OPEL GT-R 1973 Repair Manual

1 E- 40 1973 OPEL SERVICE MANUALDisassemblyI
1. Remove two (2) motor housing attaching
screw$(Item No. 4) and two (2) angle brackets (Item No.
3). See Figure lE-9.
Figure 1 E-S Removing Motor Housing Attaching
SCFS”JSFigure
1 E-l 0 Transmission and Armature Removed
from Motor Housing2. Remoyz transmission housing together with arma-
ture from motor housing. See Figure lE-10. It may
be necessary to hold armature in transmission hous-
ing with a screw driver.
3.
Rem~ove armature from transmission housing.
4. Remove five (5) transmission housing cover
screws. See Figure lE-11.Figure 1 E-l 1 Remove Transmission Housing CoverSCEWS
5. Remove cover, gasket and driven gear from trans-
mission housing. See Figure IE-12. Remove pivot
ball from driven gear. See Figure lE-15.
Figure 1 E-l 2 Remove Driven Gear
6. If required, remove brushes.
a. To remove positive brushes, cut brush leads off at
brush holder. See Figure lE-13.
b. To remove negative brush, remove brush retaining
screw from commutator end frame. See Figure
lE-
14.

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.

1 E- 421973 OPEL SERVICE MANUAL
Figure 1 E-l 7 Solder Positive Brush Lead to Brush
Holder
9. Install motor housing over armature so that large
drain hole on housing is facing downward when
mb-tor assembly is installed in car.
InSert angle brackets
into motor housing and tighten attaching screws. Be
sure to reseal angle brackets to motor housing after
retaining screws are tightened.
10. Connect assembled motor with an ammeter and
adjust end play of armature shaft grid drive gear. To
do so, turn in the respective adjusting screw until the
current consumption increases. Then back off adjust-
ing screw
l/2 turn. Secure driven gear adjusting
screw with lock nut and armature adjusting screw
with paint. See Figures lE-18 and lE-19.
Installation1. Connect wiper motor electrical connector to mo-
tor.
2. Place wiper motor in position on cowl and secure.
Torque attaching nuts 14 to 17 in.lbs.
3. Place crank arm on motor drive shaft and torque
nut as follows: Bosch and SWF, 70 to 87 imlbs. and
Siemans, 122 to 139 in.lbs.Figure 1 E-l
8 Adjusting Armature End Play
Figure
lE-19 Adjusting Driven Gear End Play
4. Check the position of the windshield wiper blades
for proper position after the crank arm is attached.
See Figure lE-3 for the proper distance the blades
should be from the windshield molding in the park
position.

WINDSHIELD WIPERSlE-43SPEhFlCATlONS
IGENEPAL SPECIFICATIONSiRated Voltage .
..__.,,,.,,,......................................,.,,... ~ __..__...__...._..................................... 12 VDC
,Test Voltage ___..................................................,...................,..,..................................... 13 VDC
Current Draw (Amps)
;No Load_, Low Speed
..__...__..__..,_,,..,,,.,,,,..,....................,,.................................................................. 1.5
I Hieh
SDeed .___,,...,,..,,._.._..............,...............................,,,..,,,.............................................. 2.2lLock:d
’
:Low Speed ___.,._,,,..,,,....................................,,.........,,..,,,.,,,,..................,,,........................... 16
,
High Speed . . . . . . . ..___.._........................................................................................................... 17
~Minimum Commutator Diameter __.................,,,,........................................................... .86 in.
‘Brush Spring Pressure
:New Brush
. . . . . . .._...__...................................................................................... 6.35 to 8.47 oz.Used Brush
..__,,,...,,.,,..................,...............................,,.,,,,.,,....................... 3.5 oz. minimum‘MinimumBrushLength
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24in.The windshield wiper motor instead of field coils has a permanent magnet
(oxide magnet). This motor design is sturdier and consumes less current.TORQirE SPECIFICATIONS
‘CrankArmtoMotorDriveShaft. . . . . . . . . . . . . . . . . . . . . . . . . .70to87in.lbs.iper Motor to Cowl
,
,.,,,.,,,,..,,............,..,,.,,.........................................14 to 17 in.lbs.

1 E- 44 1973 OPEL SERVICE MANUAL)
‘30
1.2.
3.4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.ATTACHING SCREWS16. NEGATIVE BRUSH
TRANSMISSION COVER 17. ATTACHING SCREW
HEX. NUT
THREADED END ~18. RETAiNING PLATE
19. POSlilVE BRUSH
PLAY PIN20. WIRE’
GASKET21. THRUST SPRING
BALL22. RUBBFR MOUNTS
DRIVEN GEAR23. ARMATURE
WASHER24. ATTACHING SCREWS
THREADED END25. LOCKWASHER
PLAY PIN26. ANGLE BRACKE’TS
SLEEVE27. MOTOR HOUSING
MOUNTING PLATE28. MAGNET RING
GASKET29. MAGNET THREADED
TOOTHED WASHERSPi N
LOCATORSATTACHING SCREWS30. NORTH POLE PAINT
TRANSMISSIONMARKING ON
HOUSING
THISfSIDENOTE: MOTOR HOUSING
WITH MAGNET RING HAS
TO BE INSTALLED SO THAT
THE NORTH POLE MARKING
(PAINT DOT ON MAGNET
RING) FACES TOWARDS
‘IRANSMISSION.
301 E20Figure 1620 Wi$er Motor
- Exploded View

LIGHTING SYSTEMSlF-45LIGHTING SYSTEMS
CONTENTS
Subject
DESCRIPTION AND OPERATION:
LightingSystems................................................................
DIAGNOSIS:MAINTENANCT AND ADJUSTMENTS:
Headlamp Aiming..............................................................
MAJOR REPAIR:
Opel 1900
- Manta
HeadlightSwitch............................................................
Fog Lamp or Heated Rear Window Switch
..........
SealBeam........................................................................
Tail Lamps........................................................................
LicensePlateLamp........................................................
FrontSideMarker..........................................................
Rear Side Marker..........................................................
Courtesy Light................................................................
DoorJamSwitch............................................................
GT
Front Turn Signal..........................................................
SealBeam........................................................................
Tail Lamps........................................................................
Side Marker......................................................................
LicensePlateLamp........................................................
Backup Lamp
..................................................................
InteriorLight....................................................................
Headlamp Switch..........................................................
DoorJamSwitch............................................................
SPECIFICATIONS:
Page No.
1 F-45
1 F-46
1 F-46
1 F-47
1 F-47
1 F-40
1 F-49
1 F-49
1 F-50
1 F-50
1 F-50lF-51lF-51lF-51
1 F-52
1 F-52
1 F-53
1 F-53
1 F-53
1 F-53
DESCRIPTION AND OPERATION
DESCRIPTION OF LIGHTING SYSTEMThe
three-baition light switch on Opel 1900 and
Manta corjtrols the headlights, taillights, parking
lights, side marker lights, instrument panel lights,
and the lic&se plate light.
When the
Qght switch knob is pulled out to the first
stop, the .pxking lights, side marker lights, the Ii-
cerise plate light, and the instrument panel lights will
light.
Pulling the knob out all the way turns the headlights
on.The instrument panel lights come on when the head-
light switch is pulled out to the first stop or pulled
out ‘all the way. The instrument panel lights are
turned off by turning the switch knob counterclock-
wise past the first detent.

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.

LIGHTING SYSTEMSlF-472. Install switch in panel.
3. Replace instrument cluster cover.
EXTERIOR LIGHTSModels 51-53-54
Headlamp Sealed Beam Unit Removal1. Remove two screws on headlight ring.
2. Remove four screws holding headlight retainer to
body. See Figure lF-3.
Figure 1 F-l Removing Headlight Switch
I
3.
Rep& two (2) plugs over screws and replace
heater control knobs.
FOG LIGHT OR HEATED REAR GLASS SWITCHRemoval I
1. Removd instrument cluster cover. See Section H.
I
2. Press
ddwn retaining clip and pull switch out. See
Figure lF-2.
Figure 1 F-3 - Removing Headlight Retainer
- Models
51-53-54
3. Disconnect wiring connectors,
4. Remove headlight from inside engine compart-
ment.
Figure 1Fi2 - Removal of Fog Light or Heated Rear
Glass Switch
3. Removelwires from switch.
Installation/
1. Connect;wire to switch,
Installation1. Plug in wiring connector on sealed beam and re-
place four (4) headlight retaining screws.
2. Replace headlight ring.
Models 57-57R
Removal
I. Disconnect wiring connector.
2. Remove four screws holding headlight retainer
from inside engine compartment.

1~- 48 1973 OPEL SERVICE: MANUAL/
3. Disassemble headlight assembly from retaini+g
ring. See Figure lF-4.
i
tFigure 1 F-4
- Headlight Assembly - Models 57.57R
Installation1. Assemble headlight to retaining rings.;
2. Install to body from inside engine compartmept
with four (4) screws.
3. Connect wiring harness.
Parking Light Housing or Lens Removal1. Remove two screws holding lamp lens.:
2. Remove two screws holding housing. See FigurelF- 5.
Figure lF-5 Remove Parking Light Housing
3. Disconnect wiring harness.1. Apply sealer to housing
2. Connect wiring harness.
3. Replace housing in body with two (2) retaining
screws.4. Replace lamp lens.
REAR STOP, TAIL, DIRECTIONAL SIGNAL, OR
BACK-UP LAMP HOUSINGMod&
J-I-53
Removal1. In luggage compartment, unscrew housing attach-
ing nuts. See Figure lF-6.
Figure lF-6 Tail Light Housing Attaching Nuts
Models 5 1-53
Figure lF-7
- Removing Tgil Light Lens - Models
51.53

LIGHTING SYSTEMSlF-492. Take
Le:s off housing. See Figure lF-7.
3. Remove housing.1
Installation;I
1. Install
le$ in housing.
2. Replace
+.Model 54
;,
1, Remove Ilamp lens from outside.
/
2. Remove kear quarter trim pad.
/
3. Remove
ifour screws from inside car. See FigurelF- 8.
Figure 1 F-8
I- Removing Tail Light Housing - Model 54
I
4. Disconnkct wiring connector.
I
1. Connect iwiring to lamp
2. Install hbusing using four (4)
scre%s.3. Replace
p quarter trim pad
4. Replace
Lens,Models
57-$RI
Removal1. Unscrew!lens from housing.2.
III luggage compartment, unscrew three (3) hous-
ing attaching nuts. See Figure lF-9.
Figure lF-9 Tail Light Housing Attaching Nuts
-Models 57.57R
3. Disconnect wire connector.
Installation1. Plug in wiring harness.
2. Replace housing with three (3) attaching nuts.
3. Replace lens.
Rear License Plate Lamp Assembly Removal1. Remove two screws holding housing to bumper.
2. Pull lamp assembly down.
3. To replace bulb, take out two
screws holding lens
in place.
Installation1. Replace bulb and lens to housing.
2. Replace lamp assembly to bumper with two (2)
screws.
SIDE MARKER LIGHTS
Front Removal1. Remove outer lens.
2. Remove two sheet metal screws for housing at-
tachment.
3. Disconnect wire connectors.