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Page 522 of 625

OPEL GT-R 1973 Service Manual Figure SA-35 Heater Core
Installation
1. Apply sealing compound between heater housing
and dash panel.
2. Install heater core into heater housing and attach
water hoses. See Figure 9A-35.
3. Instaii h

Page 529 of 625

OPEL GT-R 1973 Service Manual 98-20 1973 OPEL SERVICE MANUAL
If we were to put a thermometer in the cold drain
water, we would see the temperature gradually creep
upwards. That is to be expected because heat is flow-
ing into the

98-20 1973 OPEL SERVICE MANUAL
If we were to put a thermometer in the cold drain
water, we would see the temperature gradually creep
upwards. That is to be expected because heat is flow-
ing into the cold water making it warmer. Before
long the water would be as warm as the stored foods.
Then the water could no longer attract heat because
heat will not flow from one warm object to another
equally warm object. Since we no longer can draw
heat out of the foods we no longer are cooling them.
Now, let’s see what happens when we put ice instead
of cold water into the ice-box. This time, we’ll set the
thermometer on top of the ice (Fig. 9B-5). When wefirst look at the thermometer, it reads 32 degrees. A
couple of hours later, we open the ice compartment
door. The ice block is smaller because some of the ice
has already melted away
- but the thermometer still
reads 32 degrees. Again, still later, even more of the
ice has melted, yet the termometer continues to read
32 degrees. So long as any ice remains, no matter
how much of it has melted away, the temperature of
the ice stays right at 32 degrees.
All this time the ice has been soaking up heat, yet it
never gets any warmer no matter how much heat it
draws from the stored food. On the other hand, the
cold drain water got progressively warmer as it
soaked up heat. Why is it the addition of heat will
make water warmer yet won’t raise the temperature
of ice above the 32 degrees mark? If we till one
drinking glass with ice and another with cold water,
and put both glasses in the same room where they
could absorb equal amounts of heat from the room
air, we will find it takes much, much longer for the
ice to melt and reach room temperature than it did
for the water in the other glass to reach the same
temperature. Obviously, most of the heat was being
used to melt the ice. But it was the heat that appar-
ently disappeared or went into hiding because if
couldn’t be located with a thermometer. To best de-
scribe this disappearing heat, scientists turned to
Latin for the right word. They chose the word “la-
tent” which means hidden.
Latent Heat
So latent heat is nothing more nor less than hidden
heat which can’t be found with a thermometer.
What happens to the latent heat? Where does it
disappear to? At first it was thought it was in the
water that melted from the ice. But that wasn’t ex-
actly the right answer because, upon checking water
temperature as it melts from ice, it will be found that
it is only a shade warmer than the ice itself. It is not
nearly warm enough to account for all the heat the
ice had absorbed. The only possible answer is that
the latent heat had been used up to change the ice
from a solid into a liquid.
Many substances can be either a solid, or a liquid, ora gas. It just depends on the temperature whether
water for example was a liquid, or a solid (ice), or gas
(steam) (Fig.
9B-6).Figure 99-6 Temperature Determines State of Water
If we put some water in a tea-kettle, set it over a tire
and watch the thermometer as the water gets hotter
and hotter, the mercury will keep rising until the
water starts to boil. Then the mercury seems to stick
at the 212 degrees mark. If we put more wood on the
fire, despite all the increased heat, the mercury will
not budge above the 212 degree mark (Fig.
9B-7).Figure 98.7 Boiling Water Never Exceeds 2 12
DegreesEven though many housewives won’t believe it, no
matter how large or hot you make the flame, you
can’t make water hotter than 2 12 degrees. As a liquid
changes into a gas, it absorbs abnormally great
amounts of heat without getting any hotter. Here is
another instance where heat disappears.
Now we have two different kinds of latent heat,
which are quite alike. To keep their identities sepa-
rate, the first one is called latent heat of fusion. Since
fusion means the same as melting, it is a good de-
scriptive name. The other kind is called latent heat
of vaporization because‘ that means the same as
evaporation.
It may seem as though we have drifted into a story

Page 530 of 625

OPEL GT-R 1973 Service Manual REFRIGERANT COMPONENTS ALL MODELSSE- 21
about heat instead of refrigeration. But in doing so,
we have learned how a simple ice-box works. It’s
because the magic of latent heat of fusion gives ice
th

REFRIGERANT COMPONENTS ALL MODELSSE- 21
about heat instead of refrigeration. But in doing so,
we have learned how a simple ice-box works. It’s
because the magic of latent heat of fusion gives ice
the ability to soak up quantities of heat without get-
ting any warmer.
Therefore, since it stays cold, it can continue to draw
heat away from stored foods and make them cooler.
The latent heat of vaporization can be an even better
“magnet” because it will soak up even more heat.
Whenever we think of anything boiling, we instinc-
tively think of it being very hot. However, that’s not
true in every case. Just because water
boi1.s at 212
degrees doesn’t mean that all other substances will
boil at the same temperature. Some would have to be
put into a blast furnace to make them bubble and
give off vapor. On the other hand, others will boil
violently while sitting on a block of ice.
And so each substance has its own particular boiling
point temperature. But regardless of whether it is
high or low, they all absorb unusually large quanti-
ties of heat without getting any warmer when they
change from a liquid into a vapor.
Consequently, any liquid that will boil at a tempera-
ture below the freezing point of water, will make ice
cubes and keep vegetables cool in a mechanical re-
frigerator.
Figure
9B-10 Simple R-12 Refrigerator
Refrigerant - 12Refrigerant-12 is used in the air conditioning system
and boils at 21.7 degrees below zero. Maybe that
doesn’t mean very much until we picture a flask of
R-12 sitting at the North Pole boiling away just like
a tea-kettle on a stove. No one would dare pick up
the flask with his bare hands because, even though
boiling, it would be so cold and it would be drawing
heat away from nearby objects so fast that human
flesh would freeze in a very short time. If we were toput a flask of R-12 inside a refrigerator cabinet, it
would boil and draw heat away from everything sur-
rounding it (Fig.
9B-10). So long as any refrigerant
remained in the flask, it would keep on soaking up
heat until the temperature got down to 21.7 degrees
below zero.
Now we can begin to see the similarity between a
boiling tea-kettle and a refrigerator. Ordinarily we
think of the flame pushing heat into the tea-kettle.
Yet, it is just as logical to turn our thinking around
and picture the tea-kettle pulling heat out of the
flame. Both the tea-kettle and the flask of refrigerant
do the same thing they draw in heat to boil
although they do so at different temperature levels.
There also is another similarity between the ice-box
and the mechanical refrigerator. In the ice-box, wa-
ter from melting ice literally carried heat out of the
cabinet. In our simple refrigerator, rising vapors do
the same job.Rdsing
Our R-l 2Water is so cheap that we could afford to throw it
away. But R-12, or any other refrigerant, is too ex-
pensive just to let float away into the atmosphere. If
there was some way to remove the heat from the
vapor and change it back into a liquid, it could be
returned to the flask and used over again (Fig. 9B-
11).There is a way, and that is where we find the biggest
difference between the old ice-box and the modern
refrigerator. We used to put in new ice to replace that
lost by melting. Now we use the same refrigerantover and over again.
Figure 9B-1 1 Re-Using Refrigerant

Page 533 of 625

OPEL GT-R 1973 Service Manual 9B-24 1973 OPEL SERVICE MANUAL
Figure 9B-15 Compressor Assembly - GT Shown
Figure 3B-16 Condenser Assembly
condenser. The refrigerant vapor gives up its heat,
which is quickly and easily radiated into

9B-24 1973 OPEL SERVICE MANUAL
Figure 9B-15 Compressor Assembly - GT Shown
Figure 3B-16 Condenser Assembly
condenser. The refrigerant vapor gives up its heat,
which is quickly and easily radiated into the sur-
rounding air through the large finned surfaces of the
condenser. In giving up its heat, the refrigerant vapor
condenses back into liquid which collects in a pool
at the bottom of the condenser.
As we have said before, when the refrigerant con-
denses into a liquid, it again is ready for boiling in the
evaporator. So, we can run a pipe from the condenser
back to the evaporator.
Main Units of the SystemThese three units then; the evaporator, the compres-
sor, and the condenser are the main working
parts of any typical air conditioning system. We have
the evaporator where the refrigerant boils andchanges into a vapor, absorbing heat as it does so. We
have the pump or compressor to put pressure on the
refrigerant so it can get rid of its heat. And we have
a condenser outside the car body to help discharge
the heat into the surrounding air.
Pressure and FlowThere is one more unit that co-operates with thesethree. It doesn’t do any real work, but it does act as
sort of a traffic officer in controlling the flow of the
refrigerant through the system. To get a better idea
of what this does. let’s first do a li,ttle exoerimentine
with an ordinary’ tire pump.
When we use a
t,ire pump to Sate an automobile
tire, we are creating pressure only because we are
“pushing” against the air already entrapped inside
the tire. If you question this, just try pumping up a
tire that has a large puncture in it. You could pump
all day, and still not be able to build up any pressure.
As fast as you would pump the air in, it would leak
out through the puncture.
Abou~t all you would be
doing would be circulating nice fresh air through the
tire.
1Jnless you have something lo push against - to
block the tlow of air
- you can’t create more than a
mere semblance of pressure.
The same situation holds true in an air conditioning
system. The compressor can pump refrigerant vapor
through the system, but unless it has something to
push against, it cannot build up pressure. All the
compressor would be doing would be to circulate the
vapor without increasing its
pres,sure.Yet we can’t just block the flow through the system
entirely. All we want to do is put pressure on the
refrigerant vapor so it will condense at normal tem-
peratures. What’s more, this
musi: be done some time
after the vapor leaves the evaporator and before it
returns again as a liquid. We can’t have high pressure
in the evaporator because that would slow down the
boiling of the refrigerant and thus penalize the re-
frigerating effect.
Controlling Pressure and FlowPressure and flow can be controlled with a float
valve, or with a pressure-regulating valve. They do
the same job, but in a different way.
Since the float valve type will give us a better idea of
pressure and flow control, let’s look at it first (Fig.
9B-17).It consists simply of a float that rides on the surface
of the liquid refrigerant. As the refrigerant liquid
boils and passes off as a vapor, naturally the liquid
level drops lower and lower. Correspondingly, the
float, because it rides on the surface of the refriger-
ant, also drops lower and lower as the liquid goes
down.By means of a simple system of mechanical linkage,
the downward movement of the float opens a valve
to let refrigerant in. The incoming liquid raises the
fluid level and, of course, the float rides up with it.
When the surface level of the refrigerant liquid re-
aches a desired height, the float: will have risen far

Page 543 of 625

OPEL GT-R 1973 Service Manual 98-34 1973 OPEL 3ERVlCE MANUAL
9B-23Figure
98.26 Compressor Front and Rear Heads
and circulated through the system via a 3/16 inch
diameter oil passage through the shaft center and
also four 5/64 inc

98-34 1973 OPEL 3ERVlCE MANUAL
9B-23Figure
98.26 Compressor Front and Rear Heads
and circulated through the system via a 3/16 inch
diameter oil passage through the shaft center and
also four 5/64 inch diameter holes drilled perpen-
dicular to the shaft. The inner rotor is driven by the
shaft.TUBE
Figure
98-27 Compressor Oil Flow
4. Shaft and
Gash Plate Assembly - The shaft andwash plate assembly (see Figure 9B-162) consists of
an elliptical plate positioned obliquely to the shaft.
As the plate and shaft rotate, the surface of the plate
moves to and fro lengthwise relative to the centerline
of the shaft. This reciprocating motion is transmitted
to the pistons which contact the surface of the wash
plate. A woodruff key locks the wash plate onto theshaft. The wash plate and shaft are serviced as an
assembly. The shaft is driven by a pulley when the
magnetic clutch is energized. A needle thrust bearing
and
L mainshaft bearing support the shaft horizon-
tally and vertically.
5. Needle Thrust Bearing and Races
- Two needle
thrust bearings, each“sandwiched” between two
races are located on either side of the wash plate
hub. The front needle thrust bearing and races pro-
vide 0.010” to 0.015” clearance between the top of
the pistons and the rear side of the front suction valve
reed disc (see Figure
9B-28). The rear needle thrust
bearings and races provide 0.0005” to 0.0015” clear-
ance between the hub of the wash plate and the rear
hub of the rear cylinder. Races of various thicknesses
are provided for service replacement to achieve re-
quired clearances when rebuilding units.
6. Cylinder Assembly and service Pistons (Factory
installed pistons are ringless) -The cylinder assembly
(front cylinder and rear cylinder) is serviced only as
a matched set. Alignment of the two halves is main-
tained by two dowel (locater) pins.
The double ended pistons are made of cast alumi-
num. There are two grooves on each end of the ser-
vice piston. The outer grooves will receive a piston
ring. The inner grooves act as oil scraper grooves to
collect any excess oil. Two oil return holes are drilled

Page 547 of 625

OPEL GT-R 1973 Service Manual 9B-38 1973 OPEL SERVICE MANUAL
expand and return to the original gaseous state. To
accomplish this transformation it begins to boil.
The boiling action of the refrigerant demands heat.
To satisfy the

9B-38 1973 OPEL SERVICE MANUAL
expand and return to the original gaseous state. To
accomplish this transformation it begins to boil.
The boiling action of the refrigerant demands heat.
To satisfy the demand for heat, the air passing over
the core gives up heat to the evaporator and is subse-
quently cooled.\
DIAGNOSIS
GENERAL INFORMATIONThe following is a brief description of the type of
sympton each refrigerant component will evidence if
a malfunction occurs:
Compressor malfunction will appear in one of four
ways: noise, seizure, leakage, or low discharge pres-
sure.Resonant compressor noises are not cause for alarm;
however, irregular noise or rattles may indicate
broken parts or excessive clearances due to wear. To
check seizure, de-energize the magnetic clutch and
check to see if drive plate can be rotated. If rotation
is impossible, compressor is seized. Low discharge
pressure may be due to a faulty internal seal of the
compressor, or a restriction in the compressor.
Low discharge pressure may also be due to an insuffi-
cient refrigerant charge or a restriction elsewhere in
the system. These possibilities should be checked
prior to servicing the compressor. If the compressor
is inoperative; but, is not seized, check to see if cur-
rent is being supplied to the magnetic clutch coil
terminals.
CondenserA condenser may malfunction in two ways: it may
leak, or it may be restricted. A condenser restriction
will result in excessive compressor discharge pres-
sure. If a partial restriction is present, sometimes ice
or frost will form immediately after the restriction as
the refrigerant expands after pas?ing through the re-
striction. If air flow through the condenser or radia-
tor is blocked, high discharge pressures will result.
During normal condenser operation, the outlet pipe
will be slightly cooler than the inlet pipe.
Receiver-DehydratorA receiver-dehydrator may fail due to a restriction
inside body of unit. A restriction at the inlet to the
receiver-dehydrator will cause high head pressures.
Outlet tube restrictions will be indicated by low headpressures. Outlet tube restrictions will be indicated
by
low head pressures and little or no cooling. An
excessively cold receiver-dehydrator outlet may be
indicative of a restriction.
Expansion ValveExpansion valve failures usually will be indicated by
low suction and discharge pressures, and insuff%ient
evaporator cooling. The failure is generally due to
malfunction of the power element and subsequent
closing of the valve. A less common cause of the
above symptom is a clogged inlet screen.
EvaporatorWhen the evaporator malfunctions, the trouble will
show up as inadequate supply of cool air. A partially
plugged core due to dirt or a faulty blower will gener-
ally be the cause.
Refrigerant Line Restrictions
Rest~rictions in the refrigerant lines will be indicated
as follows:
I. Suction Line - A restricted suction line will cause
low suction pressure at the compressor, low dis-
charge pressure and little or no cooling.
2. Discharge Line -A restriction in the discharge line
generally will cause the pressure relief valve to open.
3. Liquid Line
- A liquid line restriction will be evi-
denced by low discharge and suction pressure, and
insufficient cooling.
Use of Receiver-Dehydrator Sight Glass for
DiagnosisAt temperatures higher than 70 degrees F, the sight
glass may indicate whether the refrigerant charge is
sufficient. A shortage of liquid refrigerant is in-
dicated after about
five minutes of compressor oper-
ation by the appearance of slow-moving bubbles
(vapor) or a broken column of refrigerant under the
glass. Continuous bubbles may appear in a properly
charged system on a cool day. This is a normal situa-
tion. If the sight, glass is generally clear and perform-
ance is satisfactory, occasional bubbles do not
indicate refrigerant shortage.
If the sight glass consistently shows foaming or a
broken liquid column, it should be observed after
partially blocking the air to the condenser. If under
this condition the sight glass clears and the perform-
ance is otherwise satisfactory, the charge shall be
considered adequate.

Page 550 of 625

OPEL GT-R 1973 Service Manual REFRIGERANT COMPONENTS ALL MODELS9s. 41
BIower Operating Normal Check for the following:Restriction or leakage in air ducts, A/C outlets not
opening.2. Do not carry cylinder in passenger compartment
o

REFRIGERANT COMPONENTS ALL MODELS9s. 41
BIower Operating Normal Check for the following:Restriction or leakage in air ducts, A/C outlets not
opening.2. Do not carry cylinder in passenger compartment
of car.3. Do not subject cylinder to high temperatures.
MAINTENANCE AND ADJUSTMENTS4. Do not weld or steam clean on or near cylinder.
5. Do not fill cylinder completely.
GENERAL SERVICE INFORMATION AND SAFETY
PRECAUTIONS6. Do not discharge vapor into area where flame is
exposed or directly into engine air intake.
General InformationAll subassemblies are shipped sealed and dehy-
drated. They are to remain sealed until just prior to
making connections, and should be at room tempera-
ture before uncapping. This prevents condensation of
moisture from air that enters the system.
All precautions should be taken to prevent damage
to fittings or connections. Even minute damage to a
connection could cause it to leak. Any fittings with
grease or dirt on them should be wiped clean with a
cloth dipped in alcohol.
Do not clean fitting or hoses with solvents because
they are contaminants. If dirt, grease or moisture
gets inside the pipes or hoses and cannot be removed,the pipe or hose is to be replaced. Use a small amount
of clean refrigeration oil on all tube and hose con-
necting joints, and lubricate the
“0” ring gasket with
this oil before assembling the joint. The oil will help
in effectitig a leak-proofjoint and assist the
“0” ring
to slip into the proper location without being cut or
damaged. Always use new
“0” rings.
When tightening joints, use a second wrench to hold
the stationary part of the connection to prevent
twisting and to prevent hose kinking. Kinked hoses
are apt to transmit noise and vibration. Tighten all
connections in accordance with recommended
torques (see Division VI, Specifications).7. Do not expose eyes to liquid
- WEAR SAFETY
GOGGLES whenever discharging, charging or leak
testing system.
CHARGING AND DISCHARGING SYSTEMRemoval of any part in the refrigerant circuit will
require discharging of the entire system.
Discharging the System1. Remove caps from gauge fittings on the compres-
sor adapter fitting on the compressor.
2. With both valves on manifold gauge set (J-5725-
04) closed (clockwise), attach manifold to the com-
pressor adapter fitting on the compressor, using
J-5420 valve adapter at suction gauge fitting and
J-9459 valve adapter at discharge gauge fitting. See
Figure
9B-41.3. Fully open high pressure valve on manifold gauge
set to allow escape of refrigerant from system
through the manifold gauge set and out the center
fitting and hose. (Place end of hose in clean container
to collect oil loss due to rapid discharge of system).
4. When hissing ceases, indicating all refrigerant
has escaped, close high pressure valve on manifold
gauge set by turning valve clockwise.
Do not connect receiver-dehydrator assembly until
all other connections have been made. This is neces-
sary to itisure maximum moisture removal from sys-
tem.It is important that air conditioning hoses do not rest
on or contact body sheet metal except where neces-
sary. Because of the high frequency at which the
compressor operates, the passenger compartment is
susceptible to transfer of noise.
Evacuating the SystemWhen the refrigeration system is depressurized and
opened for service, some air will enter the lines, re-
gardless of how quickly openings are capped. In
or-der to remove this air and as much as possible of the
moisture it contains, the complete system must be
evacuated. Evacuating is merely the process of
removing all air from the system, thereby creating a
vacuum in the system.
Safety PiecautionsThe following safety precautions should always be
followed~,when servicing refrigerant charged compo-nents:Under no circumstances should alcohol be used in
the system in an attempt to remove moisture,
regard-less of the successful use of alcohol in other refrigera-
tion systems.
Preparations for Evacuating Complete System
1. Do not leave Refrigerant-12 cylinder uncapped.
1. Check the low pressure gauge for proper calibra-

Page 551 of 625

$OPEL GT-R 1973 Service Manual 98-42 1973 OPEL SERVICE MANUAL SCHRADER VALVE ADAPTER J-54201COMPRESSOR(TOP VIEW)[/--DISCHARGE LINE ILOW PRESSURE\ GAUGE MANIFOLD AND -GAUGE SET J-5725-01 rGAUGE LINES (5) J-541899-31 Figure 98.41 Set$

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