1973 OPEL GT-R charging

1A. 81873 OPEL SERVICE MANUALELECTROLYTESPECIFIC GRAVITY
TEMPERATURE
(F)CORRECTION
-+0&&n _
THERMOMETER 30”
EXAMPLE A:
--,012---,016---,026
- -.02h
- -.028
- -.032~
-.036
YEXAMPLE 6:TEMPERATURE = 120”
i.TEMPERATURE = -0” F.HYDROMETER = ,,230HYDRdiETER
= 1.230
READINGREADING
‘,9R2Ro~CF;‘“” = +.0,6go!RFfCilON = .,032
TRUE SPECIFIC = ,.246
GRAVITY;RU”v;,‘;CIFIC = 1.198
3xA‘l
Figure
l A-4 Specific Gravity Temperature CorrectionScale
When using a hydrometer, obsqve the following
pain Is:1. Hydrometer must be clean, inside and out, to in-
sure an accurate reading.
2. Hydrometer readings must never be taken im-
mediately after water has been added. The water
must be thoroughly mixed with the electrolyte by
charging for at least 30 minutes before hydrometer
values are reliable.
3. If hydrometer has built-in thermometer, draw liq
aid into it several times to insure correct temperature
before taking a reading.
4. Hold hydrometer vertically and draw in just
enough liquid from battery cell so that float is
freefloating, and with bulb fully released. Hold bydrom-eter at eye level so that float is vertical and free
!ofouter tube, then take reading at surface of liquid.
Disregard the curvation where the liquid rises
against float stem due to surface tension.5. Avoid dropping liquid on car or clothing as it is
extremely corrosive. Any liquid that drops should be
washed off immediately with soda solution.
FUSIBLE LINKSAll 1973 Opel Models have fusible links located be-
tween the starting motor post and the generator
regulator. These links are the weakest point in the
electrical supply system for the complete car, and, as
such, will act like a fuse for every wiring harness in
the
ca.r. Every electrical accessory is still protected
by a fuse or circuit breaker, of course, but fusible
links protect the wiring harnesses before the fuses.
A fusible link consists of soldering a smaller gauge
wire to a heavier gauge wire end to end. In the event
of a circuit overload where the heavier gauge
becomes short circuited, the fusible link or smaller
gauge wire will burn out first, thus, protecting its
circuit from major damage. These fusible links are
located in the engine compartment in such a manner
that if overheated, the possibility of a fire is veryr¬e.
The attachment of the fusible links and the circuits
they protect are as follows: See Figure
l A-5.
D+61TERMIN\AL ;;!$6,,FL #3
B+ TERMINAL
I3QlA5
SOLENOID ON STARTER
Figure
t A-5 Fusible LinksFusible link (1) is connected to the starter solenoid
at the battery cable terminal, on one end and to the
red and white stripped main feed wire at the other
end.
Fusible link (2) is connected between the red wirean&s
terminal of the voltage regulateand protectsagainst a situation where the battery will not accept
a charge and the generator is charging to handle
various electrical loads. Fusible link (3) is connected
between the light blue with white stripes wire and D

BATTERY AND CABLES - ALL MODELSlA- 9
plus 61 terminal of the voltage regulator and protects
the circuit to the generator telltale light.
BATTERY RECHARGING
There are two separate methods of recharging batter-
ies which giffer basically in the rate of charge. In the
slow-charge method, the battery is supplied a rela-
tively small amount of current for an extended
period of time. In the quick-charge method, the bat-
tery is supplied with a high current for a short period
of time.
Slow-Charging
Slow charking is the best and only method of com-
pletely ch+rging a battery. The slow-charge method,
properly applied, may be safely used under all possi-
ble conditions of the battery, provided electrolyte is at proper
wl in all cells. The battery may be fully
charged by this method, unless the battery is not
capable of taking a full charge. The normal slow
charging rate for the
12.volt battery is 5 amperes.
Full ch&e of battery is indicated when all cell spe-
cific gravities do not increase when checked at three
intervals
of one hour and all cells are gassing freely.
Due to the low rate during slow charging, plenty of
time must ,be allowed. Charge periods of 24 hours or
more are often required.
Quick-Charging
Since time!is often of most importance to the battery
owner, quick-charging must sometimes be used to
partially charge the battery so that the engine will
start and the owner can be on his way.
Charge at:50 amperes for 20 minutes (50 times 20
equals
100Q ampere minutes). If charger will not give
this rate, charge for an equal number of ampere mi-
nutes at the best rate available. Too high a current
during quick-charging will damage battery plates.
A battery cannot be brought up to a fully charged
condition
by the quick-charge method. The battery
can be substantially recharged or boosted, but in
order to bring the battery to a fully charged condi-
tion, the charging cycle must be finished by charging
at a low
oi normal rate. Some quick-chargers have
a
provisioA for finishing the charging cycle at a low
rate so
tha’t the battery can be brought up to a fully
charged condition.
Used
with:care, and employing all safeguards prov-
ided by the manufacturer, a quick-charger will not
damage a battery
which is in good condition.
BATTERY REMOVAL AND INSTALLATION
Removal
1. Disconnect battery cables (remove negative cable
first to prevent possible shorting).
2. Remove battery hold down
l&acket.
3. Remove battery.
Installation
‘1. Place battery back in hold down position.
2. Tighten hold down bracket bolts.
3. Connect battery cables (connect positive cable first
to prevent possible shorting).
FUSIBLE LINK REMOVAL AND INSTALLATION
Replace a burned out fusible link as follows:
1. Disconnect battery.
2. Disconnect connector eye on end of fusible link.
3. Cut off other end of burned out link, along with
solder joint.
4. Strip insulation from end of new fusible link and
from end of wiring harness so that each will slide into
soldering sleeve.
5. Crimp new link in soldering sleeve and solder
carefully.
6. Cover new connection tightly with electrical tape.
I. Install new link connector eye on other end of
fusible link.
A burned out fusible link connected to the starter
solenoid would be indicated by:
1. All electrical accessories dead.
2. Starter dead - will not even click. Even with a
nearly dead battery, the starter solenoid will
gener-
ally engage; therefore, no click means no solenoid
action, possibly due to a burned out fusible link.
SPECIFICATIONS
BATTERY SPECIFICATIONS
Delco-General 12 volt-44 amp hour storage battery
is installed as original equipment. Replace with a
Delco Energizer
Y55.

CHARGING SYSTEMlD- 29
REGULAiOR DESCRIPTION
The regulator contains only one unit - a double con-
tact voltage regulator. See Figure
lD-2.
I Figure 1 D-2 Voltage Regulator
Since th< alternator field is grounded inside the alter-
nator, the voltage contacts are in series with the field.
Field
&rent is supplied from the D- terminal of the
alter”@, goes through a small red wire to the volt-
age contacts in the regulator, comes out of the
regulator through a brown wire, into the DF termi-
nal of the generator, and through the field winding to
grouqd inside the generator. See Figure lD-3.
:
,
!
/ I
’ A I
j
/ I
-
IF
O?
i 2
j
:
:
k
I
I
.i
A = REGULATOR
B = CHARGING
INDICATOR LAMP
C = BATTERY D = DIODES
E =STATOR
I
I F
=ROTOR301D3
kigure
lD-3 Charging Circuit Diagram
The diodes in the alternator, since they act like one-
way check valves, make a cutout relay unnecessary;
battery current can flow only as far as the diodes, but
cannot discharge through the alternator. However,
whenever alternator voltage is higher than battery
voltage, current flows freely through the diodes in
the other direction to charge the battery.
A current-regulator is not necessary. Any alternator
is limited by its design in regard to maximum current
output. Regardless of current need, an alternator
cannot put out more than its rated current output
and, therefore, cannot overheat and damage itself
due to excessive output.
MAINTENANCE AND ADJUSTMENTS
ALTERNATOR AND REGULATOR TESTS
Test Current Output
1. Check alternator belt condition and tension. Ad-
just to 45 lbs. using Gauge J-23600.
2. Install a battery post adapter at the positive post
of the battery.
3. Connect ammeter leads to adapter with red lead
toward generator and black lead toward battery posi-
tive post. Connect ground
lead to battery negative
post. See Figure
lD-4.
BATTERY POST
ADAPTER
SOID
Figure lD-4 Connecting Ammeter Leads
4. Connect voltmeter across the battery: red lead at
generator side of battery post adapter and black lead
to battery negative post.
5. Connect a tachometer to ignition system.

CHARGING SYSTEMlD- 31
Alternator Disassembly1. Remove nut and alternator pulley. See Figure
lD-6. Remove pulley and fan from rotor shaft.
2. Mark ‘drive end frame,
stator and rear end frame
to
ensurd correct installation of parts on reassembly.
Remove drive end frame. See Figure
lD-7.
Figure lD-9 Removing Drive End Frame Bearing
Figure
/l 1D-7 Removing Drive End Frame and Rotor
Assembly
3. Remoie drive end frame and rotor assembly from
generator. See Figure
lD-8.
/
301D8
Figure I11D-B Drive End Frame and Rotor Assembly
4. Pull +ve end frame off rotor shaft. See Figure
lD-9. ,
5. With puller remove rear ball bearing from rotor
shaft.
S& Figure lD-10.
6.
Remove positive diode support. See Figure lD- 11.
Figure 1D-l 1 Removing Positive Diode Support
7. Disconnect brush connector from negative diode
support. See Figure
lD-12.
8. Remove brush holder. See Figure
lD-13.

CHARGING SYSTEMlD- 33
Figure lD-17 Checking Rotor for Ground
Eigure lD-18 Checking Rotor for ShortFibwe 1 D-l 9 Checking Stator for Ground16. Check stator windings for a short, using a low
reading ohmmeter. Check two phases at a time by
holding ohmmeter prods alternately on winding
ends. Ohmmeter should read between
.26 and .29ohms. See Figure lD-20.
301 D20Figure 1 D-20 Checking Stator for Short
17. Clean slip rings with fine emery cloth and polish
them. To avoid generating flat surfaces on slip rings,
spin rotor on a lathe when cleaning and polishing.
Slip rings that are not concentric can be turned down
to a diameter of
l-1/4 inches. When doing this,
remove only enough material to just clean up the
worn surface, then polish slip rings and blow clean
with compressed air.
18. If alternator current output is low one or more
of the nine diodes may be defective. See Figure lD-3.
19. If a defective diode is suspected, test diodes.
Before testing diodes, disconnect them, otherwise it
is not possible to determine which diode is defective.
Use a test light supplied with a DC voltage of not
more than 24 volts.
20. To test a diode, place one test light prod on diode
connection and other on diode housing, then reverse
test light prods. Test light should light brightly in
,
CONNECTIONCONNECTION
I(ANODE)
(CATHODE)
IURRENTCURRENT ,I
CURREN’
FLOW+
+ HOUSING(CATHODE)HOUSING
(AN&E) 3lMD2Figure 1 D-2 1 Positive and Negative Diodes

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

:lG- 56 1973 OPEL SERVICE MANUAL
I
FUSEqOSlTlON
1
2
3
4
5
6AMPS.
5
5
8
15
15
8ClRClJlT$ PROTECTED
OPEL 1900
& ‘MANTA (51,53,54,57,57R)
LEFT PARkING LIGHT,
LEFTTAIL LIGHT, LEFTSIDE
MARKER LIGHTS
RIGHT PApKING LIGHT, RIGH TAIL LIGHT, RIGHT
SIDE MARKER LIGHTS, INSTRUMENT PANEL LIGHTS,
SHIFT GUADRANT LIGHTS, LICENSE PLATE LIGHT,
FOG LIGHTS (RALLYE ONLY)
IGNITION IKEY
WARNIN BUZZER, TRUNK LIGHT,
HAZARD WARNING FLA,SHER, COURTESY LIGHT, CLOCK
BACKUP L’IGHTS, BLOWER MOTOR, CIGAR LIGHTER; RADIO,
SAFETY BELT WARNING BUZZER AND LIGHT
WINDSHIELD WIPERS, WINDSHIELD WASHER (RALLYE
ONLY), HORN
STOP LIGtiTS,TURN
SlGsNAL AND INDICATOR LIGHT,
PARKING BRAKE WARNING AND BRAKE FAILURE LIGHT,
FUEL GAGE, TEMPERATURE GAGE, OIL PRESSUREINDICATGR LIGHT. CHARGING INDICATOR~LIGHT,
TACHOMETER AND OIL PRESSURE GAGE (RALLYE ONLY)
AIR CONDITIONING
- 20 AMP INLINE F:USE
8
5
16
5OPEL GT
(77)WINDSHIELD WIPERS, WINDSHIELD WASHER, HORN, BACKUP
LIGHT, SP;FETY BELT WARNING BUZZER AND LIGHT
STOP LIGHTS, TURN SIGNAL AND INDICATOR LIGHT,
PARKING BRAKE WARNING LIGHT (AUTOMATIC ONLY),
BRAKE FAILURE WARNING LIGHT, RADIO, TACHOMETER,
OIL PRESiURE GAGE
& INDICATOR LIGHT, FUEL GAGE,
TEMPERATURE GAGE, CHARGING INDICATOR LIGHT
CIGAR LIGHTER, BLOWER MOTORIGNITION~KEY WARNING BUZZER, COURTESY LIGHT, CLOCK,
HAZARD WARNING FLASHER
LEFT PARKING LIGHTS, LEFT TAIL LIGHT, LEFT REAR
SIDE MAdKER LIGHT
RIGHT PA’RKING LIGHTS, RIGHT TAIL LIGHT, RIGHT REAR
SIDE MAdKER LIGHT
INSTRUMENT PANEL LIGHTS, LICENSE PLATE LIGHT.
SHIFT QUADRANT LIGHT
AIR CON,DlTlONlNG
-A/C HAS A 20 AMP INLINE FUSE AND IS
CONNECTED TO THE HOTSIDE OF FUSE NO. 23OlG3

1 H- 581973 OPEL SERVICE MANUAL
/-FOG LIGHT SWITCH IRALLYEi
\HEADLIGHT HIGH BEAM INDICATOR
-HAZARD WARNINGFLASHERINDICATORSYSTEM WARN,NGLlGHT
LWINDSHIELD WIPER SWlTCH -1 LFUEL&,UGELHEATER-DEFROSTER CONTROL
CHARGING INDICATOR LlGHTHEATER’ TEMPERATURE CONTROLHEATED REAR GLASS SWITCH1
301H1Figure 1 H-l
- 1900 lnstrumellt Arrangement
INSTRUMENT PANEL
(GT)I
Headlight SwitchesThere are two headlight switches, one for turning on
the headlights and the other operates an indicator
light on the instrument panel. Both switches are
located behind the left headlamp assembly.
When the headlamp lever is @shed forward,’ the
operating mechanism rotates the headlights to open
position, tuins the headlight and instrument panel
indicator light switches on until the headlamps are
locked in full open position at which time the indica-
tar lamp switch is turned off.
Along with the headlights, the headlight switch,also
turns on the parking lights, taillights, license plate
lights and rear side marker lights.
Parking Light and instrument Panel Light SwitCh
AssemblyThe left switch of this assembly is the Parking Light
Switch. By pushing inward on the lower half of thisswitch, the parking lights, taillights, license plate
lights and rear side marker lights are turned on and
can be turned off by pushing inward on the upper
half of the switch providing the headlights are not
turned on.
The center portion of this switch assembly is inopera-
tive and controls nothing.
The switch on the right end of this assembly is the
Instrument Panel Light switch. By pushing inward
on the lower half of the switch turns on the instru-
ment panel lights. The brightness of the instrument
panel lights can be adjusted by movement of the
switch. If either the Parking Light or Instrument
Panel switch becomes defective, the switch assembly
must be replaced.
Combined Windshield Wiper, Electrically Heated
Rear Window and Heater Blower SwitchThis switch assembly is located to the right of the
cigar lighter. If any one of these switches should fail,
the complete switch assembly must be replaced.