radiator OPEL GT-R 1973 Service Manual

IoC-91973 OPEL SERVICE MANUAL
Figure OC-5 Brake Master Cylinder
I
Figure OC-6 Tire Rotation Methods
when the clutch pedal has in excess of 1
l/4 inch fr&
travel. See Figure OC-7.
Rear Axle
Change lubricant every
12,ooO miies when vehicle is
used for pulling a trailer.
Cooling SystemCheck at 12-month or
12,000~mile intervals, wash
radiator cap and filler neck with clean water, pres-
sure test system and radiator cap for proper pressure
holding capacity (tighten hose clamps and inspect
condition of all cooling and heater hoses). Replace
hoses every 24 months or 24,000 ,miles or earlier :if
checked, swollen or otherwise deteriorated.
Also each 12 months or
12,ooO miles, clean exteribr
of radiator core. Every 24 months or
24,OCO miles,Floor-Pan
-Clutch Pedal
Figure OC-7 GT Clutch Lash
drain, flush, and refill the cooline svstem with a new
coolant so&ion of permanent
6~; anti-freeze and
water for protection-of -20°F.
D-6 NOT REMOVE
RADIATOR CAP WHEN SOLUTION IS HOT
AND UNDER PRESSURE.
Wheel BearingsClean and repack front wheel bearings with a lubri-
cant as specified on the lubrication chart, Figure
oc-1.
Automatic Transmission FluidUnder normal driving conditions, change the trans-
mission fluid every 24,000 miles. Under unusual con-
ditions such as constant driving in heavy city traffic
during hot weather, trailer pulling, etc., this service
should be performed at
12,COO mile intervals.
General Motors DEXRON Automatic Transmis-
sion Fluid, which has been especially formulated and
tested for use in your automatic transmission, is
recommended. Other automatic transmission fluids
identified with the mark DEXRON are also recom-
mended.
Check the fluid level at each engine oil change
period. To make an accurate fluid level check:
1. Drive car several miles, making frequent starts and
stops, to bring transmission up to normal operating
temperature (approximately
180-190’F.)2. Park car on a level surface.
3. Place selector lever in “Park” and leave engine
running.

I
IGAUGES1 I- 69
I
I
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.
I
4. Install /instrument cluster housing.
I
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.

FRAME AND BODY MOUNTINGS28. 7A
B
C
DE
F
G
H
I
.I
K
L
M
N0
P
Q
R
S112”25-l/4”
22-314”
SO-5/16”
50-5/16”49-l/8”
59-l IS”
35-314”32”36-l/8”
28-19132”
39-118”
15-118”
12-2132”lo-3/4”
6II6”
.l l-5/16”16-l/4”GT FRAME MEASUREMENTS
From centerline of lower ball joint stud to centerline of front lower arm
bushing.
Outside of left frame horn to outside of right frame horn.
Centerline of front crossmember right attaching bolt holes to centerline of front
crossmember left attaching bolt holes.
From centerline of hole in radiator support to right front frame horn
reinforcement to centerline of left front underbody drain hole.
From centerline of hole in radiator support to left front frame horn
reinforcement to centerline of right front underbody drain hole.
From rear outside edge of right front frame rail to rear outside edge of left
front frame rail.
From centerline of lower ball joint stud to centerline of second side drain hole.
Centerline of right lower control arm to centerline of left lower control arm.
Centerline of second side underbody drain hole to centerline of rear spring seat.
Centerline of right spring seat to centerline of left spring seat.
Centerline of spring seat to bumper bracket bolt hole on outside of lower tail
panel.
Outside edge of right rear frame rail to outside edge of left rear frame rail.
Centerline of radiator support bolt hole to centerline of front crossmember front
attaching bolt holes.
Lower edge of front frame horn to datum line.
Frame rail mating surface for front crossmember to datum line.
Front portion of underbody to datum line.
Rear portion of underbody to datum line.
Center of spring seal to datum line.
Centerline of rear bumper bracket to lower tail panel bolt to datum line.

3A- 6 1973 OPEL SERVICE MANUAL
Figure 3A-10 Steering Mast Clamp Bolt
assembly at the cross member to body support from
frame and let it down onto jack. See Figure
3A-11.
Figure 3A-1 1
Installation
GT
CAUTION: Fasteners are important attachingparts in
that they could affect the performance of vitaI com-
ponents and systems, and/or
coo/d result in major
repair expense. They must be replaced with one of the same part number or with an equivalent part if
replacement becomes necessary. Do not use a re-
placement part or lesser quality or substitute design. Torque
values
must be used as speciiied during reas-
sembly to assure proper retention of these parts.
I. Support front suspension and cross member on
jack and raise into position.
2. Attach cross member to front frame rail. Torque
to 36
lb.ft.
3. Install engine mounting nut? Remove engine sup-
port.
4. Install shock absorber mounting bolts and install
air cleaner.
5. Connect brakes hoses and bleed brakes as outlined
in Group 5.
6. Install radiator mounting bolt in support cross
member.
7. Push steering column downwards until a
l/8”
clearance is obtained between steering wheel hub and
switch cover.
8. With steering wheel in centered position and front
wheels straight ahead, tighten the clamp bolt at the
lower universal joint to 22
fbs.fi. and the clamp at
the upper universal joint to 14
lbs.ft. See Figure
3A-6.
9. Inr;tall mast guide sleeve stop bolt. Always install
new lock plate. See Figure
3A-7.
10. Remove front support stands and lower vehicle.
Installation Opel 1900 - Manta
1. With jack, lift up front suspension assembly so
that the individual attaching points coincide. At the
same time, insert lower steering mast into pinion
flange. See Figure
3A-12.
2. In the rear bolt cross member to body support.
Torque to 58
ft.lbs. When doing this with a suitable
tool, counterhold damper bushing which is installed
in a certain position, to prevent it from turning. For
this purpose, detach heat
deflectqr plate on right
vehicle side.
3. Torque front suspension assembly to frame attach-
ment to 47
ft.lbs.
4. Torque lower steering mast to pinion flange at-
tachment clamp bolt to 22
ft.lbs.
5. Reinstall both brake calipers. Torque to 72 ft.lbs.
Install brake line retainer.
6. On both sides install upper control arm ball joint.
Torque bolts to 29
ft.lbs.

6A- 8 1973 OPEL SERVICE MANUAL
Actual adjustment is made by backing off adjusting
nut at the rocker arm until clearance exists between the valve stem, rocker arm, and lifter. Then slowly
tighten adjusting nut until clearance is eliminated.
When clearance is eliminated, turn adjusting nut one
full turn (clockwise). This positions the hydraulic
piston of the hydraulic lifter mid-point in its total
available travel, and no further adjustment is re-
quired.
MAJOR REPAIR
ENGINE ASSEMBLY REMOVAL AND
INSTALLATION
Removal (Opel 1900 and Manta)’
The engine assembly on the Opel 1900 and Manta
can be removed together with the transmission
through the top of the engine compartment.
1. Remove hood (scribe hood hinge to hood mount-
ing location).
2. Disconnect battery negative cable.
3. Drain coolant at lower radiator hose.
4. Remove upper and lower radiator hoses.
5. Remove radiator and fan
shrbud.
6. Disconnect heater hoses.
7. Disconnect brake booster
vacuum hose.
8. Remove air cleaner.
9. Disconnect electrical connections and accelerator
linkage. 10. Remove console.
11. Remove shift lever boot, plate, and shift lever.
12. Raise car on hoist.
13. Disconnect fuel line at pump.
14. Remove front stone shield.
15. Disconnect speedo-cable, back-up light switch,
and clutch cable.
16. Remove drive shaft. I
17. Disconnect exhaust pipe
ar$l bell housing sup-
port.
18. Disconnect transmission support. See Figure
6A-7. 19. Remove engine mount bolts. See Figure
6A-8.
20. Attach hoist chains.
21. Lift engine and transmission assembly out of car.
Figure 6A-7 Transmission Support Bolts . Opel 1900
and Manta Series
Figure
6A-B Engine Mount Bolts - Opel 1900 and
Manta Series
Removal (GT)
The removal and installation of the 1.9 liter engine is only possible towards the floor and from below
Fig, 6A-9 Left Front Engine Suspension with Cross
Member (GT)

ENGINE MECHANICAL AND MOUNTS6A- 9
The engine does not rest on the front suspension
cross member as in the Opel 1900 and Manta but on
a separate cross member. On removal and installa-
tion of the engine the front suspension cross member
need not be detached.
Fig. 6A-10 Right Front Engine Suspension with Cross
Member
(GT)1. Disconnect battery negative cable,
2. Remove air cleaner.
3. Drain radiator coolant by disconnecting lower
radiator hose. Disconnect upper radiator hose. See
Figure 6A-11. Radiator need not be disconnected.
4. Disconnect all electrical connections:
a. Coil wire to distributor.
b. Wires from alternator. Remove unit and bracket.
c. Battery positive cable at starter switch.
d. Oil pressure switch wires at cylinder block.
e. Wires from starter solenoid.
5. Remove vacuum hoses at tee mounted to intake
manifold. Remove tee from manifold to avoid inter-
ference during engine lowering.
6. Remove throttle linkage and carburetor.
7. Disconnect heater hoses.
8. Disconnect water valve bracket to manifold,
9. Remove gear shift lever.
10. Using suitable equipment lift up engine so that
front engine mounts are somewhat relieved.Figure 6A.1
1 Radiator Hose Clamp Location
11. Raise vehicle, both front and rear end. A two post
axle type hoist
IS recommended for this operation.
12. Disconnect fuel line at fuel pump and plug. Be
sure fuel line is disconnected from any engine and
transmission clips.
13. Disconnect speedometer cable from transmis-
sion.14. Disconnect clutch cable.
15. Disconnect drive shaft at rear universal joint and
remove.
16. Disconnect exhaust at manifold.
17. Remove tailpipe and mufIler hangers.
18. Remove ground strap from engine to side rail.
19. Detach transmission cross member from trans-
mission and frame. See Figure 6A-12.
20. Detach engine cross member from engine and
frame.21. Carefully lower engine and transmission and
remove from underneath vehicle.

6A- 121973 OPEL SERVICE MANUALINTAKE AND EXHAUST MANIFOLD REMOVAL
AND
INSTALLATION
Removal1. Disconnect battery.
2. Remove air cleaner.
3. Disconnect throttle linkage at carburetor.
4. Disconnect vacuum advance line at carburetor.
5. Remove fuel line at carburetor inlet.
6. Remove positive crankcase ventilation hose at
rocker arm cover.
7. Disconnect E.G.R. lines from carburetor and in-
take manifold.
8. Disconnect exhaust pipe.
9. Remove six bolts attaching manifold assembly to
cylinder head and remove manifold and carburetor
as an assembly. Discard manifold gasket.
To separate intake and exhaust, manifold, remove
carburetor and four bolts using Tool J-23016, attach-
ing intake manifold to exhaust manifold. Always in-
stall a new manifold intermediate gasket when the
manifolds are separated.
Installation1. Install new manifold gasket and place manifold in
position.
2. Install manifold bolts. New manifold to cylinder
head gasket must be installed whenever a manifold
is removed.
3. When installing the manifold, start with the No.
1 and No. 2 bolts. See Figure 6A-16. Gradually
tighten both bolts until snug. Then continue with the
rest of the bolts in the sequence illustrated in Figure6A-16. Torque bolts to 33 lb. ft.
Figure 6A-16 Manifold
Bolt Tightening Sequence4. Connect parts removed in Steps 1 thru 8 above.
CYLINDER HEAD REMOVAL AND INSTALLATION
Removal1. Drain coolant from radiator and block. Loosen
drain plug on right side of engine to avoid coolant
entering into cylmder bores. Drain plug is located onthe right rear of cylinder block above oil pressure
switch.2. Remove hoses from thermostat housing. Collect
coolant as it contains anti-freeze.
3. Remove 6 intake and exhaust manifold attaching
bolts and swing assembly aside.
4. Remove spark plug wires from plugs.
5. Remove bracket bolt holding spark plug wires
away from cylinder head.
6. Remove rocker arm cover.
7. Remove 10 cylinder head bolts using 12 MM ser-
rated drive J-22915, and 2 cylinder head to timing
chain cover bolts with a 6MM hex head wrench. See
Figure 6A- 17.
Figure 6A-17 Serrated Bits
8. Remove three bolts attaching plate to front of
cylinder head.
9. Remove plastic screw from end of camshaft.
10. Remove 3 bolts attaching camshaft sprocket to
cylinder head. Slide sprocket off of camshaft and
remove head. Place head on bench supported at each
end by a block of wood to prevent damage to valves.
Installation1. Install in reverse procedure to removal, paying
particular attention to the following:

ENGINE MECHANICAL AND MOUNTS6A- 231. NOTCH IN PISTON HEAD
POINTING TOWARD THE FRONT
2. OIL HOLE IN CONNECTING ROD
POINTING TOWARD THE RIGHT
(MANIFOLD SIDE)
3. NOTCH IN CONNECTING ROD
CAP POINTING TOWARD THE
REAR6A-36
Figure
6A-39 Piston and Rod Assemblyby oompressing the rings with a “wrap around” com-
pressor.9. Select a new connecting rod bearing, if necessary.
Otherwise install cap with bearing lower shell on rod
and tighten bolt nuts to 36
lb.ft. torque.
10. Install all other piston and rod assemblies in same
manner. When piston and rod assemblies are prop
erly installed, the oil spurt holes in the connecting
rods will be facing right.
11. Check end clearance between connecting rods in
each crankpin using feeler gages. Clearance should
be between
.0043” and .0095”.
12. Install cylinder head. Torque 10 cylinder head
bolts to 72 lb.ft (cold), and 2 cylinder head to timing
chain cover bolts to 17
lb.ft.13. Install new oil pan gasket by first installing flange
gasket with tabs in slots in rear main bearing cap and
engine front cover. Then install rubber strips in
grooves in rear main bearing cap and engine front
cover. Install oil pan, torquing bolts to 5 lb.ft.
14. Install (Opel
1900 and Manta) front suspension
assembly. (GT) Install engine suspension cross mem-
ber.After installation of new pistons and rings, care
should be used in starting the engine and in running
it for the first hour. Avoid high speeds until the parts
have had a reasonable amount of break-in so that
scuffling will not occur.
TIMING CHAIN COVER AND TIMING CHAIN
Timing Chain Cover Removal
1, Support engine in vehicle as outlined under Engine
Oil Pan Removal and Installation.
2. Remove radiator and shroud assembly
3. Remove cylinder head.
4. Remove alternator belt and remove alternator
mounting bracket.
5. Remove fuel pump
6. Remove ignition distributor.
7. Remove chain tensioner assembly out of timing
cover.8. Remove crankshaft pulley bolt and remove pulley.
9. Remove water pump assembly.
10. Remove oil pan
11. Remove timing chain cover bolts. One bolt is
covered by the water pump. See Figure 6A-39.
12. Pull off sprockets with chain. Put a paint mark
Figure 6A-39 Bolt Behind Water Pump

66.321973 OPEL SERVICE MANUAL
COOLING SYSTEM
CONTENTS
Subject
DESCRIPTION AND OPERATION:
Cooling System and Water Pump
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS:
Checking and Filling Cooling System
. . . . . . . . . . . . . . . . . . . . . . . .Draining
andFlushingCoolingSystem. . . . . . . . . . . . . . . . . . . . . .Conditioning the Cooling System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using and Testing Anti-Freeze Solutions
. . . . . . . . . . . . . . . . . .Fan Belt Adjustment or Replacement
. . . . . . . . . . . . . . . . . . . . . . . .Radiator Thermostat Inspection and Test
. . . . . . . . . . . . . . . .MAJOR REPAIR:
Water Pump Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Radiator
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:
Cooling System Capacities
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page No.
68-32
6B-32
68-32
68-33
68-33
68-33
68-33
68-34
68-34
6B-35
DESCRIPTION AND OPERATION
COOLING SYSTEM AND WATER PUMPThe coiling system is of the conventional pressurized
type. A centrifugal pump arranged in timing case
serves to circulate the coolant.
When the thermostat is closed, the coolant will re-
turn to the pump via a by-pass for swift and uniform
warming up of the engine the coolant circulates
through the radiator, only when the engine has
reached normal operating temperature.
The heater system branches off the cooling system
ahead of thermostat in flow direction so that the
heater is in operation before engine has reached full
operating temperature.
MAINTENANCE AND ADJUSTMENTS
Checking and Filling Cooling SystemThe coolant level should be checked only when the
engine is cold and only enough coolant should be
added to bring the level halfway between core andtank top. It is unnecessary and undesirable to remove
the radiator cap and check the coolant level each
time the car stops at a filling station for gasoline or
oil, since the engine is usually hot at such times.
WARNING: Never remove the radiator cap quickly
when engine is HOT Sudden release of cooling
sys-
tern pressure may cause the coolant to boil and some
of it may be ejected from the radiator
filler neck,
resulting in
inl’ury to persons or damage to the car
finish.If it is necessary at any time to remove the radiator
cap when engine is hot, rotate the cap counterclock-
wise until first stop is reached. Leave cap in this
position until all pressure in cooling system has been
released, then turn cap past the first stop and remove
it.
Draining and Flushing
Cooling SystemThe cooling system should be completely drained
and the recommended coolant installed every two (2)
years.To drain the cooling system, remove radiator cap,
remove lower radiator hose from the lower tank and

COOLING SYSTEM6B- 33
remove drain plug on right.side of cylinder block. Set
heater temperature control valve at full heat posi-
tion. After the cooling system is drained, and plugs
reinstalled, fill the system with clean water. Run the
engine long enough to open the thermostat for com-
plete circulation through the system, then com-
pletely drain the cooling system before sediment has
a chance to settle.
Conditioning the Cooling System
“Rust Inhibitor and Stop Leak”, or equivalent listed
under Group 8.800 is recommended for use in the
cooling system, particularly when preparing for in-
stallation of anti-freeze solution. This material stops
small seepage leaks, has rust preventive properties
and its soluble oil is effective in eliminating a squeal-
ing noise which sometimes develops at the water
pump seal washer. Instructions for its application are
printed on the conditioner bottle.
It is very important to make certain that the cooling
system is properly prepared before an anti-freeze so-
lution is installed, otherwise loss of solution through
leakage may occur or seepage may result in damage
to the engine. The cooling system should be drained
and flushed as described under Draining and Flush-
ing Cooling System. All joints should be checked for
leakage and corrected, and the conditioner described
above should be added with the anti-freeze solution.
Inspect the water pump, radiator core, heater and
defroster cores, water jacket plugs, and edge of cylin-
der head gaskets for evidence of water leaks. Tighten
all hose clamps in the cooling and heating systems
and replace any deteriorated hoses.
Using and Testing Anti-Freeze
Solutions
Inhibited year around (ethylene glycol type) engine
coolant solution which is formulated to withstand
two full calendar years of normal operation without
draining or adding inhibitors should be used at all
times. Freeze protection should be provided to pro-
tect against corrosion. When adding solution due to
loss of coolant for any reason or in areas where tem-
peratures lower than minus 20 degrees F. may be
encountered, a sufficient amount of any of the sev-
eral brands of year around coolant (Ethylene Glycol
base) compatible to GM Specification 1899-M avail-
able on the market should be used. Water or alcohol
base coolants are not recommended for this vehicle
at any time.
If for any reason water only is used as a coolant in
an emergency, it is extremely important that Buick
Heavy Duty Cooling System Protector and Water
Pump Lubricant or equivalent be added to the cool-
ing system as soon as possible. If any other cooling
System protector is used, be certain it is labeled toindicate that it meets General Motors Specification
GM 1894-M. It should be recognized that this is only
a temporary measure. The manufacture intends that
permanent type coolant solution be used year around
in the cooling system.
The cooling system should be completely drained
and the recommended coolant installed every two (2)years.It is advisable to test the anti-freeze solution at inter-
vals during the winter to make certain that the solu-
tion has not been weakened. Use only hydrometers
which are calibrated to read both the specific gravity
and the temperature, and have a table or other means
of converting the freezing point at various tempera-
tures of solution. Disregarding the temperature of
the solution when making the test may cause an error
as large as 30 degrees F. Care must be exercised to
use the correct float or table for the particular type
of anti-freeze being tested.
Fan Belt Adjustment or Replacement
A tight fan belt will cause rapid wear of the alterna-
tor and water pump bearings. A loose belt will slip
and wear excessively and will cause noise, engine
over-heating, and unsteady alternator output. A fan
belt which is cracked or frayed, or which is worn so
that it bottoms in the pulleys should be replaced. The
fan belt may be replaced by loosening the alternator
brace at alternator, slightly loosening the alternator
mounting bolts and moving alternator inward to pro-
vide maximum slack in the belt.
The alternator must be moved outward to adjust the
fan belt. After the generator brace and mounting
bolts are securely tightened, the fan belt tension
should be 45 lb. using Tensioner J-23600.
WARNING: Zfa
fan blade is bent or damaged in any
way, no attempt should be made to repair and reuse
the damaged part. A bent or damaged fan assembly
should always be replaced with a new
fal. assembly.
It is essential that fan assemblies remain in proper
balance and proper balance cannot be assured once
a fan assembly has been bent or damaged. A fan
assembly that is not in proper balance could fail and
fly apart during subsequent
we creating an ex-
tremely dangerous condition.
Radiator Thermostat Inspection and Test
A sticking radiator thermostat will prevent the cool-
ing system from functioning properly. If the thermo-
stat sticks in the open position, the engine will warm
up very slowly. If the thermostat sticks in the closed
position, the engine will overheat.
The thermostat may be removed for inspection and