1973 OPEL 1900 wiring

DOORSZD- 21
RIGHTLEFT ~-ZD-27
Figure ZD-27 Cables Wound On Regulators
Installation - Right DoorIn clockwise direction, wind cable onto pulley up to
the shoulder and clamp it behind lug. See Figure2D-27.
REMOVING AND INSTALLING
’
TAILGATE HINGES
Removal1. Remove screws securing hinge trim panel covering
tailgate binges and lift out trim panel. See Figure
2D-28.2. Disconnect battery, remove tail
te trun pad, and
withdraw wiring from tailgate.
u3. Mark position of tailgate hinges on tailgate,
remove bolts securing tailgate to hinges and lift off
tailgate.
,’HINGE TRIM
PANEL1IFigure ZD-28 Removing Tailgate Hinge Trim Panel
4. Release and remove torque rods. See Figure 2D-
29.Figure ZD-29 Tailgate Torque Rods
5. Remove bolts securing tailgate hinges to roof
panel and lift out tailgate hinges.
Installation1. Install tailgate hinges to roof panel and secure
with bolts.
2. Install torque rods. Installation of torque rods may
be facilitated by using vise-grip pliers to work torque
rod end over catch.
3. Install tailgate to tailgate hinges.
4. Install wiring to tailgate
5. Install tailgate trim pad and tailgate hinges panel
COVehg.6. Connect battery

9A-4 1973 OPEL SERVICE MANUAL
Figure 9A-4 Heater Control
Blower Switch - This switch actuates blower motor
to low or high blower speed.
HEATER SYSTEM OPERATION
To operate heater proceed as follows:
1. Position air inlet, heater-defroster control as
desired.
White arrow head pointing down--air out of heater
outlets. White arrow head pointing up--air out of
defroster outlets.
Between lower and upper position--air to both heater
and defroster outlets.
2. Position temperature control as desired to increase
or decrease temperature of air flow.
3. Position blower switch as desired to operate
blower at low or high speed.
Dlid3NDSlS
HEATER SYSTEM TROUBLE DIAGNOSIS
TROUBLE
Temperature of heated air at outlets too low.
CAUSE AND CORRECTION
Check radiator cap for proper sealing action-- re-
place if necessary.
Check for adequate coolant supply. If level is down,
correct cause of coolant loss and refill radiator.
Inspect hose for kinks--relieve kink or replace hoses.
Check thermostat operation by measuring tempera-
ture of coolant at radiator. Temperature should be
within 5 degrees F. of thermostat rated value (189
degrees F.).
Check that air doors and water temperature control
valye are operating properly.
Check for plugged heater core--backflush heater core
as necessary.
TROUBLE
Inadequate defrosting action.
CAUSE AND COiiRECTlON
Examine heater-defroster door for proper operat-
ions--adjust bowden cable as required so that door is
fully closed in FULL DEFROST position.
Check that air hoses connecting to defroster outlets
are secure.
Check for air leaks around edges of heater air dis-
tributor housing--seal leaks as necessary with body
sealer. Check for body air leaks and seal as necessary
with body sealer.
TROUBLE
Blower inoperative.
CAUSE AND CORRECTION
Check blower fuse--replace if necessary, fuse position
3 - amperage 8.
Check wiring for open circuit--correct as required. Inspect for defective component (i.e., blower switch
or blower motor)--replace or repair as necessary.
MAINTENANCE AND ADJUSTMENTS
CONTROL CABLE ADJUSTMENT
Adjustment of control cables is accomplished by po-
sitioning of the jacket or sheath of the control cable
as held by the clamps on the control assembly and
heater case.
To adjust control cables, loosen clamps and move
cable sheath in or out as required to obtain full travel
of lever or of door or both.

9A-i2 1973 OPEL SERVICE MANUAL
Check that air doors and water temperature control
valve are operating properly.
Check for plugged heater core-backflush heater core
as necessary.TROUBLEInadequate defrosting action.
CAUSE AND CORRECTIONExamine heater-defroster door for proper operation.
Adjust bowden cable so that door is fully closed in
FULL DEFROST position.
Check that air hoses connecting to defroster outlets
are secure.
Check for air leaks around edges of heater air dis-
tributor housing. Seal leaks, as necessary, with bodysea@. Check for body air leaks and seal, as neces-
sary, with body sealer.
TROUBLEBlower inoperative.
CAUSE AND CORRECTIONCheck blower fuse. Replace, if necessary, fuse posi-
tion 4
- amperage 15.
Check wiring for open circuit. Correct, as required.
Inspect for defective component, (i.e., blower switch
or blower motor)
- replace or repair as necessary.
MAINTENANCE AND ADJUSTMENTS
CONTROL CABLE ADJUSTMENTAdjustment of control cables is accomplished by po-
sitioning of the jacket or sheath of the control cable,
as held by the clamps on the control assembly and
heater case or by loosening screws and slidingbowden wire to obtain desired door or water valve
position.
MAJOR REPAIR
REMOVING AND INSTALLING HEATER HOUSING
Removal1. Unscrew hood lock together with ground wire(ground wire only on vehicles with radio interference
suppression). See Figure 9A-33.
Figure 9A-33 Hood Lock Attachments
2. Unscrew heater housing cover.
3. Pull hose of windshield washer system off jet and
take jet out of housing cover.
4. Unscrew bowden control wire from heater valve.
5. Unscrew heater housing from dash panel and pull
it off carefully. See Figure 9A-34.
Figure 9A-34 Heater Housing Attachments
6. Remove water hoses from heater core and pull
heater core out of heater housing. See Figure
9A-35.

96-52 1973 OPEL SERVICE MANUAL
REMOVAL AND INSTALLATION OF EVAPORATOR
AND EXPANSION VALVE. OPEL 1900 - MANTA
Removal
1. Remove negative battery cable from battery.
2. Remove left side of distributor duct, and in line
fuse. See Figure
9B-61.3. Remove glove box. See Figure
9B-62.Figure 96-64 Delay Restrictor
and Check Valve Hose
Assembly Location
5. Disconnect the delay restrictor and check valve
hose assembly from the vacuum cut-off switch and
disconnect the electrical wiring. See Figures 9B-63
and 64.
6. Remove evaporator inlet and outlet pipes re-
tainer and rubber grommet. See Figure
9B-65.Figure
98.62 Glove Box Removed
4. Discharge refrigerant from system. (Refer to
DISCHARGING SYSTEM) and disconnect refrig-
erant hose from evaporator outlet and pipe from
evaporator inlet and tape the open ends of the refrig-
erant lines and evaporator pipes. See Figure
9B-63.Figure
98.65 Inlet and Outlet Pipes retainer and
Rubber Grommet-Opel 1900 - Manta
Figure
98.63 Location of Refrigerant Hoses, Pipes,
Vacuum Cut Off Switch and Evaporator Attaching Bolt
(Left Side) - Opel 1900
- Manta

96-54 1973 OPEL SERVICE MANUAL
valve. The filter screen at the inlet port may be re-
placed. Remove screen by threading a lo-32 NF
screw into old filter screen. With a washer and a nut
on the screw arranged to work as a puller screw, hold
the body of the screw and turn the nut. Insert the
new filter screen into the inlet port and lightly tap
screen only enough to seat.
1. Install expansion valve using new o-rings during
installation. Lubricate o-rings prior to installation
using No. 525 viscosity oil.
2. Install evaporator assembly and case attaching
screws. See Figure 9B-70.3. Install blower motor assembly into case and se-
cure with attaching screws. See Figure
9B-69.4. Install finger guard shields and fan housing case.
See Figure
9B-69.5. Install resistor assembly and electrical connector.
Install blower motor connector. See Figure
9B-69.6. Install assembly into car carefully guiding
evaporator pipes up through cowl opening. See Fig-
ure
9B-71.Figure 93-7 1 Inlet and Outlet Pipes and O-Rings
-Opel 1900 Manta
7. Install two (2) upper attaching evaporator at-
taching nuts. See Figures 9B-66 and
9B-67.8. Install two (2) attaching case mounting bracket
to instrument panel screws. See Figure
9B-67.9. Connect two (2) drain hoses underneath evapora-
tor.10. Install evaporator inlet and outlet pipes retainer
and rubber grommet. See Figure
9B-65.11. Connect vacuum cut-off switch and electrical
wiring, making sure the delay restrictor and checkvalve hoses are installed correctly. See Figures
9B-63and 64.
.gB-72 Delay Restrictor and Check Valve Hose.Assembly
12. Install refrigerant hoses and pipes using new
o-rings on line fittings and evacuate system. Refer to
EVACUATING SYSTEM.
13. While system is being evacuated, install in-line
fuse and left side of distributor duct. See Figure 9B-
61.14. Install glove box.
15. Install negative battery cable and charge system.
Refer to CHARGING SYSTEM.
REMOVAL AND INSTALLATION OF CONDENSER
ASSEMBLY -OPEL 1900. MANTA
Removal
1. Remove negative battery cable from battery.
2. Remove air cleaner.
3. Discharge system. Refer to DISCHARGING
SYSTEM.
4. While system is discharging, remove lower radia-
tor hose from radiator and drain coolant into a suita-
ble container.
5. Remove fan shroud.
6. On vehicles with automatic transmission, un-
screw oil lines from connectors on lower radiator
tank and plug lines. It is essential that no dirt enters
the oil lines. When unscrewing oil lines, hold connec-
tors on lower radiator tank with pliers to avoid leak-
ages. Ensure that no dirt enters oil cooler.
7. Remove upper radiator hose from radiator.
8. Remove lower attaching nut and slide radiator
upward and out of engine compartment.
9. Remove inlet and outlet hoses from condenser

AIR CONDITIONER SYSTEM. OPEL 1900. MANTA9B- 93
2. Remove the left side of distributor duct, and the
in-line fuse. See Figure 9B-174.98.139Figure SB-174 Location of Distributor Duct (Left Side)
Retaining Screws
Figure SB-175 Removing Left Side Distributor Duct
3. Rembve the glove box assembly. See Figure 9B-
176.
4. Discharge refrigerant from system, (refer to DIS-
CHARGING SYSTEM) and disconnect refrigerant
hose from evaporator outlet and pipe from evapora-
tor inlet’and tape the open ends of the refrigerant
lines and evaporator pipes. See Figure
9B-178.5. Disconnect the delay restrictor and check valve
hose assembly from the vacuum cut-off switch and
disconnect the electrical wiring. See Figure
9B-180.6. Rempve evaporator inlet and outlet pipes re-
tainer and rubber grommet. See Figure
9B-178.Figure SB-176 Glove
Bdx Removed
Figure SB-178 Location of Refrigerant Hoses, Pipes,
Vacuum Cut Off Switch and Evaporator Attaching Bolt
(Left Side)
Figure 9B-180 Vacuum Hoses and Wiring

AIR CONDITIONER SYSTEM -OPEL 1900 - MANTA9B- 95
Figure 96.185 Evaporator Inlet and Outlet Pipes andO-Rings
7. Connect the 2 drain hoses underneath evapora-
tor.
8. Install evaporator inlet and outlet pipes retainer
and rubber grommet. See Figure
9B-178.
9. Connect vacuum cut-off switch and electrical
wiring,, making sure the delay restrictor and check
valve hose are installed correctly. See Figure
9B-180.
10. Install refrigerant hoses and pipes using new o-
rings on line fittings and evacuate system. Refer to
EVACUATING SYSTEM.
Il. While system is being evacuated install the in-line
fuse and left side of distributor duct. See Figure
9B-
174.
12. Install the glove box.
Figure 98.186 Delay Restrictor and Check Valve Hose
Assembly
Figure 9B-187 Fuse Block Connections
13. Install negative battery cable and charge the sys-
tem. Refer to CHARGING SYSTEM.

98.96 1973 OPEL SERVICE MANUALr DARK BLUE
LIGHT BLUE STRIPE
CUTOUT111111DARK GREEN DARK GREEN
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BATTERYl LJ
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TTEVAPO.RATOREVAPO.RATOR
BLACK WITH RED STRIPE BLACK WITH RED
Sl96-143
Figure 9B-188 Wiring Schematic‘RIPE96-143
Figure 9B-188 Wiring Schematic
SPECIFICATIONS
Blower Motor Type
......................................................................................................12 VDC
Blower Fan Type
..................................................................................................Squirrel Cage