1973 OPEL GT-R service

96-52 1973 OPEL SERVICE MANUAL
REMOVAL AND INSTALLATION OF EVAPORATOR
AND EXPANSION VALVE. OPEL 1900 - MANTA
Removal
1. Remove negative battery cable from battery.
2. Remove left side of distributor duct, and in line
fuse. See Figure
9B-61.3. Remove glove box. See Figure
9B-62.Figure 96-64 Delay Restrictor
and Check Valve Hose
Assembly Location
5. Disconnect the delay restrictor and check valve
hose assembly from the vacuum cut-off switch and
disconnect the electrical wiring. See Figures 9B-63
and 64.
6. Remove evaporator inlet and outlet pipes re-
tainer and rubber grommet. See Figure
9B-65.Figure
98.62 Glove Box Removed
4. Discharge refrigerant from system. (Refer to
DISCHARGING SYSTEM) and disconnect refrig-
erant hose from evaporator outlet and pipe from
evaporator inlet and tape the open ends of the refrig-
erant lines and evaporator pipes. See Figure
9B-63.Figure
98.65 Inlet and Outlet Pipes retainer and
Rubber Grommet-Opel 1900 - Manta
Figure
98.63 Location of Refrigerant Hoses, Pipes,
Vacuum Cut Off Switch and Evaporator Attaching Bolt
(Left Side) - Opel 1900
- Manta

96-54 1973 OPEL SERVICE MANUAL
valve. The filter screen at the inlet port may be re-
placed. Remove screen by threading a lo-32 NF
screw into old filter screen. With a washer and a nut
on the screw arranged to work as a puller screw, hold
the body of the screw and turn the nut. Insert the
new filter screen into the inlet port and lightly tap
screen only enough to seat.
1. Install expansion valve using new o-rings during
installation. Lubricate o-rings prior to installation
using No. 525 viscosity oil.
2. Install evaporator assembly and case attaching
screws. See Figure 9B-70.3. Install blower motor assembly into case and se-
cure with attaching screws. See Figure
9B-69.4. Install finger guard shields and fan housing case.
See Figure
9B-69.5. Install resistor assembly and electrical connector.
Install blower motor connector. See Figure
9B-69.6. Install assembly into car carefully guiding
evaporator pipes up through cowl opening. See Fig-
ure
9B-71.Figure 93-7 1 Inlet and Outlet Pipes and O-Rings
-Opel 1900 Manta
7. Install two (2) upper attaching evaporator at-
taching nuts. See Figures 9B-66 and
9B-67.8. Install two (2) attaching case mounting bracket
to instrument panel screws. See Figure
9B-67.9. Connect two (2) drain hoses underneath evapora-
tor.10. Install evaporator inlet and outlet pipes retainer
and rubber grommet. See Figure
9B-65.11. Connect vacuum cut-off switch and electrical
wiring, making sure the delay restrictor and checkvalve hoses are installed correctly. See Figures
9B-63and 64.
.gB-72 Delay Restrictor and Check Valve Hose.Assembly
12. Install refrigerant hoses and pipes using new
o-rings on line fittings and evacuate system. Refer to
EVACUATING SYSTEM.
13. While system is being evacuated, install in-line
fuse and left side of distributor duct. See Figure 9B-
61.14. Install glove box.
15. Install negative battery cable and charge system.
Refer to CHARGING SYSTEM.
REMOVAL AND INSTALLATION OF CONDENSER
ASSEMBLY -OPEL 1900. MANTA
Removal
1. Remove negative battery cable from battery.
2. Remove air cleaner.
3. Discharge system. Refer to DISCHARGING
SYSTEM.
4. While system is discharging, remove lower radia-
tor hose from radiator and drain coolant into a suita-
ble container.
5. Remove fan shroud.
6. On vehicles with automatic transmission, un-
screw oil lines from connectors on lower radiator
tank and plug lines. It is essential that no dirt enters
the oil lines. When unscrewing oil lines, hold connec-
tors on lower radiator tank with pliers to avoid leak-
ages. Ensure that no dirt enters oil cooler.
7. Remove upper radiator hose from radiator.
8. Remove lower attaching nut and slide radiator
upward and out of engine compartment.
9. Remove inlet and outlet hoses from condenser

98-56 1973 OPEL SERVICE MANUAL
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 11-15 Ibs. ft.
7. Install fan shroud.
8. Install upper radiator hose.
9. Install lower radiator hose and add collected coo-
lant.
All Opel
1900’s and Manta’s are provided with a
radiator initial fill of an anti-freeze solution contain-
ing corrosion inhibitor. The anti-freeze 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. Anti-freeze added, must have
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.).
IO. Install negative battery cable and air cleaner.
11. Charge system. Refer to CHARGING SYS-
TEM.
Figure 99.80 Location of Idler Pulley and Bracket
Assembly
- GTFigure 99.81 Idler Pulley and Bracket Assembly and
Support Bracket GT
REMOVAL AND INSTALLATION OF
COMPRESSOR. GT
I. Removenegative battery cable from battery.
Figure 98-82 Compressor Adapter Fitting, Ground
Wire. and Front and Rear Mounting Bolts
- GT
Figure 99.83
Elecirical Connector and Ground Wire
GT

98-58 1973 OPEL SERVICE MANUAL
2. Discharge system. Refer to DISCHARGING
SYSTEM.
3. While system is discharging remove air cleaner
and loosen idler pulley and bracket assembly. See
Figure 98-80.
4. Remove bolt holding compressor adapter fitting
into rear head. Disengage from compressor and tape
closed openings in both lines and ports in rear head.
It is important to seal compressor ports to avoid a
loss of refrigeration oil and also to prevent foreign
material and moisture from entering compressor. See
Figure 9B-82.
5. Remove bolt and ground wire, unplug electrical
connector, and remove 2 rear compressor mounting
bolts. See Figure 98-82.
6. Remove 2 front compressor mounting bolts,
clutch drive belt, and lift out compressor. During
removal, maintain the compressor position so that
the sump is downward. Do not’rotate compressor
shaft. See Figure 9B-84.
Installation1. Install compressor into mounting brackets and
secure with 4 mounting bolts. See Figure
9B-84.2. Untape lines and ports, and install compressor
adapter fitting and bolt using new o-rings. See Figure
9B-82.3. Evacuate system. Refer to, EVACUATING
SYSTEM.
4. While system is being evacuated, install drive belt
and tighten idler pulley. See Figure
9B-80.5. Install bolt and ground wire and plug in electrical
connector. See Figure
9B-83.6. Install air cleaner and negative battery cable.
7. Charge system. Refer to, CHARGING SYS-
TEM.
REMOVAL AND INSTALLATION OF
RECEIVER.DEHYDRATOR
ASSEMBLY. GT
Removal1. Discharge system. Refer to DISCHARGING
SYSTEM.
2. Disconnect refrigerant lines to both ends of re-
ceiver-dehydrator and tape closed open ends of
re-
9862Figure 98.85 Refrigeration Hose Clamps Installation
GT
frigerant lines, and also the open
e:nds of the inlet and
outlet pipes of the receiver-dehydrator. See Figure
9B-86.Figure 98.86 Receiver-Dehydrator GT
3. Remove 2 screws securing receiver-dehydrator
and clamps to support bracket and lift out receiver
dehydrator. See Figure
9B-86.
Installation1. Install receiver-dehydrator using new o-rings
during installation. Lubricate o-rings prior to instal-
lation using No. 525 viscosity oil.
.

9B-60 1973 OPEL SERVICE MANUAL
EVAPORATOR EVAPORATOR
DRAIN HOSE DRAIN HOSE
Figure 96-91 Drain Hose GT
Figure 98.92 Evaporator Mounting Bracket Bolts
Driver Side GT
9. Lift off the mounting bracket and remove the
evaporator assembly from the car.
10. Remove the resistor assembly. See Figure
9B-90.Figure 98-93 Evaporator Mounting Bracket Bolts
Passenger Side
- GT“0” RING-----
OUTLET TUBE
SEAL
9870Figure 98-94 Inlet and Outlet Pipes and O-Rings GT
11. Remove blower case and blower motor attaching
screws and remove assembly.
12. Remove all remaining attaching screws and
remove evaporator assembly. See Figure
9B-95.13. Disconnect expansion valve capillary tube bulb
attached to the outlet pipe of the evaporator. See
Figure 9B-95.
14. Disconnect inlet and outlet ends of expansion

98-62 1973 OPEL SERVICE MANUAL
Figure 98.99 Refrigerant Hoses Retainer Grommet
-Under Car - GT
8. From under car install four (4) nuts securing
evaporator mounting bracket to floor. See Figures9B- 92 and
9B-93.Figure 98.100 Refrigerant Hoses
- Under Car GT
9. Evacuate system. Refer to EVACUATING SYS-
TEM.
10. While system is being evacuated, connect drain
hoses underneath evaporator housing.
11. Plug in the resistor assembly electrical connector
plug and connect the blower motor connection and
install ground wire and 2 mounting brackets to case
screws using the rearward holes. See Figure
9B-90.12. Install the evaporator cover and all cover screws.
See Figure
9B-88.13. Install luggage tray and attaching screws. See
Figure
9B-87.14. Connect the negative battery cable.
15. Charge system. Refer to CHARGING SYS-
TEM.
REMOVAL AND INSTALLATION OF CONDENSERRECIWER- DEHYDRATOR ASSEMBLY
- GT
Removal
1. Disconnect negative battery cable.
2. Discharge system. Refer to DISCHARGING
SYSTEM.
3. While the system is discharging, remove the
charcoal cannister, washer jar, battery and battery
tray. Battery needs only to be set up out of the way
and not removed from the car.
4. Disconnect inlet and outlet pipes of condenser
receiver-dehydrator and tape closed the open ends of
refrigerant lines, and also the open ends of the inlet
and outlet pipes of the condenser. See Figure 9B-101.
5. Disconnect discharge line from condenser and
tape closed open ends of discharge pipe and con-
denser inlet.
6. Remove 4 condenser attaching screws and lift out
condenser. See Figure 9B-101.
7. Remove 2 screws retaining receiver-dehydrator
to condenser and remove.
Figure
9B-101 Receiver - Dehydrator. Condenser
Attaching Screws and Brackets
- GT
Installation
If refrigerant circuit or condenser has been exposed
to the atmosphere and moisture may be present in
the circuit, the system and/or component must be
flushed prior to installation. Refer to FLUSHING
THE SYSTEM.
1. Install receiver-dehydrator to condenser and fas-
ten with 2 clamps and 2 screws.

9B-64 1973 OPEL SERVICE MANUAL
4. Using No. 21 Truarc pliers (J-5403) take out
retainer ring from hub of clutch drive plate (see Fig-
ure 9B-106). Lift our spacer.
Figure 95.106 Removing
or Installing Retainer Ring inClutch Drive Plate5. If compressor has an absorbent sleeve in the neck,
pry out the sleeve retainer and remove the sleeve.
Remove the seal seat retainer ring, using No. 21
Truarc pliers, Tool J-5403, (see Figure
9B-107).
SEAL SEATFigure 98.107 Removing or Installing Shaft Seal Seat
Retaining Ring6. Thoroughly clean the area inside the compressor
neck surrounding the shaft, the
ezxposed portion of
the seal seat and the shaft itself of any dirt or foreign
material. This is absolutely necessary to prevent any
such material from getting into
t:he compressor.
7. Remove the seal seat (see Figure 9B-108) using
Tool J-23128. Insert Tool
J-2312E; into seal seat and
tighten, using a twisting motion remove the seal seat.96-82
Figure SE-108 Removing or Installing Ceramic Shaft
Seal seat
8. Remove the seal assembly, using Tool J-9392.
Press tool downward on seal while twisting it clock-
wise to engage the tabs of the seal assembly. Gently
but firmly, pull tool straight out (see Figure
9B-109).9. Remove the seal seat
“0” ring, using Tool J-9553
(see Figure
9B-110).10. Recheck the inside of the compressor neck and
the shaft. Be sure these areas are perfectly clean
before installing new parts.
Reassembly
1. Coat the new seal seat
“0” ring with clean refrig-
eration oil and install it in its groove in the compres-
sor neck. Tool J-21508 may be used to accomplish
this. (See Figure
9B;,lll)2. Coat the
“0” ring and seal face of the new seal
assembly with clean refrigeration oil. Carefully
mount the seal assembly to Tool J-9392 by engaging
the tabs of the seal with the tangs of the tool.
3. Place seal protector, Tool J-22974, over end of
shaft and carefully slide the new seal assembly onto
the shaft. Gently twist the tool clockwise while push-
ing the seal assembly down the shaft until the seal

9B-66 1973 OPEL SERVICE MANUAL
LEAK TEST
FIXTURE
\ Js - s ---Y623
\COMPRESSOR
ADAPTERS
J-5420
USE LINE ONLY
DURING
-
COMPRESSOR
SEAL TEST
-4
-
It-’rDISCHARGE LINE
-
LOW PRESSUREHIGt
GAGE
4
PRESSURE
GAGE
(TOP VIEW)
GAGE
*-LINE (3)
J-54 18
GAGE SET
REFRIGERANT
J-5725-01
-CYLINDER
LMANIFOLD AND
9&86
Figure 9B-112 Leak Testing Shaft Seal and Seal Seat O-Ring
the sleeve retainer is recessed approximately l/32”
from the face of the compressor neck. 11. Reassembly spacer into hub ofclutch
drive plate.
9. Insert woodruff key into hub of clutch drive plate
so that it projects out approximately
3/16 inch (see
Figure
9B-113) and position clutch drive plate onto
shaft.
10. Using drive plate installer (J-9480), screw in-
staller on end of shaft as shown in Figure
9B-114.
Hold nut and turn bolt until clutch drive plate is
pressed within
3/32 inch of the pulley assembly.
12. Reassemble retainer ring into hub of clutch drive
plate (see Figure
9B-106) using No. 21 truarc pliers
(J-5403).
13. Thread on new shaft nut using special thin wall
9/16 inch socket (J-9399) and 3/8 inch drive. Hold
clut~ch drive plate secure using Wrench (J-9403) and
torque nut to 15 lb. ft. The air gap between the
friction surfaces of the pulley assembly and clutch