1973 OPEL 1900 manual transmission

6A- 101973 OPEL SERVICE MANUAL
Fig. 6A.12 Transmission Cross MemberInstallation (Opel 1900 and Manta)1. Lower engine and transmissior assembly into car.
2. Install components as
remov&d in steps .1 through
19 above.
Installation (GT)1. Install bell housing, transmission and starter.
2. Using suitable equipment raise assembly into vehi-
cle.
3. Install components as removed in steps 1 thru 21.
ENGINE OIL PAN REMOVAL AND INSTALLATION
Removal (Opel 1900 and Manta)To remove the engine oil pan, a device similar to the
one illustrated in Figure 6A-14 can be made and used
to support the front of the engine. This particular
device was made up using hardwood, bolts, and
chain.
1. Assemble chains to engine.
Figure 6A-14 Engine Support Tool
- Opel 1900 and Manta.

6A- 18 1973 OPEL SERVICE MANUAL
pressure. If heavy pressure is required, shell was not
started squarely and will be distorted if force into place.
12. Place lower bearing shell in bearing cap, then
check clearance
with plastic-type gauge, as previ-
ously described.
13. The desired clearance with a new bearing is
.0009” to .0025”. If this clearance cannot be obtained
with a standard size bearing, insert an undersize
bearing and check again
w&h plastic-type gauge
material.
14. When the proper size bearing has been selected,
clean out all plastic gauge material, oil the lower
shell and reinstall bearing cap. Clean the bolt holes
and lube bolts, then torque cap bolts to 72 lb. ft. The
crankshaft should turn freely at flywheel rim; how-
ever, a very slight drag is permissible if an undersize
bearing is used.
15. If the thrust bearing shell is disturbed or replaced
it is necessary to line up the thrust surfaces of the
bearing shell before the cap bolts are tightened. To
do this, move the crankshaft fore and aft the limit of
its travel several times (last movement fore) with the
thrust bearing cap bolts finger tight.
16. After bearing is installed and tested, loosen all
bearing cap bolts
l/2 turn and continue with other
bearings. When bearings have been installed and
tested, tighten all bearing cap bolts to 72 lb. ft.
17. Replace rear bearing oil seals.
18. Install pipe and screen assembly and oil pan.
Installation of Rear Bearing Oil
Seals (Engine in Vehicle)
1. Remove transmission, bell housing and clutch.
Refer to appropriate section for removal procedures.
Figure 6A-28 Removing Rear Main Oil Seal
2. Remove flywheel.
3. Punch a hole into oil seal and screw in a sheet
metal screw and pull out oil seal. See Figure
6A-28.
4. To insure proper sealing, lubricate seal with a
suitable protective grease and install on taper ring
J-22928. Turn seal to ensure lip of seal is not turned
back. See Figure
6A-27.
OIL SEAL’6A-29
Figure
6A-29 Installing Oil Seal on Tool J-22928
5. Place tapered ring with oil seal on crankshaft
flange and move lip of seal
over rear of crankshaft.
Be careful not to tilt seal.
Figure 6A-30 Installing Rear Main Bearing Oil Seal
6. Drive in oil seal using Tool J-22928-2. See Figure
6A-30.
7. Install flywheel, clutch, bell housing and transmis-
.

6A- 28 1973 OPEL SERVICE MANUAL
Part
ConnectingRod Bolts..........................................................
Crankshaft Main Bearing Bolts
..........................................
FlywheeltoCrankshaft AttachingBolts..........................
Cylinder Head Attaching Bolts....Cold 72 -Warm 58
Camshaft Sprocket Attaching Bolts................................
Generator Bracket to Cylinder Block
Attaching Bolts ..................................................................
Generator Bracket to Timing Case Attaching Bolts
....
Crankshaft Pulley Attaching Bolts ....................................
Rocker Arm Stud in Cylinder Head ..................................
Spark Plugs ........................................................................\
....
Clutch Housing to Cylinder Block Attaching Bolts
......
Timing Case to Cylinder Block AttachingBolts ............
Water Pump to Timing Case AttachingBolts................
Engine Support to Cylinder Block Attaching Bolts
......
Rear Engine Suspension to Transmission Rear Bearing Retainer Bolts ....................................................
Transmission to Clutch Housing Attaching Bolts
........
Starter to ClutchHousing AttachingBolts....................
Support to Starter Attaching Nut
....................................
Intake and Exhaust Manifold to Cylinder Head Attaching Bolts ..................................................................
Unless Otherwise Noted:
10
@i Bolt (15 MM Hall.....................................................................- -
36
72
43
18
;i
72
29
30
36
14
11
40
22
29
40
4
33 ............30
8 MM Bolt (13 MM Head)........................................................................\
........................................................................\
........................................15
6 MM Bolt (10 MM Head)
30 Lb.In.
Torque
Lb.Ft.
GENERAL SPECIFICATIONS
Type - No. of Cylinders
Valve Arrangement........................................................................\
........................................................................\
......................................................I;nlinzai
Bore and Stroke Piston Displacement Cu. In.
........
3.66 x1:;:;
Compression Ratio......................................................................................\
........................................................................\
........................................................................\
........................................
\fô\
²…..............7.6:1Octane Requirement........................................................................\
..........
Firing Order........................................................................\
........................
Regular - Lo;-?::
....................Cylinder Block Material....... ...............................................................................\
..............................................Cast Iron
Crankshaft Bearings Number and Type 5 Removable Steel Backed
In-Metal Babbitts
Bearing Which Takes End Thrust
........................................................................\
...................5
Connecting Rod Bearing Material
........................................................................\
..................
Steel Backed Tri-Metal Babbttts
Piston Material and Surface Aluminum Alloy, Lead Coated
Piston Pin Offset
........................................................................\
............,031 In. to the RightCompression Rings Material and Surface Treatment
No.
1....... ........... ............... ........ ............. ................Chrome-plated, Cast Iron
- Rectangular
No. 2
........................................................................\
..............................Cast Iron - Tapered
Oil Ring
........................................................................\
..................Chrome-plated, Cast Ir?n
Location of All Piston Rings
........................................................................\
Above Ptston Pm
Camshaft Material
........................................................................\
....................Alloy Cast Iron
Camshaft Drive........................................................................\
........................................Chajn
Number and Type of Camshaft Bearings 4 Steel-Backed Babbttt
Valve Lifter Type
..............................................................................................\
..........................................~..........Hydraulic
Oiling System Tvoe........................................................................\
Circulatmg High Pressure
Oil
&ppiied to: - .
Bearing Surfaces, Crankshaft, Camshaft and Connecting Rods............................Pressure
Piston, Pins
........................................................................\
............................................Vapor
Cvlinder Walls........................................................................\
..........................Nozzle Spray
Rocker Arms _,,,..,,....,._..___.,,..,,..............,,,,...,.......,..,,,.,.,,.....\
....,,...,.,.................~...... Pressure
Oil Reservoir Capacity
- Quarts .,,,...,,__.,,..,..,,..,...,..,,,...,,..............,,,... 3 l/4 With Dry Fdter
Oil Filter
- Type ,,....,__.,,...,....,....,,..,,,..,,...........,........................\
............ Throw Away Element

6B- 341973 OPEL SERVICE MANUAL
test by partially draining the cooling system and dis-
connecting the water outlet housing from the ther-
mostat housing which is mounted on the right front
side of cylinder head.
The standard thermostat valve should start to open
at 189 degrees F and fully open at approximately 212
degrees F. If thermostat does not operate at specified
temperatures, it should be replaced as it cannot be
repaired.MAJOR REPAIR
WATER PUMP REPAIRSThe water pump bearing outer race is shrunk fit into
the water pump cover. For this reason the cover,
shaft bearing, and hub are not repairable.
Water Pump RemovalOpel radiators do not have a drain plug. Drain radia-
tor by first, loosening radiator cap, then remove
lower hose from lower radiator tank.
1. Drain coolant into a clean container. Remove
radiator and shroud.
2. Remove fan belt.
3. Remove fan blade and pulley on water pump shaft.
4. Disconnect inlet hose and heater hose from water
pump. Remove bolts, pump assembly and gasket
from timing chain cover.
5. Check pump shaft bearing for end play or rough-
ness in operation. If bearings are not in serviceable
condition, the assembly must be replaced.
Water Pump Installation1. Make sure the gasket surfaces on pump and timing
chain covers are clean. Install pump assembly with
new gasket. Bolts must be tightened uniformly.
Torque to 11 lb. ft.
2. Install radiator and shroud. Connect radiator hose
to pump inlet and heater hose to nipple.
3. Install fan pulley and fan blade, tighten attaching
bolts securely. Install belts and adjust for proper
tension.4. Fill cooling system and check
,for leaks at pump
and hose joints.
RADIATOR REMOVAL AND INSTALLATION
RemovalI. Loosen radiator cap, then remove lower radiator
hose and drain radiator coolant into suitable con-
tainer.
2. On vehicles with automatic transmission, unscrew
oil lines from connectors on lower radiator tank and
plug lines. On GT models with automatic transmis-
sion the lines have to be disconnected at the coupling
before removing from the tank. It is essential that no
dirt enters the oil lines. When unscrewing oil lines,
hold connectors on lower radiator tank with pliers to
avoid leakages. Ensure that no dirt enters oil cooler.
3. Remove lower attaching nut and slide radiator
upward and out of engine compartment.
Installation1. Install radiat,or into engine compartment and se-
cure lower attaching nut.
2. On vehicles with automatic transmissions, fasten
oil cooler lines to lower radiator tank. It is essential
that no dirt enters the oil lines. When tightening oil
lines, hold connectors on lower radiator tank with
pliers to avoid leakages. Ensure that no dirt enters oil
cooler. Torque to 1 I-15
lbs.ft.3. Install lower radiator hose and add collected coo-
lant.
All Opels are provided with a radiator initial fill of
an antifreeze solution containing corrosion inhibitor.
The antifreeze has either a glycol or glycerin base
and protects the engine against freezing, down to
minus 22 degrees F. (minus 30 degrees C.). Before
the start of the cold season, coolant must be checked
with a hydrometer and if necessary, brought to the
necessary specific gravity by adding anti-freeze with
a glycol or glycerin base. As the specific gravities of
all anti- freeze solutions having a glycol or glycerin
base are practically the same, the hydrometer can be
used for all these types. Because of the tolerances of
the hydrometer, or slight differences in specific
gravity, variations of plus or minus 5 degrees can be
expected. Coolant must be checked at a temperature
of plus 68 degrees F. (plus 20 degrees C.)

CARBURETOR AND THROTTLE LINKAGE6E- 51
water, adjust the throttle stop screw to read 6 inches
of water (3 inches down and 3 inches up).
4. Disconnect manometer and reconnect the vacuum
advance hose.
5. Adjust idle air speed screw and mixture screw to
obtain maximum idle at 850 to 900 R.P.M. (auto-
matic transmission) or 900 to 950 R.P.M. (manual
transmission).
6. Make final adjustment by turning idle mixture
screw in to reduce idle speed 50 R.P.M.
7. Install red plastic caps over the air speed screw
and idle mixture screw. Replace plastic cap over the
throttle valve stop screw and secure in place with
Loctite.
Fast Idle Speed Adjustment
1. Remove air cleaner cover.
2. With engine off, open the throttle halfway and
close the choke valve, release the throttle, then re-
lease the choke.
3. Start engine without moving the throttle. Adjust
to 3200 to 3300 R.P.M. using 2 nuts on fast idle rod.
See Figures 6E-13 and
6E-14.Figure
6E-13 Decreasing Fast Idle Speed
CARBURETOR LINKAGE ADJUSTMENT
GT Series1. Remove air cleaner.
2. Have helper depress accelerator pedal to floor and
check to see if wide open throttle is reached at carbu-
retor.
3. If adjustment is necessary, proceed as follows:
6E-14Figure
6E-14 Increasing Fast Idle Speed
(a) Unhook accelerator pedal return spring.
(b) Remove lock spring at upper end of vertical con-
trol rod and detach rod.
(c) Lengthen or shorten control rod so that wide
open throttle is obtained at the carburetor when ac-
celerator pedal is
l/4” - l/2” from floor mat.
(d) Reinstall rod, lock spring and pedal return
spring.
Opel 19W and Manta SeriesThe carburetor bowden control wire is properly ad-
justed if, with correctly-adjusted engine idle speed,
engine at operating temperature and accelerator
pedal at an angle of 25 degrees to the vertical plane,
the ball (A) of the carburetor bowden control wire
rests against the accelerator pedal lever. See Figure
6E-15.
1. Position accelerator pedal at an angle of 25 degrees
to the vertical plane. To do this, loosen lock nut of
adjusting bolt (c) and unscrew adjusting bolt a few
turns.
Squeeze a 1 3/S” wood block (D) between accelera-
tor pedal and dash panel. See Figure
6E-15.Screw in adjusting bolt until the accelerator pedal
lever releases the wood block (D). Tighten lock nut.
2. Adjust bowden control wire at adjuster. See Figure
6E-16. Prior to doing this, adjust engine idle speed
with engine at operating temperature.
Set carburetor bowden control wire adjuster at the
bracket so that the ball (A) of the control wire rests
against part (B) of the accelerator pedal lever and the
wire core between bracket and segmental disc is not
sagging.

6F. 62 1973 OPEL SERVICE MANUAL
bleed into the vacuum line, allowing more manifold
vacuum to reach the vacuum motor. Whenever there
is nine inches or more of vacuum in the vacuum
motor, the diaphragm spring is compressed, the door
is opened.
When the engine is not running, the diaphragm
spring will always hold the door closed. However,
when the engine is running, the position of the door
depends on the air temperature in the air cleaner.
When starting a cold engine (air cleaner temperature
under 85 degrees), the air door will open immedi-
ately. This is because the air bleed valve in the sensor
is closed so that full manifold vacuum, is applied in
the vacuum motor. As soon as the air cleaner starts
receiving hot air from the heat stove, the sensor will
cause the air door to close partially, mixing cold air
with the hot air as necessary to regulate air cleaner
temperature within 20 degrees of the ideal 115 de-
grees air inlet temperature.
If underhood air temperature rises to 135 degrees,
the air bleed valve in the sensor will be wide open so
that vacuum to the vacuum motor approaches zero.
The diaphragm spring in the vacuum motor will hold
the air door closed tightly. If underhood temperature
rises above 135 degrees, carburetor inlet air tempera-
ture will also rise above 135 degrees.
While air cleaner temperature is being regulated, ac-
celerating the engine hard will cause the vacuum
level in the intake manifold and in the vacuum motor
to drop. Whenever vacuum drops below 5 inches, the
diaphragm spring will close the air
door in order to
get the
maxumum outside air flow required for max-
imum acceleration.
The carburetor is set by the manufacturer for
800-
850 RPM (automatic transmission) or 850-900 RPM
(manual transmission) and 1.5 to 2.5 percent CO.
Figure 6F-3 E.G.R. System
EXHAUST GAS RECIRCULATION SYSTEM
All 1973 Opel 1900’s, Manta’s and GT’s are
equipped with an exhaust gas recirculation (E.G.R.)
system. See Figure
6F-3.
The E.G.R. system consists of a pipe connected to
the center of the front exhaust pipe, an E.G.R. valve,
a short pipe from the valve to the intake manifold
and a short vacuum hose from the E.G.R. valve to
the base of the carburetor. See Figure
6F-4.
The system does not receive sufficient vacuum at idle
to operate, but will operate during acceleration and
part throttle providing sufficient intake manifold
vacuum is present.
Figure 6F-4 E.G.R. Valve Location
DIAGNOSIS
TESTING THERMO AIR CLEANER OPERATION
Since failure of the therm0 air cleaner will generally
result in the snorkel air door staying open, failure
will probably go unnoticed in warm or hot weather.
In cold weather, however, owners will complain of
leaness, hesitation, sag, surge, or stalling. When any
type of lean operation complaint is received, always
test the thermo air cleaner for
proper functioning
before doing any work on the carburetor.
Always perform checks in the same order as listed
below.
Vacuum Motor Check
1. Check all hoses for proper hookup. Check for
kinked, plugged, or damaged hoses.

GROUP 7
TRANSMISSION7A IClutch. . . . . . . . . . . . . . . . . . . . . . . . .7A- 1
7B IManualTransmission1 76-12 1
7c IAutomatic Transmission1 7C-36 1I
I
I

7A- 21973 OPEL SERVICE MANUALDIAGNOSIS
CLUTCH TROUBLE DIAGNOSIS
ConditionPossible Cause
CorrectionFails to release (pedal
1. Improper cable1. Adjust cable.
pressed to floor
- shiftadjustment.
lever does not move
freely in and out of
“Reverse” gear.
2. Faulty pilot bearing.2. Replace bearing.
3. Faulty driven plate.3. Replace driven plate.
4. Yoke off ball stud.4. Install properly.
5. Clutch driven plate hub5. Repair or replace main drive
binding on main drive gear
gear.spline.
Slipping1. Improper adjustment (no1. Adjust cable.
lash).2. Oil-soaked driven plate.2. Install new driven plate and
correct oil leak at its source.
3. Worn facing or facing3. Replace driven plate.tofn from driven plate.
4. Warped pressure plate or4. Replace same.
flywheel.
5. Weak diaphragm spring.5. Replace cover assembly.
6. Driven plate not seated6. Make 20-50 normal starts.
in.7. Driven plate overheated.7. Allow to cool
- check lash.
Grabbing1. Oil on facing or burned1. Repair oil leak and install
or glazed facings.new driven plate.
2. Worn splines on main2. Replace transmission main drive
drive gear.gear.
3. Loose engine mountings.3. Tighten or replace mountings.
4. Warped pressure plate or4. Replace pressure plate or
flywheel.flywheel.
5. Burned or smeared resin5. Sand off if superficial, replace
on flywheel or pressureburned or heat checked parts.
plate.