OPEL GT-R 1973 Manual Online

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I1 H- 601973 OPEL SEW& MANUAL
1. Remove headlight switch button by depressing
retaining clip on shaft and pulling back on switch
knob. See Figure lH-3.
Figure 1 H-5
- Removing Cluster Screws
Figure lH-3
- Removing Headlight Switch Knob,
2. Remove two (2) plugs on cluster panel. See FigurelH-4.301H6
-Figure 1 H-4 Removing Plugs
3. Remove two (2) sheet metal screws behind plugs
on cluster. See Figure lH-5.
4. Pull off heater control knobs toward front.
j5. On top, carefully pull instrument ‘trim plate
:to-wards steering wheel and remove plate.
6. Remove two screws for lower housing
attach&t.See Figure lH-6.Figure 1 H-6 Lower Housing Attaching Screws
7. Disconnect speed0 cable at cluster by turning cou-
pling counterclockwise.
8. If equipped, pull heated rear window or fog lamp
switch out of instrument housing and disconnect
wires from switches.
9. Pull cluster right and left sides partially out and
disconnect wires on back of cluster. See Figure lH-7.
Installation
1.
P&e instrument cluster in position and connect
wires on back of cluster.
2. Pull fog light or heated back glass switch wires
into opening, if equipped, and connect wires and
replace switch.
3. Connect two screws on lower housing attachment.

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IINSTRUMENT PANELlH- 61Figwe 1 H-7
- Disconnecting Cluster Wires
4. Install instrument cluster trim plate and replace
two screw and plugs.
5. Con&t speed0 cable by turning coupling clock-
wise. 1
6. Install light
.switch button and heater control
knobs. I
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7. Con+ct battery cable.
Removidg Windshield Wiper Switch - Opel 1900Manta I
1.
Rem* instrument cluster trim plate.
2. Corndress retaining clips and remove switch. See
Figure iH-8.
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Figure lH-8 . Removing Windshield Wiper Switch3. Disconnect wiring connector.
Installation1. Connect wiring to switch.
2. Snap switch back into panel.
3. Replace instrument cluster trim plate.
Removing Instrument Cluster Bulbs - Opel 1900.
Manta1. Remove instrument cluster assembly.
2. Replace bulbs from back ofcluster. See Figure
lH-
9.Figure lH-9 Removing Instrument
Clu’ster Bulbs
Installation1. Replace bulbs in cluster.
2. Replace instrument cluster assembly.
Removing and Installing Ignition SwitchRefer to Group 3, Section F.
Removal of Instrument Cluster Housing Assembly.
GTDisconnect battery before making any electrical re-
pairs.
1. Disconnect battery cable.
2. Remove right access cover and remove screw. See
Figure lH-10.

1 H- 62 1973 OPEL SERVICE, MANUAL
4. Remove flasher unit. See Figure IH-12.
5. Position steering so that wheels are straight ahead.
6. Pull off heads of both tear bolts by first drilling a3/16 inch pilot hole and then using a stud extractor
to remove tear bolts. See Figure lH-13.
Figure 1 H-10 Removing Right Aicess Cover andSWW3. Remove left access cover and f”rnove screw. See
Figure lH-11.
Figure 1 H-l 3 Steering Column Attaching Bolts
7. Disconnect ignition (white) and directional signal
(black) wire set plugs.
8. Support steering column assembly and remove
both hex head bolts. See Figure lH-13.
9. Drop steering column assembly to floor.
10. Disconnect speedometer cable.
11. Remove six (6) screws on instrument cluster. See
Figure
lH- 14.
Figure lli-1 1 Removing Left Access Cover and
SC&Figure lH-14 Instrument Cluster Screws
12. Pull back on instrument cluster from top to
remove. See Figure lH-15.
Figure l H-12 Flasher Unit Installed13. Disconnect wires on back of radio. See FigurelH-16.

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,INSTRUMENT PANELlH-63Figure l;H-15 Removing Instrument Cluster AssemblyFibure1 H-l 6 Disconnecting Radio Wires
14. Disdonnect antenna lead-in at right lower corner
of radio!
15. Pull’ cluster housing out and turn sideways to
remove
&~y instrument gauge or switches.
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lnstallaiion
CAUTlOI$ Fasteners in subparagraph B are impor-
tant attaching parts in that they coo/d
affect the
perform>nce of vital components and systems, and-
/or
cou!d result in major repair expense.They must
be
repraced with one of the same part number, or
with an equivalent part if replacement becomes
necessa?y. Do not use a replacement part of lesser
quality
br substitute design. Torque values must be
used as
&ified during reassembly to assure proper
retention of these parts.
1. Plug antenna lead-in cable and power source to
radio. I
2. Put i&trument cluster in position and replace six
(6) screbs in cluster.3. Connect speedometer cable.
4. Raise steering column into position and install hex
head
bolt% Be sure to install ground wire. Tighten
hex head bolts to 14 lb.ft.
5. Tighten tear lock bolts until hex head of bolt is
torn off.
6. Connect ignition and directional signal wire set
plugs.
7. Install flasher unit.
8. Replace screws in right and left lower instrument
panel and replace both access covers.
9. Connect battery cable.
Removal of Combined Switch Assemblies. GT1. Remove instrument cluster.
2. Turn instrument cluster to the side to remove
switch assembly.
3. Remove switch by removing two retaining nuts.
See Figure lH-17.
4. Remove wiring from switch.
Figure 1 H-l 7 Removing Switches
Installation1. Plug wiring into switch.
2. Install switch on panel.
3. Install instrument cluster.

lti- 64 1973 OPEL SERVICE MANUALj
Removal of Cigar Lighter GT/
1. Remove instrument housing.I
’ 2. Disconnect electrical wire.
3. Remove hex nut on back of cigar lighter
base’.’4. Remove cigar lighter base.
Installation1. Install cigar lighter base.
2. Install hex nut on back of lighter base.
3. Connect wire to lighter.
4. Replace instrument cluster.

GAUGES
CONTENTS
Subject
DESCRIPTION AND OPERATION:
DIAGNOSIS:
Temperature and Fuel Gauge
System-Opel1900-Manta. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FuelGauge-GT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAINTENANCE AND ADJUSTMENTS:
MAJOR REPAIR:
Opel 1900
- Manta
Voltage Stabilizer
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Speedometer
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric
ClockorTachometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperature Indicator or Fuel Gauge
. . . . . . . . . . . . . . . . . . . .Rallye
Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperature
SendingUnit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Pressure Sending Unit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GT
Speedometer
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tachometer
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperature Indicator and Fuel Gauge Dash, Unit
Electric
Clock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ammeter
andOilPressureGauge. . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:
DIAGNOSISITEM(ERATURE
& FUEL GAUGE - SYSTEM
DIAGNOSIS (OPEL 1900, MANTA)
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ConditionPossible Cause
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Page No.
1l-65
1l-67
1l-67
1l-68
1l-68
1l-69
1l-69
1l-69
1l-70
1l-70
1l-70
1l-70
1l-71
1l-71
Correction
Temperature and gas gaugeinopetative1. Blown fuse1. Replace fuse. If new fuse
blows, repair short.
2. Defective voltage
stabilizer1. Install 40 ohm resistors
between ground
& connectors
(disconnect from units)
of temperature sending imit
and gas gauge tank unit. If
both dash units do not move
to full scale (tolerance
-one pointer width of either
side of full scale reading)
and the distance of movement
on the scale is the same,,
replace the voltage stabdner.

ll- 66 1973 OPEL SERVICE MANUALi
ConditionPossible CauseCorrection
Gas gauge does not read
full when tank tilled1. Tank unit misadjusted1. Install 40 ohm resistor
between connector and ground
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(disconnect from unit). If
dash unit reads full within
one pointer width. Remove
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Igas tank unit from tank, install
connector, ground unit and
adjust tab to obtairi full reading on
dash. Reinstall tank unit.
2. Defective’ voltage
stabilizer1. See corrective action above.
Gas gauge not operating1. Corroded tank unit
terminal I1. Check tank unit terminal, if
corroded clean, pack connector
with grease and reinstall
connector..
2. Loose dash gauge
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1. Install 40 ohm resistor between
sending unit connector. and
ground (disconnect from tank
terminal). If dashgauge does
not read rull, check dash gauge
attaching nuts for secureness
and tighten if required.
(Requires removal of dash panel)
Momentarily touch dash gauge
attaching studs to 12 volt
source. If indicator moves,
reinstall panel; if not, replace
gauge. (Caution do not keep
studs connected to 12 volt
source for more than a few
seconds
- damage to gauge can
result)
3. Open
w&g1. Remove connector from sending
unit and ground (40 ohm
resistor may be used if
ohmmeter available. Remove
multiple connector from rear
of dash. Connect test light
to ground and touch other end
to connector socket with blue
and black wire, if it does not
light (40 ohm reading of ohm
meter used) repair open circuit.
4. Defective gas tank
sending unit1. Install 40 ohm resistor between
temperature sending unit and
ground (disconnect from unit)
if dash unit reads full scale.
Replace tank unit (check for
terminal corrosion before
replacing).

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GAUGES1 I- 67I
I Condition
Car
&s out of gas with
gauge indicating fuel in
tank. 1
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IPossible Cause
1. Tank unit misadjusted
2. Defective voltage
stabilizer.Correction
1. Follow corrective action as
stated above (obtain empty
reading on dash)
1. See corrective action above.
Temperature gauge not1. Loose dash gauge1. See corrective action above.
Iattaching nut.
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I2. Defective temperature1. Install 40 ohm resistor
Isending unitbetween temperature sneding
Iunit and ground (disconnect
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from unit). If dash unit reads
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full scale, replace temperature
Isending unit.
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I3. Open wiring.1. Follow corrective action as
Istated above (connector socket
Iwith blue wire).Tempkrature gauge indicates
hot when engine temperature1. Incorrect temperature1. Check for correct sending unit
sending unit
normal.(white porcelain) replace if
incorrect.
2. i>efective temperaturesending unit.1. See corrective action above.
3. Dkfective voltage
stabilizer.
1. See Corrective action above.
GAS
GdUGE TROUBLE DIAGNOSIS - GT4. Disconnect the tank unit lead wire (light blue with
black tracer) from the tank unit.
An inoperative gas gauge reading can normally be
found to result from a poor grounding condition
within the circuit. Using the procedure as outlined
below may lead to the correction of the inoperative
reading without replacement of either the tank unit
or the
dph unit.5. Connect ihe stock tank unit; ground unit, and
operate manually.
6. If the dash unit shows a correct reading, then
replacement of the tank unit is required as the cor-
rection.
1. Makelcertain the gas tank (ground) strap is prop-
erly secured.A correct reading will be one which resembles the
movement of the manually-operated tank unit.
2. Make’certain the ground wire (brown in color) for
gasoline/ and temperature gauges is properly con-
nected tb the windshield wiper motor and is secured.
(This
gl?ound wire is also common for the heater
blower
etor.)7. If the dash unit does not show a correct reading,
then its replacement is necessary.
If the adove procedure does not produce a satisfac-
tory gaube reading, an attempt to isolate the defec-
tive
par<, i.e. tank or dash unit should be made.
3. Rem&e a tank unit from parts stock.MAJOR
AEPAIR
OPEL 1900. MANTA
Removing Voltage Stabilizer1. Remove instrument cluster housing assembly.

1 I- 68 1973 OPEL SERVICE MANUAL
2. Pull voltage stabilizer of back of printed circhit.
See Figure
11-l.
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L-_ -~~---,~. _^__, _-_~
Figure 1 l-3 - Speedometer Attaching Screws
Figure
11-l -Voltage Stabilizer
installation
2. Install six (6) screws holding instrument cluster
lens in housing.
3. Replace cluster housing.
1. Install voltage stabilizer on
back of printed circuit.
2. Install instrument cluster
ho*sing assembly. j
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Removing Speedometer I
1. Remove instrument cluster housing.:
2. Remove six screws shown in Figure
11-2 and
remove both instrument
cluster’lens.
Figure 1 l-2 - Removing Instrument Cluster Lens
3. Remove three speedometer attaching screws. L&X
Figure 11-3.
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Installation
1. Replace speedometer in cluster with three (3) at-
taching screws.
Removing Electric Clock or Tachometer
1. Remove instrument housing.
2. Remove six screws and remove both instrument
cluster lens, as shown in Figure
11-2.
3. Remove three screws, as shown in Figure 11-4, and
remove clock or tachometer.
L-u-.------ _._- -----G1.-A-... -.
Figure 1 l-4 - Removing Electric Clock or Tachometer
1. Install clock or tachometer in instrument cluster
with three (3) attaching screws.
2. Install six (6) screws holding instrument cluster
lens.

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IGAUGES1 I- 69
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3. Replace instrument housing.InstallationFiemoving~Temperature Indicator or Fuel Gauge
1. Remov+ instrument cluster housing.
2. Remov; six screws and remove both instrument
cluster
le+ See Figure 11-2.3. Pull v&age stabilizer off printed circuit and
remove fohr instrument attaching screws, as shown
in Figure
111-5.Figure
11-5 Removing Four Instrument Attaching\SCWWS
4. Take temperature or fuel gauge out of clusterlnstallatidn
1. Install itemperature or fuel gauge in cluster.
2. Replack voltage stabilizer on back of printed cir-
cuit. I
3. Replack both instrument cluster lens.
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4. Install /instrument cluster housing.
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IRemwind Rallye Gauges
1. Removt glove compartment.
2. Remo?e radio, if equipped.
3.
Remoje screws holding instrument carrier frominstrumejf
pane!.4. Disconpect wres from instrument gauge.
5.
Removal attaching nuts from gauge and remove.I1. Replace gauge with attaching nuts on panel.
2. Hook up wires to gauges.
3. With holding screws, attach gauge cluster to in-
strument panel.
4. Replace radio.
5. Replace glove compartment.
Removal of Temperature Sending Unit
1. Drain and collect coolant.
To drain radiator, remove end of lower radiator hose
that is connected to radiator.
2. Remove wire from temperature sending unit.
3. Unscrew temperature sending unit from thermo-
stat housing. See Figure
11-6.Figure
11-S -Temperature Sending Unitlnstalletian
1. Screw temperature sending unit into thermostat
housing after sealing unit with non-hardening per-matex.
2. Install wire on sending unit.
3. Replace coolant.