1973 OPEL 1900 crank

19- 12 1973 OPEL SERVICE MANUAL :ConditionPosiible CauseCorrection4. Voltage drop.1. Check wiring and wiring
connections.
5. Overrun&g clutch slips.1. Replace overrunning clutch.
The cranking motor keeps
on rotating after ignition
switch is off.1. Ignition
{witch does not
cut off or solenoid switch
sticks.
1, Immediately disconnect cranking
motor cable from battery. Inspect
and/or replace or repair ignition and
solenoid switches as required.
The drive pinion does notdemesh after engine has
been cranked.1. Drive pinion or ring gear
1. Clean components as specified.
teeth clogged or flattened.Replace as required.
Return spring slack or broken.MAlNTEilANCE AND ADJUSTMENT
/
STARTING SYSTEM CHECKS
Voltage Loss ChecksWhen the starter cranks too slowly, check the bat-
tery state of charge and all electrical connections
between the battery and starter.
1. Turn on headlights and
opera’te starter. If head-
lights dim considerably when starter is engaged, the
battery may be discharged or be defective. Check the
battery.
2. If the headlights stay bright but the starter d&s
not turn over, the starter cables may be faulty or the
starter defective.
(a) Test battery voltage while cranking engine
1(9volts minimum).
(b) Check voltage from starter tkrminal of solenoid
to starter frame while cranking engine.
3. The difference in readings taken in Operations 2a
and 2b above represents the
volt& drop through the
cables and solenoid switch. Voltdge drop should
Gotexceed
.5 volt.
4. Locate excessive resistance as follows:
(a) Turn voltmeter to scale above 12 volts and con-
nect voltmeter leads
across connection or switch: to
be checked.
(b) With starter switch closed, turn voltmeter switch
to lowest scale and take reading as quickly as possi-
ble, then turn switch back to higher scale and stop
cranking engine.(c) Voltmeter must not read more than
.2 volt across
any
c:onnection. If voltmeter reads more than .2 volt,
the
d~efect must be corrected.
Starter Current Draw - Lock Test1. Make sure battery is fully charged and in good
condition.
2. Connect a volt ampere starter tester according to
manufacturer’s instructions.
3. Pull parking brake on securely, shift transmission
into 4th (direct) gear and actuate starter. (Starter will
not
t,urn engine because engine is locked through
transmission.)
4. While starter is actuated, read voltage and current.
Refer to Specification Chart.
(a) Voltage low
_ poor battery or a voltage loss in the
starter circuit.
(b) Current high
- short circuit in starter. Overhaul
starter.
(c) Current low
- commutator dirty, brushes worn,
solenoid switch contacts defective or open circuit in
starter. Overhaul starter.
Starter Current Draw. On Car1. Bring engine to normal operating temperature.
2. Stop engine and disconnect coil wire from dis-
tributor.
3. Ground coil wire to prevent excessive coil voltage
build up.

STARTING SYSTEMlB- 13
4. Connect test equipment and, with transmission in
neutral, turn engine over until voltage stabilizes.
Note read.ings.5. Current draw should be between 90-130 amperes.
I3. Remove end frame from field frame and pull both
insulating tubes out of field frame.
4. To prevent brushes from coming out when remov-
ing the field frame, place a 29 millimeter socket over
commutator while lifting up on the field frame. The
brushes will be held in place by the socket. See FigurelB-4.
STARTER
:OVERHAULStarter
R&~moval1.
Dixon&t starter wiring.
2. Remove starter support bracket.
3. Removk two starter bolts, one nut and lockwash-en.
4. Removi starter.
Starter
Di+assembly1. Hold starter in a vise, as shown in Figure
lB- 3.
Mark end’ frame and field frame to ensure correctinstallatioli of parts on reassembly.
rTHRU BOLTS7Figure
18-4 Removing Field Frame
5. Remove the two (2) solenoid attaching screws and
remove solenoid and spring.
Figure 1 B-3 Cranking Motor in Vise
2. Remove both starter through bolts and field coil
end from solenoid switch lower threaded bolt. See
Figure lB13.Figure
lb5 Driving Retaining Ring Back

STARTING SYSTEMlB- 17
7. Seal area between solenoid and frame. See FigurelB-17.
8. With brushes and spring in housings held in place
with a 29 @llimeter socket, slide frame assembly in
position.
9. Install i+ulating sleeves in field frame.
10. Install knd frame and replace through bolts and
tighten bolts.
11. Install bolt holding field frame to solenoid.
SPEClFltjATlONS
Starter SpecificationsStarterNumber. . . .
.._.._..._...........................RatedVoltage
. . . . . . . . . . . . . . . . . . . . . . . . .No voad Test:
...............................................EF 12V0 .8 PS
.....................................................................12Volts
................................................................................................................................10.6Amperes
........................................................................................................................30-50RPM
......................................................................................................................7300-8500Cranking Amperes Test (InCar-Engine atOperating Temp.)
..................................175-205
Lock Test:
Volts
............................................................................................................................6 Min.
Amperes
....................................................................................................................280-320Volt$geRequiredtoCloseSolenoidContacts
....................................................................7.5MinimumDiameterof Commutatorin
Inches................................................................1.46Brush Spring Pressure in Ounces
....................................................................................40-46Minimum Length of Brushes in Inches...............................................................................2812. Check starter on bench before installing.
Starter Installation
1. Hold starter in position.
2. Install two bolts, one nut and lockwashers.
Tighten securely.
3. Install support bracket. To ensure a stress-freeintitallation, install bolt and two nuts only finger
tight. First tighten the bolt at the engine, then tighten
the two nuts at the starter end frame.

I
ilC- 201973 OPEL SERVICE MANUAL
There is also a plastic hood slipped over the distrivu-tar cap with an outlet for the ignition cables as an
added protection against moisture from the outside.
See Figure lC-2.
Figure lC-2 Ignition Distributor With Hood Installed
MAINTENANCE AND ADJUSTMENTS
CONTACT POINT REPLACEMENT
Removing Contact Points1. Remove contact support lock
,screw and remqve
contact point support. If condenser is to be replaced,
it will be necessary to replace condenser and
1eads;asan assembly.
Installing Contact Points1. Lightly lubricate distributor cam with high tein-perature cam and ball bearing lubricant. Excessive
lubricant will throw off into contact points.
:
,
2. Position support on breaker plate and install lock
screw leaving slightly loose for later adjustment..
3. Plug breaker arm wire in.
4. Adjust breaker point gap to ,016”.
/
DWELL ANGLE ADJUSTMENT
1. Connect dwell meter.
2. Remove distributor cap. Remove rotor. Loosen
breaker point set screw approximately
l/8 turn.
3. Insert screwdriver in notch of stationary breaker
point. Observe dwell meter while cranking engine.
Twist screwdriver as required to obtain a reading of
50 degrees plus or minus 3 degrees.4. Tighten breaker point set screw, then recheck
dwell.
5. Install rotor and cap.~Start engine and recheck
dwell. It is important that dwell be rechecked, as
instal~lation of rotor and cap will sometimes change
the dwell angle.
IGNITION TIMING ADJUSTMENT
Preliminary Timing (Engine Won’t Run)To time the ignition on any engine which will run,
use subparagraph b only. However, if the timing of
an engine is completely off, the following procedure
must first be used to get the engine to run.
1. With rocker arm cover removed, rotate crankshaft
in a clockwise direction until both valves for No. 1
cylinder are closed and the timing marks line-up.
(Valves are completely closed if rocker arms can be
“rocked” slightly.)
2. Install distributor in engine so that vacuum ad-
vance unit is in original position and notch in dis-
tributor rotor lines-up with notch in housing. See
Figure lC-3. If distributor does not seat in engine
block., turn distributor shaft so that rotor points
about 20 degrees clockwise from distributor timing
notch
(see Figure lC-18), then press lightly on dis-
tributor housing while cranking engine with starter.
After oil pump tang snaps into slot in distributor
shaft, start timing again from Step 1, leaving dis-
tributor installed.
Figure lC-3 Rotor Position for Filing No. 1 Cyliqder
3. Install distributor clamp and bolt, leaving bolt just
loose enough to permit movement of distributor. In-
stall distributor primary wire.L

IGNITION SYSTEMlC-214. Rota&distributor counterclockwise slightly until
contact pbints just start to open. This must be done
very carefully or engine will not start.
5. Install distributor cap. Make sure spark plug wires
are correctly installed in distributor cap, through clip
and on spark plugs.
Finish TimingIContact boint gap
(.016” at widest gap) or dwell 50
degrees plus or minus 3 degrees should always be
checked before adjusting ignition timing.
1. Connekt timing light to No. 1 spark plug.
2. Disconnect and plug vacuum advance unit and
retard u$it hoses.
3. Connect a tachometer from distributor side of coil
to
groun$l.4. Start dngine. Set idle speed to 900 RPM.
5. Rotate distributor as necessary to align timing
marks. T;ming mark is a steel ball embedded in the
flywheel and a pointer in a window in the right fly-
wheel housing. See Figure lC-4.:Figure lC-4 Ignition Timing Marks
6.
Tightq clamp bolt securely and recheck timing
mark ahgnment.
7. Reconnect vacuum hoses and adjust engine idle
speed
an: mixture.
IGNlTlOFj WIRE INSPECTION
1. The c$il and spark plug wires are of a specialresistance type. These secondary ignition wires
reduce television and radio interference.
2. Wipe ignition wires with a cloth moistened with
solvent and wipe dry. Bend wires to check for brittle,
cracked or swollen insulation. Defective insulation
will permit missing or cross-firing of spark plugs,
therefore any defective wires must be replaced.
3. If wire insulation is in good condition, clean any
terminals that are corroded and replace any termi-
nals that are broken or damaged. Terminals must tit
tight on spark plugs and in distributor cap.
4. Replace any hardened, cracked or loose cap nip-
ples or spark plug boots.
5. Check resistance of each wire from contact inside
distributor cap to spark plug or coil terminal. Re-
place any wire having over 10,000 ohms resistance
reading. See Figure lC-5.
Figure fC-5 Checking Ignition Wire Resistance
CHECK IGNITION OUTPUT
1. Disconnect secondary coil ivire so that engine will
not start. Connect a voltmeter from the battery side
of the coil primary to ground and check voltage
while engine is cranking. Reading should be 10 volts
or more. Low reading could be caused by a defective
battery, a discharged battery, high starter current
draw, a bad connection in the starter circuit or a bad
connection in the primary ignition circuit.
2. Connect an oscilloscope according to manufac-
turer’s instructions. Disconnect coil wire. Crank en-
gine and read coil output voltage. Reading should
exceed 20 KV (20,000 volts).

IGNITION SYSTEMlC- 23
9. Install:spark plugs using a 13/16 deep socket, an
extension and a torque wrench. Tighten to 22-29Ib.ft. 1
MAJOR REPAIRDlSTRlBtiTOR OVERHAULDistributbr Removal
1. Remove fuel pump. This is necessary because the
fuel
punp will block the distributor drive gear,
thereby preventing removal of the distributor. See
Figure lC-6.
2. Set No; 1 cylinder at firing point by turning engine
INOTCH IN STATIONARY& -.until cutout in distributor shaft (or rotor tip) points
to notch in distributor housing. See Figure
lC- 7.
3. Ball imbedded in flywheel should be approxi-
mately aligned with pointer in housing. See FigurelC-4.
4. Remove distributor hold-down clamp and remove
distributor. See Figure lC-8. Cover bore in timing
case to prevent foreign material from dropping into
engine. To make reinstallation of distributor easy, do
not rotate crankshaft or oil pump.
Disassembly
1. Remove distributor cap retaining spring clips, and
vacuum control units. See Figure lC-9.
Figure lC-9 Removing Retaining Clips
Figury lC-7 Aligning Shaft Cutout With Notch
Figure lC-8 Removing DistributorFigure lC-10 Removing Retaining Ring

WINDSHIELD WIPERSlE- 37WINDSHEILD WIPERS
ALL MODELS
CONTENTS
Subject
DESCRIPTION AND OPERATION:
Windshield Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS:
Windshield Wiper
. . . . . . . . . . . . . . . . . . . , , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAINTENANCE AND ADJUSTMENTS: (Not
Applicable)
MAJOR REPAIR:Wiper Transmission
- 1900 and Manta. . . . . . . . . . . . . . . . . . . .W/per Transmission
- GT. . . . . a.* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly of Wiper Motor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning and Inspection of Parts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly of Wiper Motor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:
GeneralSpecifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torque Specifications
. . . . . . . a.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTIOfV AND OPERATION
GENERAL;DESCRlPTlDNThe two-sbeed wiper consists of a round shaped per-
manent magnet type motor and speed reduction gear
box. IOPERATldN
=The wipei motor is controlled through a dash
mounted &itch on all cars. The Rallye and GT, in
addition tb the dash mounted switch, also have a
switch moimted in conjunction with the windshield
washer fodt pump. Depressing the washer pump will
allow the bipers to operate while the pump is de-
pressed. i
DIAGNO;SIS
PRELIMINj9RY INSPECTION
1. Make
c&in of firm wire connections at wiper
motor fuse block and wiper switch.
Page No.
1 E-37
1 E-37E-38
E-38
E-40
E-41
E-4 1E-42
1 E-43
1 E-432. Check to see that the fuse is not blown.
3. Be sure wiper motor is not loose on fire wall.
4. With the yellow wire disconnected from terminal
No. 53 on the
wi@er motor, turn the ignition switch
and wiper switch to the on position and check volt-
age available to the wiper motor. There should be 12
volts available at the durple wire with a properly
charged battery.
Checking Wiper Operation1. Turn ignition switch on and engage wiper switch
to see if wiper motor will operate.
2. If wiper action is slow or inoperative, turn swit-
ches off and detach wiper control
inn from crank
arm.3. Operate wiper manually checking for excessive
bind in linkage. Correct if necessary.

1 E- 381973 OPEL SERVICE MANUAL
4. Turn switch on to see if wiper niotor will function
with wiper linkage’detached. If wiper motor will ndt
run, disconnect connector at wiper motor and co?-
nect hot lead from battery to terminal No. 53 onwiper motor. If wiper motor runs, the wiper switch
is faulty or there is an break in the lead wire. If wiper
motor still will not run, remove and bench test.
MAJOR REPAIRWIPER TRANSMISSIONS
Removal (1900 and Manta)1. Remove wiper blade (2).
2. Remove the wiper transmission retaining nut,
washer, and rubber seal ring. See .Figure lE-1.
Figure lE-1 Crank Arm Retaining Nut3. Remove instrument cluster housing.
If only left wiper transmission is to be serviced, it can
be done without removing any ‘other instrument
panel components. If the right side, or both, trans-
missions are to be serviced, then
it will be necessary
for complete instrument panel removal. On the Ral-
lye models, the gauge carrier must also be remove&Qn all
1900 and Manta Models the defroster ducts
are secured to the instrument panel cover, by two (‘2)
spring clips, and should not be removed from
dayhcover. Remove cover and duct as, a unit.
4. Remove retaining clips from transmission co;-netting rod pins. Pull connecting rods off pins. See
Item “A”, Figure lE-2.
5. Remove the screws securing the wiper transmis-
sion to the inner side of the cowl (Items “B”, Figuie
13), and remove the transmission assemblies.I
Figure lE-2 Connecting Rod Retaining Clips
Installation1. Place wiper transmissions into position at cowl
and install holding screws.
2. Push connecting rods onto transmission cranking
arm pins and install retaining clips. See Figure lE-2,
Item “A”.
3. Reinstall dash and instrument cluster parts.
4.
1nst:all the rubber seal ring, washer, and transmis-
sion retaining nut. See Figure IE-1.
5. Install wiper blades and check the position of the
blades in the park position. See Figure lE-3.
Figure lE-3 Wiper Blades in Park Position
Removal and Installation of GT W/per Transmission1. Remove nuts and remove both wiper
arms. See
Figure lE-4.
2. Remove three (3) bolts from each windshield