key OPEL GT-R 1973 Service Manual

GENERAL INt=ORMATION OA-1
GENERAL INFORMATIONKEYS AND LOCKSEvery key has a number engraved on one side which
identities the key blank manufacturer. On the oppo-
site side of GT keys, is a removable adhesive foil on
which, the profile and cutting code letters and num-
bers are imprinted. Attached to the protective key
cover of Opel
1900 and Manta keys, is a tab on which
the profile and cutting code letters and numbers are
imprinted. Record the key cutting code letters and
numbers before the adhesive foil or plastic tabs are
discarded as this information is necessary to obtain
replacement keys.
In the event of lost keys and code records, one or
more locks may be removed to obtain the code num-
bers. The codes are stamped on the trunk and igni-
tion lock cylinders and on the door lock plunger
shaft. If a lock cylinder is damaged, it must be re-
placed. This then means that the owner will have an
additional key.REMOVE ANDDOOR &
IGNIKEY CODELOCK. OPELIGNITION
LOCKGAS CAP LOCKGTGT
Figure OA-1 1973 Keys
FEDERAL CERTIFICATION LABELIn accordance with Federal Motor Vehicle Regula-
tions, a certification label is
affIxed to all 1973 mod-
els.The label has a certification statement, vehicle iden-
tification number, and month and year that the vehi-
cle was built. The label is attached vertically to the
left front door inner panel lock facing. See Figure
OA-2.
VEHICLE IDENTIFICATION
Model Identification PlateThe model identification plate as illustrated in Fig-
ure OA-3 is attached to the inside right front inner
fender panel on Opel
1900 and Manta and on top of
the right side of the cowl on the GT. The information
embossed on this plate includes such things as; type
and model of vehicle, allowable front axle load, al-
lowable maximum vehicle weight, allowable rear
axle load, paint color code and chassis serial number.
The key to identification is that the first two digitsFigure OA-2 Federal Certification Label Location
of the serial number represents the vehicle model.
The remaining digits are the actual serial number.
Figure OA-3 Model Identification Plate
Engine Number
The engine number is stamped in a machined boss on
the upper left center of the engine block. The number
starts with 1.9US which denotes the displacement in
Liters and also that the engine is equipped with the
Opel Emission Control System.
Vehicle Identification NumberA new thirteen digit vehicle identification number is
used on all Opel models imported for 1973. It is
embossed on a narrow strip of metal which is at-
tached to the left windshield post on Opel 1900 and
Manta models and to the top of the left end of the
instrument panel cover. In all cases the number isvisable when looking through the windshield from
outside the vehicle.
This new identification number includes; model
designation, engine code, model year, assembly plant
and the sequential number. See Figure OA-4.

LUBRICATION AND MAINTENANCE OC-9
4. Remove dipstick and wipe clean.
5. Reinsert dipstick untip cap seats.
6. Remove dipstick and note reading.
If fluid level is at, or below the ADD mark, add
sufficient fluid to rais the level to the FULL mark.
One pint raises the level from ADD to FULL. Do
not overfill.
3OC8Figure OC-8 Automatic Transmission Dipstick
SAFETY MAINTENANCE
Brake Lines and HosesCheck for proper attachment, leaks, cracks, chafing,
deterioration, etc. Any questionable parts noted
should be replaced or repaired immediately. When
abrasion or wear is evident on lines or hoses, the
cause must be corrected.
Tires and WheelsCheck tires for excessive wear, nails, glass, cuts or
other damage. Make certain wheels are not bent or
cracked and wheel nuts are tight. Uneven or abnor-
mal tire wear may indicate the need for alignment
service. Tire inflation pressure should be checked by
the owner at least monthly, or more often if daily
visual inspection indicates the need.
Exhaust SystemCheck complete exhaust system and nearby body
areas and trunk lid for broken, damaged, missing orm&positioned parts, open seams, holes loose connec-
tions or other deterioration wiuch could permit ex-haust fumes to seep into the trunk or passenger
compartment. Dust or water in the trunk may be an
indication of a problem in one of these areas. Any
defects should be corrected immediately. To help
insure continued integrity, exhaust system pipes and
resonators rearward of the muftler must be replaced
whenever a new mufIler is installed. Use genuine
GM parts specified for the vehicle.
Engine Drive BeltsAdjust belts driving fan, alternator and other acces-
sories at first 4 months or
6,ooO miles of vehicle
operation. At each subsequent 4 month/6,000 mile
interval, check belts for cracks, fraying, wear and
tension. Adjust or replace as necessary. It is recom-
mended that belts be replaced every 24 months or
24,C00 miles, whichever occurs first.
Suspension and SteeringCheck for damaged, loose or missing parts, or parts
showing visible signs of excessive wear or lack of
lubrication in front and rear suspension and steering
system. Questionable parts noted should be replaced
without delay.
Safety Checks to be Performed by OwnerListed below are the safety checks that should be
made by the owner (items a thru t). These checks
should be made at least every 4 months or
6,ooOmiles, whichever occurs first, or more often when the
need is indicated. Any deficiencies should be brought
to the attention of your dealer or another service
outlet, as soon as possible, so the advise of a qualified
mechanic is available regarding the need for repairs
or replacements.
A. Steering Column Lock
_ Check for proper operat-
ion by attempting to turn key to LOCK position and
turning steering wheel with car stationary. Steering
wheel should turn as long as key remains in lock.
When key is removed steering wheel should lock.
Key should be removable only in LOCK position.
B. Lap and Shoulder Belts
- Check belts, buckles,
retractors and anchors for cuts, fraying or weakened
portions, loose connections, damage, and for proper
operation. Check to make certain that anchor
mounting bolts are tight.
C. Steering
- Be alert to any changes in steering
action. The need for inspection or servicing may
beindicated by “hard” steering, excessive free play or
unusual sounds when turning or parking.
D. Windshield Wipers and Washers
- Check operat-
ion of wipers, as well as condition and alignment of

CC-10 1973 OPEL SERVICE MANUAL
wiper blades. Check amount and direction of fluid
sprayed by washers during use.,
E. Defrosters - Check performance by moving con-
trols to “DEF” and noting
am$nmt of air directed
against the windshield.
I
F. Wheel Alignment and
Balabce - In addition to
abnormal tire wear, the need fbr wheel alignment
service may be indicated by a pull to the right or
!eftwhen driving on a straight and level road. The need
for wheel balancing is usually
iddicated by a vibra-
tion of the steering wheel or
se;+ tihile driving at
normal highway speeds.I
IG. Brakes
- Be alert to illumiriation of the brake
warning light or changes in braking action,
SUCK as
repeated pulling to one side, unusual sounds when
braking or increased brake pedal travel. Any of thesecould indicate the need for
brakk system inspection
and/or service.
H. Parking Brake and Transmission “PARK”
Mechanism
- Check parking brake holding ability by
parking on a fairly steep hill and restraining the vehi-
cle with the parking brake only.
eon cars with auto-
matic transmissions, check the holding ability of the
“PARK” mechanism by releasing all brakes after
the transmission selector lever hak been placed in the“P” position.
I. Glass
- Check for broken, scrritched, dirty or da-
maged glass on vehicle that
coulld obscure vision’or
become an injury hazard.
J. Lights and Buzzers
- Check all instrument panel
illuminating and warning lights,’ seat belt reminder
light and buzzer, ignition key
b&er, interior lights,
license plate lights, side marker! lights, headlamps,
parking lamps, tail lamps, brake lights, turn signals,
backup lamps, and hazard warding flashers. Have
someone observe operation of
&ach exterior light
while you activate the controls: The operation of
instrument panel warning lights is covered in the
“Starting and Operating“ section of your
Own&%
Manual.K. Transmission Shift Indicator
‘- Check to be sure
automatic transmission shift
indiCator accurately i”-
dicates the shift position selected.
I
CAUTION: Before making thk check below,I
be sure to have a clear dist&e ahead and:
behind the car, set the parking brake and
firmly apply the foot brake.
Do not depress
accelerator pedal. Be prepared to
turn off ’
ignition switch
immediat+y if engine
should start.L. Starter Safety Switch (Automatic Transmissibn
Cars)
- Check starter safety switch by placing the
transmission in each of the driving gears while
at-tempting to start the engine. The starter should oper-ate only in the Park (“P”) or Neutral (“N”)
positions.
M. Horn
- Blow the horn occasionally to be sure thatit works. (Ignition switch must be in the “ON” posi-
tion.)
N. Seat Back Latches
- Check to see that seat back
latches are holding by pulling forward on the top of
each folding seat back.
0. Rearview Mirrors and Sun Visors
- Check that
friction joints are properly adjusted so mirrors and
sun visors stay in the selected position.
P. Door Latches
- Check for positive closing, latch-
ing and locking.
Q. Hood Latches - Check to make sure hood closesfirmly by pressing on the hood at the latching point
after each closing. Check also for broken, damaged
or missing parts which might prevent secure latch-
ing.R. Fluid Leaks
- Check for fuel, water, oil or other
fluid leaks by observing the ground beneath the vehi-cle after it has been parked for a while. If gasoline
fumes or fluid are noticed at any time, the cause
should be determined and corrected without delay
because of the possibility of fire.
S. Exhaust System
- Be alert to any change in the
sound of the exhaust system or a smell of fumes
which may indicate a leak.
Head Restraints
- Check that no head restraint
components are missing, damaged or loose. (Does
not apply to GT Models).
Disc BrakesCheck brake pads and condition of rotors while
wheels are removed during tire rotation. (Note belowregarding more frequent checks also applies to disc
brakes.)
Parking and Drum BrakesCheck drum
brake linings and other internal brake
components at each wheel (drums, wheel cylinders,
etc.). Parking brake adjustment also should be
checked whenever drum brake linings are checked.
NOTE: More frequent checks should be
made if driving conditions a.nd habits result
in frequent brake application. When brakes
require relining, it is recommended thatyou use those genuine General Motors
parts specified for your car,and Delco fluid
as required.

1 C- 18 1973 OPEL SERVICE MANUAL
IGNITIPN SYSTEM
CbNTENTS
Subject
DESCRIPTION AND OPERATION: Ignition System ..................................................................
Ignition
Switc,h....................................................................
Ignition Coil
..........................................................................\
Distributor
............................I...............................................
DIAGNOSIS: (Not Available)
MAINTENANCE AND ADJUSTMENTS: Contact PointReplacement ............................................
Dwell Angle Adjustment :
................................................
Ignition Timing Adjustment ..........................................
Ignition Wire Inspection :
..................................................
Check Ignition Output ......................................................
Check Distributor
..............................................................
Check Spark Plugs
............................................................
MAJOR REPAIR: Distributor Removal ..........................................................
Disassembly ........................
I...............................................
Reassembly
..........................I...............................................
Distributor Installation
....................................................
SPECIFICATIONS: /
Ignition
Coil ..........................................................................
Distributor
....‘........................i...............................................
Spark Plugs ........................................................................\
..
DESCRIPTION AND OPERATION
INGITION SYSTEM
The ignition system basically consists of an ignitipn
switch, ignition coil, distributor, battery and related
wiring. The ignition switch is located in the steering
column, the ignition coil is located left front inner fender
skirt and the distributor is located at the left
front of the engine.
IGNITION SWITCH
The combined ignition switch and steering lock ian
be switched to any one of the below listed positions.
Insert key with notch pointing upward.
Page No.
lC-18
lC-18
lC-19
lC-19
1 c-20
1 c-20
1 c-20
lC-21 r
lC-21
1 c-22
1 c-22
1 r-23
1 C-23
1 c-24
1 C-25
1 C-26
1 C-26
1 C-26
(Fully counterclockwise) Lock position. Ignition
locked, steering locked, only with key removed.
Electrical circuits disconnected except to main light-
ing switch and dome lamp. The
key can be removed.
0- (First position clockwise from lock) Garage posi-
tion. ‘The key and lock assembly must be pushed “in”
to reach this position from lock. The steering is un-
locked and the ignition is off. The electrical circuits
are the same as in lock position. The key cannot be withdrawn.
l- [Chposition.) All electrical circuits controlled by
ignition switch are completed through the switch.
The key cannot
be removed while switch is in drive
position.

IIIGNITION SYSTEMlC- 19
11. (Startx position.) The ignition key must be
released as soon as engine starts. The switch then
returns aujomatically to the on position.
IGNITION
GOILThe ignition coil consists of a laminated non- mag-
netic iron
(core enclosed by two coils; the primary
winding and the secondary winding.
The prim+y circuit consists of the power source
(battery), the ignition switch, the ignition coil pri-
mary winding, the distributor breaker points with
ignition condenser connected in parallel, and all con-
necting
lo& tension wiring.
The secondary circuit consists of the ignition coil
secondary ‘winding, the spark plugs, all connecting
high tens@ wiring, the distributor cap and the
ro-tor.
When the’ ignition switch is turned on and the
breaker pdints are closed, current flows through the
ignition
c&l primary winding and produces a mag-
netic field wound the coil windings.
When the breaker points are separated by the revolv-
ing distributor cam, the magnetic field collapses and
induces a high voltage surge in the secondary wind-
ing,
produ;cing a spark between the spark plug elec-
trodes. ,
The ignitidn condenser which is connected in paral-
lel with the breaker points, prevents arcing between
the
separa’ted breaker contacts, and current flow
after~ the breaker points have been separated, thus
causing a kery rapid collapse of the magnetic field
around th$ Ignition coil.
/
IGNITION ‘DISTRIBUTORThe ignitidn distributor breaks the primary current,distributeslthe high voltage surges induced in the coil
secondary winding to the spark plugs according to
the engin< tiring order and sets ignition timing in
relation to. engine RPM and load.
The housi+g of the distributor contains the centrifu-
gal advance mechanism and the movable breaker
plate with’s breaker lever and contact support. The
vacuum advance mechanism is attached to the
breaker plate and mounted on the outside of the
distributor, housing. See Figure lC-1.
The distributor shaft is driven by a helical gear on the
camshaft and in turn drives the engine oil pump. The
ignition condenser is mounted on the outside of the
housing. The engine output is to a large extent in-
fluenced b) the ignition timing. Maximum engine
performance is obtained when the combustion proc-
ess is well underway as the piston starts down on thepower stroke. The air-fuel charges are, however, not
burned instantly, so it is necessary to advance the
spark in relation to the piston top dead center as
engine speed increases or as engine load decreases.
If the spark is too far advanced, the engine knocks,
causing a drop in engine power output and overheat-
ing. If the spark is retarded, part of the energy deve-
loped during combustion is wasted which will result
in reduced engine power output, excessive fuel con-
sumption and overheating.
The ignition distributor has a double acting double
diaphragm vacuum unit. See Figure lC-1. The ad-
vance unit is supplied with “ported” vacuum. That
is, vacuum is supplied from a port in the primary
barrel of the carburetor located just above the closed
throttle valve. This port supplies no vacuum during
idling nor during closed throttle deceleration, but
supplies full intake manifold vacuum at all speeds
where the throttle valve is opened enough to uncover
the port.
Figure lC-1 Ignition Distributor
The retard unit is supplied with intake manifold
vacuum at all times by means of a line connected
directly to the intake manifold. During idling and
deceleration, when there is no vacuum to the ad-
vance unit, the retard unit will cause the timing to be
retarded 5 degrees. However, during part throttle
operation when there is vacuum to the advance unit,
the advance unit will overpower the retard unit so
that the retard unit has no effect on timing.
The purpose of the retard unit is to reduce hydrocar-
bon and carbon monoxide emissions during idling
and deceleration, where they are especially bad.
In order to avoid voltage losses for easier starting, a
plastic cover has been inserted in the distributor be-
low the rotor as a seperator to keep the inside of the
distributor cup free from condensation.

:lG- 56 1973 OPEL SERVICE MANUAL
I
FUSEqOSlTlON
1
2
3
4
5
6AMPS.
5
5
8
15
15
8ClRClJlT$ PROTECTED
OPEL 1900
& ‘MANTA (51,53,54,57,57R)
LEFT PARkING LIGHT,
LEFTTAIL LIGHT, LEFTSIDE
MARKER LIGHTS
RIGHT PApKING LIGHT, RIGH TAIL LIGHT, RIGHT
SIDE MARKER LIGHTS, INSTRUMENT PANEL LIGHTS,
SHIFT GUADRANT LIGHTS, LICENSE PLATE LIGHT,
FOG LIGHTS (RALLYE ONLY)
IGNITION IKEY
WARNIN BUZZER, TRUNK LIGHT,
HAZARD WARNING FLA,SHER, COURTESY LIGHT, CLOCK
BACKUP L’IGHTS, BLOWER MOTOR, CIGAR LIGHTER; RADIO,
SAFETY BELT WARNING BUZZER AND LIGHT
WINDSHIELD WIPERS, WINDSHIELD WASHER (RALLYE
ONLY), HORN
STOP LIGtiTS,TURN
SlGsNAL AND INDICATOR LIGHT,
PARKING BRAKE WARNING AND BRAKE FAILURE LIGHT,
FUEL GAGE, TEMPERATURE GAGE, OIL PRESSUREINDICATGR LIGHT. CHARGING INDICATOR~LIGHT,
TACHOMETER AND OIL PRESSURE GAGE (RALLYE ONLY)
AIR CONDITIONING
- 20 AMP INLINE F:USE
8
5
16
5OPEL GT
(77)WINDSHIELD WIPERS, WINDSHIELD WASHER, HORN, BACKUP
LIGHT, SP;FETY BELT WARNING BUZZER AND LIGHT
STOP LIGHTS, TURN SIGNAL AND INDICATOR LIGHT,
PARKING BRAKE WARNING LIGHT (AUTOMATIC ONLY),
BRAKE FAILURE WARNING LIGHT, RADIO, TACHOMETER,
OIL PRESiURE GAGE
& INDICATOR LIGHT, FUEL GAGE,
TEMPERATURE GAGE, CHARGING INDICATOR LIGHT
CIGAR LIGHTER, BLOWER MOTORIGNITION~KEY WARNING BUZZER, COURTESY LIGHT, CLOCK,
HAZARD WARNING FLASHER
LEFT PARKING LIGHTS, LEFT TAIL LIGHT, LEFT REAR
SIDE MAdKER LIGHT
RIGHT PA’RKING LIGHTS, RIGHT TAIL LIGHT, RIGHT REAR
SIDE MAdKER LIGHT
INSTRUMENT PANEL LIGHTS, LICENSE PLATE LIGHT.
SHIFT QUADRANT LIGHT
AIR CON,DlTlONlNG
-A/C HAS A 20 AMP INLINE FUSE AND IS
CONNECTED TO THE HOTSIDE OF FUSE NO. 23OlG3

r
2UREDp
IM
BRNIWHI
BUZZER
3 CLOSED POSlTlONl
/-
14 RED - TO STEERING
COLUMN CONN.
20 RED
12 RED FROM BATTERY--18 GRAY--12 RED
-I
J
DOME LIGHT
&SWITCH1
1
.,_ &,,,.~~
STEER I NG
COLUMN
CONNECTORTRUNK LIGHT?&SWITCH
IGNITION
SWITCH‘\BUZZER SWITCH(HELD CLOSED WITH
KEY IN “OFF” & “LOCK”POSITION1
3OlJll

ENGINE MECHANICAL AND MOUNTS6A- 3
Figure 6A-1 Side Cross Section View of Engine
This engine has full skirt “Autothermic” type pistons
with two horizontal slots in oil control ring groove,
which partly separate head and skirt to maintain
good contact with the cylinder walls throughout the
entire temperature range.
The camshaft located in the cylinder head is an
important design feature of the new power units.
This arrangement permits an extremely rigid valve
train which accounts for precise valve timing. Thegray cast iron camshaft has induction hardened bear-
ing journals and cams. Installation of camshaft is
facilated by each diameter of the four bearings and
journals being slightly smaller than the preceding.
Camshaft end play is controlled at forward end bythe camshaft front bearing seat outer face in one
direction, and by the front bearing cover in the other
direction. A nylon bolt in camshaft forward end
serves to adjust end clearance.
The camshaft is driven by an endless Duplex
rollerchain. The crankshaft double sprocket and pulley
arc held by one key. The camshaft sprocket is fixed
with a guide pin and attached with 3 bolts.
Inside the timing case, a long damper block is prov-
ided on the driving side of the chain and a shorter,
curved spring plate tensioner on the non-driving
side. Both have wear-resistant and oil-proof
sny-thetic rubber slipper pads. The self adjusting chain
tensioner located on driving side of chain at right

6A- 24 1973 OPEL SERVICE: MANUAL
on front side of timing chain to permit reinstallation
in original position.
Timing Chain Cover and Timing
Chain installation
Reinstall timing chain cover by reversing removal
procedures, pay particular attention to the following
points.
1. Clean all parts, check for wear and replace as
required. The Parts Department supplies either the two sprockets complete with chain or the chain
alone. It is not permissible to replace sprockets alone.
The chain tensioner is, with the, exception of the
tensioner body, only available as a complete unit.
2. Turn crankshaft so that key for sprocket is on top
and vertical. Assemble chain’, with camshaft
sprocket, then put chain on crankshaft sprocket al-
ready installed. Be sure paint dot
on chain is in front
so that chain moves in same direction as prior to
disassembly.
3. Make sure camshaft sprocket mark is in alignment
with mark on support and chain in parallel with
damper block.
4. To install new timing case oil seal, drive out oil
seal from the rear using a drift. Coat circumference
of oil seal sparingly with suitable sealer and press seal
in, using tool J-22924. Take care not to damage tim-
ing case. See Figure
6A-40. 5. Inspect chain tensioner for proper operation and
reusability.
6. Install timing case rubber gaskets to cylinder
block. Stick on with grease as necessary. Gaskets will
somewhat overlap with oil pan gasket.
7. Position timing cover onto guide pin in upper left
corner of cylinder block and insert centering bolt
through timing chain cover into lower right corner
of cylinder block. See Figure
6A-40A. No sealing is
required.
SA-40.4
Figure 6A-40A Installing Timing Chain Cover
INSTALLER
Figure 6A-40 Installing Timing Cover Oil Seal onProtector
It is not necessary to use crankshaft bolt to install
seal when cover is off engine. 8. Install cylinder head
After sprocket has been attached to camshaft, re-
check alignment
LO see that chain has not slipped. At
this time both No.
1 and No. 4 pistons will be at TDC
position. No. 4 piston will be in tiring position and
No. 1 piston up on exhaust stroke. To time engine to
fire on No. 1 cylinder, rotate crankshaft 360 degrees.
This will position the timing mark 180 degrees from
original alignment of camshaft sprocket and support
bracket, and will completely close No. 1 intake and
exhaust valves. Also, the timing mark on the fly-
wheel
(ball) and cylinder block (pointer) will coin-
cide. See Figure
6A-41.
Replacing Timing Cover Oil Seal
(Engine Installed)
1. Remove fan belts.
2. Remove crankshaft pulley bolt and remove pulley. 3. Insert screwdriver behind seal and rest screw-
driver on crankshaft pin. Pry out oil seal.

ENGINE MECHANICAL AND MOUNTS6A- 251, CAMSHAFT SPROCKET
2. CAMSHAFT SPROCKET SUPPORT
3. LONG DAMPER BLOCK
4. CRANKSHAFT SPROCKET
5. CHAIN AND DAMPER BLOCK
IN PARALLEL
6. CRANKSHAFT KEY
7. PAINT MARK ON FRONT
8. TIMING CHAIN
9. MARK ON CAMSHAFT
SPROCKET SUPPORT
IO. MARK ON CAMSHAFT
SPROCKET
6A-41Figure 6A-4 1 Valve Timing Marks
Removal4. Lubricate new oil seal and place on installer
J-
22924.1. Remove cylinder head.
5. Place installer J-22924 on crankshaft. Using
crankshaft bolt and washer install seal into cover. See
Figure 6A-42.2. Loosen self-locking rocker arm nuts and swing
rocker arms off valve lifters.
6. Install crankshaft pulley, bolt and washer. Torque
bolt to 72
Ib.ft.3. Remove valve lifter. Place lifters in a suitable hold-
ing fixture so that they may be reinstalled in original
position.
7. Install belts and torque to proper tension 45
lb.ft.4. Remove cover from access hole on left side andFigure 6A-42 Installing Timing Chain Cover Oil Seal
Replacing Distributor Drive Gear
On Crankshaft1. Remove fan belt.
2. Remove fuel pump. Plug end of fuel line with a
suitable stop.
3. Remove spark plug wires, distributor hold down
clamp. Remove distributor.
4. Turn crankshaft so key is on top.
5. Pry oil seal out of timing chain cover.
6. Insert a screwdriver through opening for fuel
pump and push out distributor drive gear, which has
a push tit on crankshaft, through oil seal seat in
timing cover.
7. Install new gear. Be sure key tits in
keyway. When
installing components, use new gaskets as required.
8. Install new oil seal.
9. Connect parts removed in steps 1 thru 3.
CAMSHAFT