1973 OPEL GT-R oil

98.74 1973 OPEL SERVICE MANUAL
(a) Using a feeler gage, select a leaf or combination
of leaves which result in satisfactory “feel” when
inserted between rear piston drive ball and wash
plate (see Figures 9B-141 and 9B-142).CHECi(lNG?OR
SHAFT END PLAY
CHE&NG FOR
PISTON PLAY
98113Figure 98-141 Checking Piston and Shaft End Play
Figure 98-142 Checking Clearance Between Rear
Piston Drive Ball and Swash Plate(b) Remove selected leaf or leaves from feeler gage
and attach end of spring scale that is calibrated in
ounces. (A generator brush spring scale (J-5 184) or
the spring scale for checking distributor point setting
may be used for this step).
(c) Reinsert feeler gage leaf or leaves between rearpiston drive ball and wash plate and draw leaf or
leaves out again, simultaneously measuring “drag”
on leaf or leaves (see Figure
9B-143). If correct leaf
(leaves) has been selected, spring
:scale will read be-
tween 4 to 8 ounces pull (the higher reading is
desired). To perform this step correctly, feeler gage
leaf (leaves) must be withdrawn straight out with a
steady even motion, and all surfaces involved must
be coated with No. 525 viscosity oil. Record gage
dimension.
Y
i15Figure 98.143 Checking Drag
on Selected Feeler
Gage Leaf with Spring Scale
Use of the spring scale establishes a standard of
measurement of the amount of feeler gage leaf
“drag” required.
(d) Rotate the shaft and wash plate assembly 120
degrees and perform a second check (Steps “a, b and
c”) between same piston drive ball and wash plate.
Record gage dimension.
(e) Rotate shaft and wash plate again approximately
120 degrees and repeat third check (Steps “a, b and
c”) between same piston drive ball and wash plate.
Record gage dimension.(0 From the three recorded checks (Steps
“c, d and
e”) select minimum feeler gage reading and obtain
from
stock (ref. to the Shoe Disc Table for part num-
ber of shoe disc) one shoe disc corresponding to the
minimum gage reading (ref. example below). Place
shoe disc in respective position on parts tray
(J-
9402).

REFRIGERANT COMPONENTS ALL MODELS9B- 75Shoe Disc TableSERVICEID. NO.
PART NO. STAMPED
6557000
6556175
6556180
65561856556190
65561956556200
65562056556210
65562156556220
EXAMPLESHOE
DISC
0
(“ZSXO”Shoe
Disc)
17
l/218%
1919
l/2202&2
2121
l/2
22
Piston’
1st2nd3rdNo.
CheckCheckCheck
1,019,020,019(Select
No.19 -ShoeDisc)
2,020,020,019(Select
No.19-ShoeDisc)
3
.021,020.021(Select
No.20ShoeDisc)
(g) Repeat Steps “c, d, e and f’ for other two pistons
and obtain two more selected shoe discs for other
two pistons. In the rebuilt cylinder assembly, each
piston will have one selected shoe disc and one
“zero” shoe disc.
12. Gage shaft end play as follows:
(a) Using a feeler gage, select a leaf or combination
of leaves which result in satisfactory “feel” when
inserted between rear needle thrust bearing and outer
rear thrust race (see Figure
9B-144).
(b) Remove selected leaf or leaves from feeler gage.
Attach to end of spring scale calibrated in ounces. (A
generator brush spring scale (J-5184) or the spring
scale for checking distributor point setting may be
used for this step).(c) Reinsert feeler gage leaf (leaves) between rear
needle thrust bearing and outer rear thrust race and
draw leaf (leaves) out again, this time simultaneously
noting the “drag” or pull on the leaf (leaves) as mea-
sured by the spring scale (see Figure
9B-145). If
correct leaf (leaves) have been selected, spring scale
will read between 4 to 8 ounces pull (the higher
reading is desired). To perform this step correctly,
the feeler gage leaf (leaves) must be withdrawn
straight out with a steady, even motion. All contact-Figure 98.144 Gaging Clearance Between Rear
Needle Thrust Bearing and Outer Rear Thrust Race
ing surfaces involved in gaging operation must be
coated with No. 525 viscosity oil.
Figure 98.145 Checking Drag on Selected
FeeletGage Leaf with Spring Scale
The measurement for selection of the thrust race
needs to be performed at only one place on the shaft
and wash plate assembly.
(d) Select from stock one thrust race (ref. Thrust
Race Table for part number of thrust race) corre-
sponding to the feeler gage reading determined in
step
“C”,and place the selected thrust race in the
parts tray slot designated for the outer rear thrust

REFRIGERANT COMPONENTS ALL MODELS99.77
In order to tit the piston onto the wash plate and
into the cylinder bore, the wash plate must be raised
approximately l/2 inch, the front needle thrust bear-
ing and races must be held up against the hub of thewash plate, and the service piston rings must be
squeezed together (see Figure
9B-147). Lubricate
cylinder bore, piston assembly and wash plate with
No. 525 viscosity oil to facilitate reassembly.
4. Repeat procedure in Steps 1 and 2 for installation
of No. 2 and No. 3 pistons.
5. Obtain new service replacement discharge tube
and assemble into front cylinder (see Figure
9B-148).Figure SE-150 Pistons Positioned in Stair-Step
DISCHARGE
TUBEArrangement
- Service Pistons Shown
suction pass cover and lips ofsuction passage in body
of cylinder assembly, and reassemble suction pass
cover over suction passage (see Figure
9B-151).98.27
Figure
SB-148 Service Replacement Discharge Tube
6. Liberally lubricate cylinder bores of rear cylinder
with No. 525 viscosity oil and reassemble rear cylin-
der onto front cylinder being sure to compress ser-
vice piston rings. Align discharge tube and dowel
pins, and tap cylinder halves together. Check for free
rotation of shaft.
If pistoni are positioned in a “stair-step” arrange-
ment (see Figure
9B-150), installation of rear cylin-
der will be facilitated. In addition once the service
piston and ring are started into the cylinder, slight
rotation of the shaft to and fro will work the ring into
the bore. ‘IFigure
98.151 Installing Suction Pass Cover
8. Assemble both service replacement discharge
tube
“0” rings and bushings (see Figure 9B-152)
onto cylinder assembly.
Reassembly of Front Suction Valve Reed Disc, Front
Discharge Valve Plate, Front Head. and Installing
of Cylinder Assembly
7. Liberally lubricate with No. 525 viscosity oil,1. Assemble suction reed valve disc to front of cylin-

98-78 1973 OPEL SERVICE MANUAL
der assembly and align with dowel pins, suction poitand discharge port (see Figure
9B-153).2. Assemble front discharge valve plate to front of
cylinder assembly and align with dowel pins.
3. Coat sealing surfaces on front head (see Figure9B- 154) with No. !?5 viscosity cdl.
Figure 98.152 Installing Discharge Tube O-Ring and
BushingFigure 98.154 Placing Front Head on Cylinder
Assembly4. Murk with pencil on side of front head the loca-
tion of dowel pin holes (see Figure 9B-154), align
front head with dowel pins, and tap head lightly with
mallet to seat on cylinder assembly.
5. Place new shell to head
“0” ring on shoulder of
front head (see Figure 9B-155) and liberally coat
“0” ring and front head sealing surface with No. 525
viscosity oil.
6. Install she11 in holding fixture (J-9396) and posi-
tion so that rear studs of shell are up. Coat inside
surface of shell with No. 525 viscosity oil.
Figure 9B-153 Front Suction Valve Reed Disc
installed7. Reassemble, as a unit, cylinder assembly and
front head into the shell. See Figure 9B-156. Extreme
care must be used to prevent she11 to head
“0” ring
seal from being damaged.
Reassembly of Rear Suction Valve Reed Disc, Rear
Discharge Valve Plate, Oil Pump and Rear Head
1. Rotate the cylinder assembly and front head until

REFRIGERANT COMPONENTS ALL MODELS9B- 79
HELL TO HEAD
O-RING(BE SURE
INSIDE SHELL
GRASP FRON
Figure SB-156 Installing Front Head and Cylinder
Assembly in Shell
Figure
96-155 Shell To Front Head O-Ring Installment
the hole for the oil inlet tube in the cylinder assembly
is aligned with the reservoir hole in the shell, and
reassemble the oil inlet tube and
“0” ring.
2. Assemble suction reed valve disc to rear of cylin-
der assembly and align with dowel pins, suction port,
and discharge port of cylinder assembly.
3. Assemble rear discharge valve plate to rear of
cylinder assembly and align with dowel pins.
4. Reassemble inner and outer oil pump rotors so
that the sides previously identified are in their origi-
nal location, and then position oil pump outer rotor
as shown in Figure
9B-157.5. Generously coat with No. 525 viscosity oil new
“0” ring and install in shell (see Figure shell to head
9B-157).6. Coat Teflon sealing surface of rear head with No.
525 viscosity oil, mark with pencil on side of rear
head the lpcation of the dowel pin holes and reassem-
ble onto compressor.Figure
98.157 Positioning Oil Pump Outer Rotor
It may be necessary to repositipn oil pump outer
rotor slightly in order to install rear head. In addi-
tion, if dowel pins do not engage’ holes in rear head,
grasp front head and rotate cylinder assembly
slightly (see Figure
9B-158).7. Assemble new nuts to threaded shell studs and
torque to 10 lb. ft. If pressure relief valve has been
removed, reassemble using a
riew pressure relief
valve gasket.
8. Reassemble new lubricated suction and discharge

96-80 1973 OPEL SERVICE MANUAL
LINE UP LOCA
PINS AND
HOFigure SB-158 Installing Rear Head
“0” rings into suction and discharge ports of rear
head.9. Reassemble shaft seal onto front of shaft andwash plate assembly. Do not reassemble clutch
drive plate at this time.
Leak ‘Testing Compressor1. After the shaft seal pressure test has been per-
formed, change the test circuit to the configuration
shown in Figure 9B-160.
2. With hose attached only to high pressure side of
Leak Test Fixture J-9625, open high pressure valve
to charge high pressure side of compressor. As soon
as high pressure gage stabilizes reading, close valve.
If high pressure gage drops back immedaitely when
valve is closed, an internal leak is indicated. Correct
leak as necessary.
If an internal leak is indicated, the leak may exist
about the head sealing surface or Teflon seal,
dis-
charg,e tube, shell to head “0” rings, or suction valve
reed discs.
3. Remove drain screw from shell and add No. 525
viscosity oil as specified.
4.
R~eassemble pulley assembly, and coil and hous-
ing assembly onto hub of front head.
5. Complete reassembly by installing clutch drive
plate onto hub of front head. See Figure 9B-164
disassembled view of compressor.

r98-82 1973 OPEL SERVICE MANUAL
SPECIFICATIONS
Tightening Specifications
Part
Location
NutDrivePlateNut toCompressorShaft..............................
NutRear Head to Shell................................................................
CaPSchraderServiceValve......................................................
Compressor Specifications
Torque
Lb. Ft.
15
21
5Type
..............................................................................................Six Cylinder Axial Opposed
Make
............................................................................................................................Frigidaire
Effective Displacement (Cu. In.)
..........................................................................................
9.2Oil
..........................................................................................................................525 Viscosity
Oil Content (New)
....................................................................................................10 Fl. Oz.
Air Gap Between Clutch Drive Plate and Pulley
......................................0.022 to 0.057 In.
Clutch Type
................................................................................................................h4agnetic
Belt Tension
..............................................................................................1 lo-125 Lbs. Irritial
....................................................................................................................80 Lbs. Retension
Pipe and Hose Connection Torque Chart
Metal TubeThread andSteel TubingAluminum orNominal Torque
I
Outside Dia.Fitting SizeTorqueCopper TubingWrench Span
Lb. Ft.Torque
Lb. tit.
5-7
General SpecificationsThermostat Opening Temperature
.._.....,,,...__....,,.............................................................. 189
Capacity of Cooling System With Air Conditioner (Quarls)
.,,..___....___............... 6 (Approx.)Type of Refrigerant
.___,,,._...,.,,,.__.....,,,.......,,,,.......,,,...................,,,......,,,............ Refrigerant 12
Refrigerant Capacity (Fully Charged)
Opel
1900-Manta,,._....,,,,._...._.,,,,.......,,,........,,............................................................2 Lbs.
GT
,..__..,..,..__..,,,.......,,,,.......,,,........,,,.,......,,,,,......,,.,,........,,.......,,..........,,............... 2 l/4 Lbs.
Functional Test Procedures1. Place transmission in park for automatics and in
neutral for manuals. Apply hand brake.
2. Turn blower switch to HI position,
3. Turn temperature switch to MAX position-.
4. Run engine at 2000 RPM for ten (10) minutes with
car doors and windows closed and the hood up. Place
a commercial high volumn fan in front of condenser
if head pressure should exceed 250 psig.A commercial high volumn fan should be placed in
front of the condenser at high ambients to bring the
pressures to within the limits specified in the Func-
tional Charts. When testing the Opel 1900 and
Man& a thermometer should be placed in a position
to read the temperature of the air discharging from
the right-hand A/C outlet. When testing the GT, a
thermometer should be placed in a position to read
the temperature of the air discharging, from the left-
rear
,A /c outlet.

REFRIGERANT COMPONENTS ALL MODELSSB- 85
123 45 6 7a910 11 12 131415 lb1718 19
_202122232425 26 272a2930313233 34 35 3b
I. Rear Head13. Coil and Housing
Assemblv
2. Rear Head to Shell “0” Ring
3. Rear Discharge Valve Plate14. coil Housiq Retaining Ring25. Thrust Race
4. Rear Suction Reed Plate
15. Pulley and Bearing Assembly26. Thrust &zarin~27.16. Pulley BearingThrust Race
28.
5.
PistonRingCompressor Shell6. Piston Drive Ball17. Pulley Bearing Retainer Ring
18. Pulley and
Bearing Retainer Ring29. Cylinder Assembh30.Shaft Seal
7. Ball Seat (Shae Disc)
8. Piston
19. Clutch Hub and Drive Plate Assembly 31. Shaft Seal Seat “0” Rjn820. Oil Pump Gears
32. Shaft Seal sear
9. Front Suction Reed Plate
10. Front Discharge Valve Plate21. Mainshaft
Bearing (Rear)
22. Oil inlet Tube “0” Ring33. Shaft Seal Seat Rrrainer Ring
11. Fr&t Head to Shell “0” Rin8 23. Oil Inlet Tube34. Spacer
12. Front Head24. Wobble
(Skash) Plate and Mainshaft35. Clutch flub Retainer Ring36:Shaft Nut
Assembly98.131Figure 98.162 Compressor Section View