See Figure SA-
14
“B.”8. Remove rear adjusting nut. See Figure 8A-14
“CL”9. Remove cable from retainers.
Figure SA-13 Removing Headlamp Trunion Block
Installation10. Thread cable through bearing and clip retainers.Figure 8A-14 Removing Ball Seat at Control Lever
11. Install adjusting lock nut approximately
l/2” on
thread. See Figure 8A-13 “B.’
12. Install lock nut and ball stud on end of cable. See
Figure 8A-14 “B.”
13. Connect ball stud to control lever with clip. See
Figure 8A-14 “A.”
14. Adjust lock nut under vehicle for maximum cable
length. See Figure 8A-14
“CL”15. Thread cable through proper openings in body
and install adjusting lock nut, trunion lock nut, trun-
ion, and lock clip.
16. Adjust cable length for proper headlight operat-
ion.
REMOVAL AND INSTALLATION OF RADIATOR
GRILLE
(GT)
RemovalRemove screws securing grille screen to opening.
InstallationInstall grille screen to opening and secure with
screws.
REMOVAL AND INSTALLATION OF
RADIATOR GRILLE EXTENSIONS
(GTI
Removal
1. Remove hex head screw and washer holding grille
extension to baffle plate.

HOOD, FENDERS, AND GRILLE8A- 72. Remove two plastic caps and phillips screws from
outer end of grille extension.
3. Remove grille extension,
Installation1. Install grille extension and secure with Phillips
screws and two (2) plastic caps.
2. Install hex head screw and washer holding grille
extension to baffle plate.
REMOVAL AND INSTALLATION OF RADIATOR
GRILLE
(OPEL 1900. MANTA)
A. Removal (Model 57)1. Remove the
five (5) radiator grille attaching
screws. See Figure
8A-15.Figure 8A-15 Radiator Grille Attaching Screws
2. Remove radiator grille towards the top so that the
lower guide pins do not break off. See Figure 8A- 16.Figure 8A-16 Removing Radiator Grille
Installation (Model 57)
1. Install radiator grille, aligning guide pins into
lower panel. See Figure
8A-16.2. Secure grille with five (5) attaching screws. See
Figure 8A-2.
Removal (Models 51.53, and 54)
1. Remove the three (3) radiator grille attaching
screws. See Figure
8A-17.Figure 8A.17 Location of Radiator Grille AttachingSCWWS
2. Remove radiator grille towards the top SO that the
lower guide pins do not break off.

GROUP 9
ACCESSORIESSectionTitlePage No.HEATER
9AGT,9A-2Opel
1900-Manta. 9A- 10
AIR CONDITIONING
Refrigerant
Components9B- 179B
Air Conditioner System
Opel
1900~Manta.9B- 90
Air Conditioner System
GT.
OB- 97
RADIO
9cGT..............9c-105Opel
1900~Manta. PC-109