OPEL GT-R 1973 Service Manual

96-52 1973 OPEL SERVICE MANUAL
REMOVAL AND INSTALLATION OF EVAPORATOR
AND EXPANSION VALVE. OPEL 1900 - MANTA
Removal
1. Remove negative battery cable from battery.
2. Remove left side of distributor duct, and in line
fuse. See Figure
9B-61.3. Remove glove box. See Figure
9B-62.Figure 96-64 Delay Restrictor
and Check Valve Hose
Assembly Location
5. Disconnect the delay restrictor and check valve
hose assembly from the vacuum cut-off switch and
disconnect the electrical wiring. See Figures 9B-63
and 64.
6. Remove evaporator inlet and outlet pipes re-
tainer and rubber grommet. See Figure
9B-65.Figure
98.62 Glove Box Removed
4. Discharge refrigerant from system. (Refer to
DISCHARGING SYSTEM) and disconnect refrig-
erant hose from evaporator outlet and pipe from
evaporator inlet and tape the open ends of the refrig-
erant lines and evaporator pipes. See Figure
9B-63.Figure
98.65 Inlet and Outlet Pipes retainer and
Rubber Grommet-Opel 1900 - Manta
Figure
98.63 Location of Refrigerant Hoses, Pipes,
Vacuum Cut Off Switch and Evaporator Attaching Bolt
(Left Side) - Opel 1900
- Manta

REFRIGERANT COMPONENTS ALL MODELS9B- 537. Remove two (2) upper evaporator attaching nuts.
See Figures 9B-66 and 9B-67.
8. Remove two (2) attaching case mounting bracket
to instrument panel screws. See Figure
9B-67.Figure
98.67 Evaporator and Blower Assembly
Brackets and Attachments - Opel 1900 - Manta
Figure :9B-68 Evaporator and Blower Assembly
Center Support Bracket-Opel 1900 Manta
CASE ATTACHING
SCREFINGER GUARD
Figure
98.69 Assembly Removed - Opel 1900
Manta9. From underneath evaporator case, disconnect
two (2) drain hoses.
10. Carefully remove assembly from car. See Figure9B- 69.
11. Disconnect resistor electrical connector and
remove resistor assembly. See Figure
9B-69.12. Remove blower case and blower motor attaching
screws and remove assembly. See Figure
9B-69.13. Remove all remaining attaching screws and
remove evaporator assembly. See Figure
9B-70.Figure
98.70 Evaporator and Expansion Valve
Assembly
- Opel 1900 Manta
14. Disconnect expansion valve capillary tube bulb
attached to the outlet pipe of the evaporator. See
Figure
9B-70.15. Disconnect inlet and outlet ends of expansion
valve from refrigerant lines, and tape closed open
ends of refrigerant lines and inlet and outlet ports of
expansion valve.
Installation
If expansion valve or refrigerent lines have been ex-
posed to the atmosphere for any amount of time and
moisture may have entered the valve or the system,
flush the system and install new receiver-dehydrator
or valve as necessary.
Due to the possible adjustment difficulties involved
if the expansion valve is disassembled, disassembly of
the valve is not recommended. The valve may be
cleaned by submerging it in a bath of trichlorethy
lene, alcohol, or similar solvent. Dry by blowing fil-tered compressed air through the outlet port of the

96-54 1973 OPEL SERVICE MANUAL
valve. The filter screen at the inlet port may be re-
placed. Remove screen by threading a lo-32 NF
screw into old filter screen. With a washer and a nut
on the screw arranged to work as a puller screw, hold
the body of the screw and turn the nut. Insert the
new filter screen into the inlet port and lightly tap
screen only enough to seat.
1. Install expansion valve using new o-rings during
installation. Lubricate o-rings prior to installation
using No. 525 viscosity oil.
2. Install evaporator assembly and case attaching
screws. See Figure 9B-70.3. Install blower motor assembly into case and se-
cure with attaching screws. See Figure
9B-69.4. Install finger guard shields and fan housing case.
See Figure
9B-69.5. Install resistor assembly and electrical connector.
Install blower motor connector. See Figure
9B-69.6. Install assembly into car carefully guiding
evaporator pipes up through cowl opening. See Fig-
ure
9B-71.Figure 93-7 1 Inlet and Outlet Pipes and O-Rings
-Opel 1900 Manta
7. Install two (2) upper attaching evaporator at-
taching nuts. See Figures 9B-66 and
9B-67.8. Install two (2) attaching case mounting bracket
to instrument panel screws. See Figure
9B-67.9. Connect two (2) drain hoses underneath evapora-
tor.10. Install evaporator inlet and outlet pipes retainer
and rubber grommet. See Figure
9B-65.11. Connect vacuum cut-off switch and electrical
wiring, making sure the delay restrictor and checkvalve hoses are installed correctly. See Figures
9B-63and 64.
.gB-72 Delay Restrictor and Check Valve Hose.Assembly
12. Install refrigerant hoses and pipes using new
o-rings on line fittings and evacuate system. Refer to
EVACUATING SYSTEM.
13. While system is being evacuated, install in-line
fuse and left side of distributor duct. See Figure 9B-
61.14. Install glove box.
15. Install negative battery cable and charge system.
Refer to CHARGING SYSTEM.
REMOVAL AND INSTALLATION OF CONDENSER
ASSEMBLY -OPEL 1900. MANTA
Removal
1. Remove negative battery cable from battery.
2. Remove air cleaner.
3. Discharge system. Refer to DISCHARGING
SYSTEM.
4. While system is discharging, remove lower radia-
tor hose from radiator and drain coolant into a suita-
ble container.
5. Remove fan shroud.
6. On vehicles with automatic transmission, un-
screw oil lines from connectors on lower radiator
tank and plug lines. It is essential that no dirt enters
the oil lines. When unscrewing oil lines, hold connec-
tors on lower radiator tank with pliers to avoid leak-
ages. Ensure that no dirt enters oil cooler.
7. Remove upper radiator hose from radiator.
8. Remove lower attaching nut and slide radiator
upward and out of engine compartment.
9. Remove inlet and outlet hoses from condenser

REFRIGERANT COMPONENTS ALL MODELS99.55pipes and tape closed the open ends of refrigerant
lines, and also the open ends of the inlet and outlet
pipes of the condenser.
10. Remove two (2) top retaining screws.
Figure
9,S-73 Condenser Retaining Screws - Opel
1900
- Manta
11. Remove radiator grille and two (2) condenser to
body mounting screws. See Figure 98.74.
Figure 98-74 Condenser Assembly and Attachments.
Opel 1900
- Manta
12. Remove condenser.
Installation
If refrigerarit circuit or condenser has been exposed
to the atmosphere and moisture may be present in
the circuit, the system and/or component must beFigure 98-75 Condenser Assembly Mounting Brackets
Opel 1900 Manta
flushed prior to installation. Refer to FLUSHING
THE SYSTEM.
1. Install comjenser into car and install 2 condenser
to body mounting screws. See Figure 98-74. Install
radiator grill.
2. Install 2 top retaining screws.
3. Remove tape from the condenser pipes and re-
frigerant hoses and install hoses using new o-rings on
lines lubricated with No.
525 viscosity oil.
4. Evacuate system. Refer to EVACUATING SYS-
TEM.
5. While system is being evacuated, install radiator
into engine compartment and secure lower attaching
nut.
Figure 98.76 Clearance Between Lower Radiator
Tank and Fan Blades
- Opel 1900 Manta
6. On vehicles with automatic transmissions, fasten

98-56 1973 OPEL SERVICE MANUAL
oil cooler lines to lower radiator tank. It is essential
that no dirt enters the oil lines. When tightening oil
lines hold connectors on lower radiator tank with
pliers to avoid leakages. Ensure that no dirt enters oil
cooler. Torque to 11-15 Ibs. ft.
7. Install fan shroud.
8. Install upper radiator hose.
9. Install lower radiator hose and add collected coo-
lant.
All Opel
1900’s and Manta’s are provided with a
radiator initial fill of an anti-freeze solution contain-
ing corrosion inhibitor. The anti-freeze has either a
glycol or glycerin base and protects the engine
against freezing, down to minus 22 degrees F. (minus
30 degrees C.). Before the start of the cold season,
coolant must be checked with a hydrometer and if
necessary, brought to the necessary specific gravity
by adding anti-freeze. Anti-freeze added, must have
a glycol or glycerin base. As the specific gravities of
all anti-freeze solutions having a glycol or glycerin
base are practically the same, the hydrometer can be
used for all these types. Because of the tolerances of
the hydrometer, or slight differences in specific
gravity, variations of plus or minus 5 degrees can be
expected. Coolant must be checked at a temperature
of plus 68 degrees F. (plus 20 degrees C.).
IO. Install negative battery cable and air cleaner.
11. Charge system. Refer to CHARGING SYS-
TEM.
Figure 99.80 Location of Idler Pulley and Bracket
Assembly
- GTFigure 99.81 Idler Pulley and Bracket Assembly and
Support Bracket GT
REMOVAL AND INSTALLATION OF
COMPRESSOR. GT
I. Removenegative battery cable from battery.
Figure 98-82 Compressor Adapter Fitting, Ground
Wire. and Front and Rear Mounting Bolts
- GT
Figure 99.83
Elecirical Connector and Ground Wire
GT

REFRIGERANT COMPONENTS ALL MODELS9B- 57SUPPORT BRACE (LARGE)Figure 98-84 Compressor Installation GT

98-58 1973 OPEL SERVICE MANUAL
2. Discharge system. Refer to DISCHARGING
SYSTEM.
3. While system is discharging remove air cleaner
and loosen idler pulley and bracket assembly. See
Figure 98-80.
4. Remove bolt holding compressor adapter fitting
into rear head. Disengage from compressor and tape
closed openings in both lines and ports in rear head.
It is important to seal compressor ports to avoid a
loss of refrigeration oil and also to prevent foreign
material and moisture from entering compressor. See
Figure 9B-82.
5. Remove bolt and ground wire, unplug electrical
connector, and remove 2 rear compressor mounting
bolts. See Figure 98-82.
6. Remove 2 front compressor mounting bolts,
clutch drive belt, and lift out compressor. During
removal, maintain the compressor position so that
the sump is downward. Do not’rotate compressor
shaft. See Figure 9B-84.
Installation1. Install compressor into mounting brackets and
secure with 4 mounting bolts. See Figure
9B-84.2. Untape lines and ports, and install compressor
adapter fitting and bolt using new o-rings. See Figure
9B-82.3. Evacuate system. Refer to, EVACUATING
SYSTEM.
4. While system is being evacuated, install drive belt
and tighten idler pulley. See Figure
9B-80.5. Install bolt and ground wire and plug in electrical
connector. See Figure
9B-83.6. Install air cleaner and negative battery cable.
7. Charge system. Refer to, CHARGING SYS-
TEM.
REMOVAL AND INSTALLATION OF
RECEIVER.DEHYDRATOR
ASSEMBLY. GT
Removal1. Discharge system. Refer to DISCHARGING
SYSTEM.
2. Disconnect refrigerant lines to both ends of re-
ceiver-dehydrator and tape closed open ends of
re-
9862Figure 98.85 Refrigeration Hose Clamps Installation
GT
frigerant lines, and also the open
e:nds of the inlet and
outlet pipes of the receiver-dehydrator. See Figure
9B-86.Figure 98.86 Receiver-Dehydrator GT
3. Remove 2 screws securing receiver-dehydrator
and clamps to support bracket and lift out receiver
dehydrator. See Figure
9B-86.
Installation1. Install receiver-dehydrator using new o-rings
during installation. Lubricate o-rings prior to instal-
lation using No. 525 viscosity oil.
.

REFRIGERANT COMPONENTS ALL MODELS9s. 59
2. If the receiver-dehydrator has been exposed to
the atmosphere for any amount of time, (more than
5 minutes), the receiver-dehydrator should be re-
placed, since the life of the dessicant is probably
expended.
3. Evacuate and charge system. Refer to CHARG-ING AND DISCHARGING SYSTEM.
REMOVAL AND INSTALLATION OF EVAPORATOR
AND EXPANSION VALVE. GTRemoval
1. Disconnect negative battery cable.
2. Discharge system. Refer to, DISCHARGING
SYSTEM.3. While system is discharging, remove attaching
screws and lift out luggage tray. See Figure
9B-87.Figure 98.88 Evaporator Cover Assembly and
Attaching Screws GT
Figure 98.87 Luggage Tray
4. Remove all evaporator cover screws and removecover. See Figure
9B-88.
5. Remove electrical plug connector from the resis-tor assembly and unplug blower motor connection
and remove ground wire. See Figure
9B-90.6. From underneath evaporator housing, discon-
nect two (2) drain hoses. See Figure
9B-91.
7. From under car remove 4 nuts securing
evapora-Figure 96.90 Electrical Connections, Ground Wire
GTtar mounting bracket to floor. See Figures
9B- 92
and
9B-93.8. Remove inlet and outlet pipes from evaporator
and tape closed the refrigerant lines and also the
open ends of the inlet and outlet pipes of the evapora-tor. See Figure
9B-94.

9B-60 1973 OPEL SERVICE MANUAL
EVAPORATOR EVAPORATOR
DRAIN HOSE DRAIN HOSE
Figure 96-91 Drain Hose GT
Figure 98.92 Evaporator Mounting Bracket Bolts
Driver Side GT
9. Lift off the mounting bracket and remove the
evaporator assembly from the car.
10. Remove the resistor assembly. See Figure
9B-90.Figure 98-93 Evaporator Mounting Bracket Bolts
Passenger Side
- GT“0” RING-----
OUTLET TUBE
SEAL
9870Figure 98-94 Inlet and Outlet Pipes and O-Rings GT
11. Remove blower case and blower motor attaching
screws and remove assembly.
12. Remove all remaining attaching screws and
remove evaporator assembly. See Figure
9B-95.13. Disconnect expansion valve capillary tube bulb
attached to the outlet pipe of the evaporator. See
Figure 9B-95.
14. Disconnect inlet and outlet ends of expansion

REFRIGERANT COMPONENTS ALL MODELS96.61
CAPILLARY T”BEFigure 98.95 Evaporator and Expansion Valve
Assembly GT
valve from refrigerant lines, and tape closed open
ends of lines and inlet and outlet ports of expansion
valve.
Installation5. Install resistor assembly.
6. Install evaporator assembly into car and install
mounting bracket. See Figure
9B-96.Figure 98.96 Evaporator and Blower Assembly
- GT
If expansion valve or refrigerant lines have been ex-
posed to
,the atmosphere for any amount of time and
moisture may have entered the valve or the system,
flush the system and install new receiver-dehydrator
or valve as necessary.7. Untape the refrigerant lines and the inlet and
outlet pipes from the evaporator and install using
new o-rings on line fittings.
Due to the possible adjustment difficulties involved
if the expansion valve is disassembled, disaisembly of
the valve is not recommended. The valve may be
cleaned by submerging it in a bath of trichlorethy-
lene, alcohol, or similar solvent. Dry by blowing iil-tered compressed air through the outlet port of the
valve. The filter screen at the inlet port may be re-
placed. Remove screen by threading a lo-32 NF
screw intp old filter screen. With a washer and a nut
on the screw arranged to work as a puller screw, hold
the body of the screw and turn the nut. Insert the
new filter screen into the inlet port and lightly tap
screen only enough to seat.
1. Install expansion valve using new o-rings during
installation. Lubricate o-rings prior to installation
using No. 525 viscosity oil.
2. Install evaporator assembly and case attaching
screws.
3. Install blower motor assembly into case and se-
cure with attaching screws.
4. Install finger guard shields and fan housing case.Figure 98-97 Refrigerant Hoses and Hose Clamps
Under Car
- GT