1973 OPEL GT-R alternator

CHARGING SYSTEMlD- 35
’Figure lD-25 Installing Diode
I
7. Instail rotor together with drive end frame intostator and assemble generator in reverse order ofdisasse+bly. Make sure marks made during disas-
sembly
+-ire aligned.
8. Insta!l pulley and fan. Tighten nut to 30 lb.ft.
9. Test benerator on test bench, if available. If not,
install alternator on car and test.
Alternator Installation
1. Hold /alternator in position and install pivot bolt,
plain washer, lockwasher and nut finger tight.
2. Install alternator belt.
3. Install adjusting brace bolt, lockwasher, plain
washer and nut finger tight.
4.
Posit& a belt tension gage such as Gage J- 23600Figure 1 D-26 Alternator Installation
on belt. Pull alternator outward until gage reads 45
Ibs., then tighten adjusting brace bolt.
5. Tighten alternator pivot bolt.
6. Connect battery lead to alternator.
7. Plug three-way wiring connector into alternator
and engage safety catch.8. Connect battery ground strap.SPECkICATIONS
ALTERNATOR
35, AMPAlternatorNumberRated
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kl 14V35AZOOutputinVolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14ContinuousRatedOutputinAmperes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Test Output in Amperes at
2000 Engine RPM. . . . . . . . ..__.._...........................................23 Min.RksistanceofFieldCoilinOhms
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4.4Resistanceof StatorWindingsinOhms
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-29AlternatorPulleyNutTorqueinLb.Ft.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
BfltTensioninPounds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
REGULATORRegulatorNumber
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ADl/14V
Regulator Setting in Volts at 2500 Engine R.P.M.
. . . . . . . . . . ..___................................14 f .5

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1 D- 361973 OPEL SERVICE MANUALI‘\
Figure 1 D-27 Alternator - Exploded View301D27

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.

ENGINE MECHANICAL AND MOUNTS6A- 11
a. Attach left chain to alternator support rear bolt.
b. Bolt right chain to existing threaded hole at lower
right front of engine.
2. Assemble loose ends of chain to support device J-bolts and adjust to remove engine weight from motor
mounts.
3. Remove the two motor mount bracket to motor
mount retaining nuts.
4. Remove the two front suspension to frame rail bolt
retaining nuts.
5. Remove nut and bolt at lower end of steering shaft
U-joint.
6. With a floor jack under the center of the front
suspension cross member, raise car high enough for
wheels and suspension assembly to be rolled from
under car.
7. Position jack stands under both front jack brackets
on underbody to support car in this position.
8. Remove both front cross member support to frame
attaching bolts.
9. Remove brake pipe to brake hose retaining clips
at frame rails and disconnect brake hose from brake
pipes. Use an absorbent material or suitable con-
tainer for the brake fluid that will drain out.
10. Lower the front suspension assembly and remove
from under car.
11. Drain engine oil and remove oil pan and gasket.
Installation (Opel 1900 and Manta)1. Apply a light bead of sealer to the clean sealing
surfaces of the oil pan and affix a new gasket.
2. Bolt oil pan and gasket assembly to engine block.
3. Roll front suspension and floor jack under car and
raise into position careful to pilot the cross member
to frame rail attaching bolts and steering shaft to
their respective locations.
4. Install cross member’support to frame attaching
bolts and torque to 22 lb.ft.
5. Connect brake hose to brake pipes and install
retaining clips.
6. Bleed front brake system. Maintain brake fluid1Wd.
7. Remove jack stands and lower car.8. Install suspension to frame rail bolt retaining nuts.
9. Release and remove engine supporting device.
10. Install motor mount bracket to motor mount
retaining nuts.
11. Install steering shaft U-joint lower bolt and nut.
12. Replace engine oil.
Removal (GT Series)1. Support engine in vehicle using Tool J-23375. See
Figure 6A- 15.
Figure 6A-15 Engine Holding Fixture
Install tool by removing upper engine mount nut and
installing fixture. Replace nut and tighten. The en-
gine will now be supported by the tool, between the
frame rails. The front suspension need not be
removed on GT Models.
2. Drain oil.
3. Remove oil pan bolts and remove oil.
Installation (GT Series)1. Replace oil pan and bolts.
2. Remove engine holding fixture and replace engine
mounts.
3. Replace engine oil.

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

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

SubjectPage Number
Subject Page Number
A
Air Conditioning Refrigerant Components .................
98.17
Opel 1900
& Manta-In Car Components .....9B-90
GT.ln Car Components..................98-97
Alignment Opel 1900
& Manta .....................3C-22
GT-Opel ..............................
3C-22
Alternator Description ...........................
lD-28
Specifications. .........................1 D-35
Overhaul K-l..........................lD-30
Removal & Installation ..................lD-30
Testing...............................lD-29
Wiring Diagrams
Manta .............................
1 J-105
Opel 1900
..........................lJ-103
GT ................................
lJ-107
AM
Radio-GT............................9C-105
AM Radio-Opel 1900 &Manta ...............
9C-109
Antenna, Installation .......................
9C-111
Antenna Trimmer .........................
9C-110
Assembly of Transmission from Major Units Manual ...............................
78-23
3 Speed Automatic .....................
7C-103
Axle,
R&r, Disassembly ....................48~11
Bolt Torque Specifications
Engine ...............................
6A-27
Transmission. Manual ....................
78-33
3 Speed Automatic .....................
7C-136
Clutch ...............................
7A-7
Body ................................
2A-4
Brakes
Brake Drum, Shoes & Linings .............5C-28
Hydraulic Wheel Cylinder ................
5C-30
Hydraulic Master Cylinder ................
5A-2
Parking Brake Cables .....................
5C-33
Standard Brakes ........................
X-22
Disc Brakes...........................5B-10
Brake Booster and Vacuum
Coritrol Valve ....5A-5
Bumpers, Front and Rear ...................
ZH-33
C
B
Balance,,Wheel and Tire....................3G-62
Ball
J&tUpper .........................3A-7
Lower ...............................
3A-7
Battery
Specifications ..........................
lA-9
Testing...............................lA-6
Charging ..............................lA-9
Trouble Diagnosis ......................lA-4
Battery Test 421.........................l A-6
Belt Tensions ............................
68.33
Blower and Air Inlet Assembly, Removal and Installation
Owl 1900&Manta.....................9A-15
GT
.: ................................9A-5
Body Name Plate ............................
OA-1
Style’Numbers ......................... OA-2
Windows and Weatherstrips ...............
ZC-9
Doors ................................
ZD-13
Interior Trim and Headlining ..............
26-33
Seatsi................................26-33
Roof&d Sunroof-Opel 1900
& Manta ......2F.24 Camshaft,
1.9L
Engine .....................6A-25
Car Model Identification .......
.,............OA-1
Carburetor..............................6E-44
Trouble Diagnosis ......................
6E-49
Description ...........................
6E-44
Overhaul .............................
6E-53
Adjust ...............................
6E-50
Removal
& Installation ......,............6E-52
Specifications ..........................
6E-58
Charging
System
Description ..............
:............ 1 D-28
Specifications. ............
.,............lD-35
Testing..................:............lD-29
Wiring Diagrams
Manta .............................
lJ-105
Opel 1900 ..........................
lJ.103
GT ................................
lJ-107
Chart Lubrication ........................ OC-5
Chassis Springs, Front. ........
!............3A-15
Clutch, Second-Automatic Transmission .......
7C-103
Clutch Adjustment .........................
7A-4
Control Arm Front Upper ...................
:............3A-10
Lower ...............................
3A-11
Converter Checking Procedure ................
7C-125
Coolant Flow ............................
68-32
4 Speed Manual Transmission ...
!,...........7B-12
Cranking System. See Starting
SyStem
Crankshaft..............................6A-16
Cylinder Head ...............
:............6A-12
D
Description
3.Speed Automatic.....................7C-37