1973 OPEL GT-R transmission oil

PROPELLER SHAFT AND CENTRAL JOINT4A- 3MAJOR REPAIR
PROPELLER SHAFT REMOVAL AND
INSTALLATION
Removal
1. Raise rear of car and support on jack stands at rear
jack brackets.
2. Disconnect parking brake cable equalizer from
rod.3. On the Opel
1900 and Manta, unhook parking
brake cable from floor panel.
4. On the Opel 1900 and Manta, unhook exhaust
system and let it down.
5. Mark the mating parts of the U-joint and the drive
pinion extension shaft flange.
6. Loosen bolt locks and remove bolts or nuts.
7. Work propeller shaft slightly forward, lower rear
end of shaft and slide assembly rearward. Remove
thrust spring from front of propeller shaft.
S. Install plug in transmission extension housing to
prevent loss of lubricant.
installation
CAUTION:
Fasteners in the foJlowing steps are impor-
tant attaching parts in that they could affect the
performance of
vital components and systems, and-
/or could
result in major repair expense. They must
be replaced with one of the
samepart number or with
an equivalent part
ifreplacement becomes oecessary.
Do not use a replacement part of lesser quality or
substitute design. Torque values must be used as
specirid during reassembly to assure proper reten-
tion of these parts.1. Remove plug from rear of transmission.
2. Slide thrust spring onto transmission output shaft
and slide propeller shaft through the oil seal and onto
the transmission output shaft. Make certain trans-
mission rear seal is not damaged.
3. Align rear universal joint and pinion flange locat-
ing marks and secure with respective bolts and lock
plates. Torque bolts to 11
lb.ft. Bend lock plate tangs
to secure bolts or nuts.
4. Connect parking brake cable equalizer to brake
rod and adjust to specifications.
5. On the Opel 1900 and Manta connect parking
brake cable to floor panel.DISASSEMBLY AND ASSEMBLY OF THE
CENTRAL JOINT
Disassembly of Central Joint1. Raise and support rear of car under axle tubes.
2. Release brake line bracket from rear of torque
tube.3. Disconnect parking brake cable equalizer and re-
turn spring from brake rod.
4. On the Opel 1900 and Manta, unhook exhaust
system and let it down.
5. Mark universal joint and flange. Disconnect pro-
peller shaft from flange and support it out of the way.
6. Support torque tube with floor jack using mini-
mum pressure.
7. Remove the central joint bracket to underbody
attaching bolts.
8. Allow floor jack to lower the torque tube.
9. Disconnect torque tube from differential carrier by
removing the attaching bolts.
10. Install pinion flange holder J-8614 and remove
self-locking flange nut. See Figure 4A-2.
FLANGE HOLDER4A-2
Figure 4A-2 Removing Pinion Flange Nut
11. Pull pinion flange using J-8614 adapter. See Fig-
ure 4A-3.
12. Remove drive pinion extension shaft from torque
tube using a soft faced mallet. See Figure 4A- 4.
13. Removal ball bearing from cushion.
14. With torque tube placed in vise remove support

REAR AXLE48. 9
MAJOR REPAIRREMOVAL AND INSTALLATION OF REAR AXLE
ASSEMBLYRemoval
1. Raise rear of car with floor jack under differential
carrier and position jack stand under jack bracket on
each side of car. Remove rear wheel assemblies and
one brake drum.
2. Disconnect parking brake cable equalizer and re-
turn spring from brake rod.
3. Detach parking brake cable from actuator lever
and backing plate at wheel with brake drum
removed. Disconnect cable from lower control arm
brackets and pull loose end over exhaust system.
4. Disconnect shock absorbers at lower end.
5. Disconnect track rod at left end.
6. On cars equipped with a stabilizer rod, disconnect
the shackles at rear axle housing.7. Disconnect universal joint from pinion flange and
support or tie propeller shaft out of way after mark-
ing mating areas. If propeller shaft is removed, install
plug in rear of transmission to prevent loss of lubri-cant.8. Disconnect brake hose from brake pipe at differen-
tial and remove retaining clip.
9. Lower rear axle assembly far enough to remove
coil springs.
10. Remove central joint support bracket to under-
body retaining bolts.
11. Disconnect lower control arms at rear axle assem-
bly bracket and roll the assembly from under the car.
See Figure
4B-2.Installation
CAUTION: Fasteners in the following steps are impor-tant attaching parts in that they could affect the
performance of vital components and systems, and-
/or coo/d
resuJt in major repair expense. They must
be rep/aced with one of the same part number or withREAR SHOCK ABSORBERS
SPRING SEAT
4B-1Figure
4B-l Differential and Rear Suspension Assembly

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.

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.)

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.