1973 OPEL GT-R Service Manual

6A. 61973 OPEL SERVICE MANUALDIAGNOSIS
EXCESSIVE OIL CONSUMPTION
ConditionCorrectionExternal Oil Leaks at:Tighten attaching bolts. If leaks
Rocker Arm Coverspersist, remove cover (or pan),
Crankcase Front Covercheck sealing surfaces for burrs
Oil Pan and Gasketor scoring, replace gasket, and
seal bolts with silastic sealer or
equivalent. Make sure oil level
,is not overfull.
Improper Reading of Dip-Car may not be level when taking r
StickInsuffIcient oil “drain-back” time
after stopping engine (three
minutes must be allowed). Dip-
stick may not be completely pushed
down against stop. Dipstick may
be bent.
Oil Viscosity Too LightUse recommended SAE viscosity for
prevailing temperatures.
Continuous High-SpeedAt speeds above 60 mph, increased
Drivingsumption can be expected with any
Inform customer of this fact.
High-Speed DrivingWhen principal use of automobile i
Following Normal Slowcity driving, crankcase dilution f
Speed City Drivingcondensation occurs. High speed a
temperatures will remove water,
resulting in what appears to be
rapid lowering of oil level.
Inform customer of this fact.
Piston Rings NotAllow engine to accumulate at leas
“Broken In”
4,OCO miles before attempting any
engine disassembly to correct for
oil consumption.
NOISY VALVES AND LIFTERSIf the preceding check indicates valve mechanism is
abnormally noisy, remove the rocker arm cover so
that the various conditions that cause noise may be
The noise level of the valve mechanism cannot bechecked. A piece of heater hose of convenient length
properly judged where the engine is below operatingmay be used to pick out the particular valves or valve
temperature when the hood is raised, or when thelinkages
thit are causing abnormal noise. With the
valve rocker arm covers are removed.engine running at a speed where the noise is pro-
nounced; hold the end of hose to an ear and hold
Before attempting to judge valve noise level, the en-other end about
l/2 inch from point of contact be-
gine must be thoroughly warmed up (at least 20tween rocker arm and valve stem. Mark or record the
minutes of operation at
1200 to 1500 RPM) to stabil-noisy valves for investigation of following causes:ize oil and coolant temperatures and bring all engine
parts to a normal state of expansion. When the
en-1. Sticking, Warped, or Eccentric Valves, Worngine is warmed up, listen for engine noise while
sit-Guides Sticking valves will cause irregular engine
ting in the driver’s seat with the hood closed. Run theoperation or missing on a low speed pull and will
engine at idle and at various higher speeds.usually cause intermittent noise.

ENGINE MECHANICAL AND MOUNTS6A- 7
Pour penetrating oil over the valve spring cap andengine off. It makes no difference whether the engine
allow it to drain down the valve stem. Apply pressureis cold or is at operating temperature. Set piston of
to the one side of the valve spring and then the other,the respective cylinder to upper top center on the
and then rotate the valve spring about l/2 turn. Iffiring stroke. This can be accomplished by removing
these operations affect the valve noise, it may bethe distributor cap and observing the rotor. Check
assumed that valves should be reconditioned.position of the rotor and follow spark path for the
2.Worn or Scored Parts in the Valve Train Inspectrotor tip through the distributor cap, high tension
rocker arms, push rod ends for scoring. Check pushwire to spark plug. This determines which cylinder
rods for bends, valve lifters, and camshaft surfacesis at upper top center on the firing stroke. Adjust the
for scoring. Replace faulty parts.hydraulic lifters of the two valves for that cylinder at
this time. When they are adjusted, turn engine so
MAINTENANCE AND ADJUSTMENTSthat another.cylinder is at upper top center on the
firing stroke and adjust the two valve lifters for that
VALVE LIFTER ADJUSTMENTcylinder. Repeat process until all valves are adjusted.
See Figure 6A-6 for correct rotor position for each
Perform hydraulic valve lifter adjustment with thecylinder.
CORRECT ROTOR POSITION TO ADJUSTCORRECT ROTOR POSITION TO ADJUST
VALVES ON CYLINDER NO. 1VALVES ON CYLINDER NO. II
CORRECT ROTOR POSITION TO ADJUSTCORRECT ROTOR POSITION TO ADJUST
VALVES
ON CYLINDER NO. IllVALVES ON CYLINDER NO. ,VW-6Figure
6A-6 Rotor Positions for Valve Lifter Adjustment

6A- 8 1973 OPEL SERVICE MANUAL
Actual adjustment is made by backing off adjusting
nut at the rocker arm until clearance exists between the valve stem, rocker arm, and lifter. Then slowly
tighten adjusting nut until clearance is eliminated.
When clearance is eliminated, turn adjusting nut one
full turn (clockwise). This positions the hydraulic
piston of the hydraulic lifter mid-point in its total
available travel, and no further adjustment is re-
quired.
MAJOR REPAIR
ENGINE ASSEMBLY REMOVAL AND
INSTALLATION
Removal (Opel 1900 and Manta)’
The engine assembly on the Opel 1900 and Manta
can be removed together with the transmission
through the top of the engine compartment.
1. Remove hood (scribe hood hinge to hood mount-
ing location).
2. Disconnect battery negative cable.
3. Drain coolant at lower radiator hose.
4. Remove upper and lower radiator hoses.
5. Remove radiator and fan
shrbud.
6. Disconnect heater hoses.
7. Disconnect brake booster
vacuum hose.
8. Remove air cleaner.
9. Disconnect electrical connections and accelerator
linkage. 10. Remove console.
11. Remove shift lever boot, plate, and shift lever.
12. Raise car on hoist.
13. Disconnect fuel line at pump.
14. Remove front stone shield.
15. Disconnect speedo-cable, back-up light switch,
and clutch cable.
16. Remove drive shaft. I
17. Disconnect exhaust pipe
ar$l bell housing sup-
port.
18. Disconnect transmission support. See Figure
6A-7. 19. Remove engine mount bolts. See Figure
6A-8.
20. Attach hoist chains.
21. Lift engine and transmission assembly out of car.
Figure 6A-7 Transmission Support Bolts . Opel 1900
and Manta Series
Figure
6A-B Engine Mount Bolts - Opel 1900 and
Manta Series
Removal (GT)
The removal and installation of the 1.9 liter engine is only possible towards the floor and from below
Fig, 6A-9 Left Front Engine Suspension with Cross
Member (GT)

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.

ENGINE MECHANICAL AND MOUNTS6A- 11
a. Attach left chain to alternator support rear bolt.
b. Bolt right chain to existing threaded hole at lower
right front of engine.
2. Assemble loose ends of chain to support device J-bolts and adjust to remove engine weight from motor
mounts.
3. Remove the two motor mount bracket to motor
mount retaining nuts.
4. Remove the two front suspension to frame rail bolt
retaining nuts.
5. Remove nut and bolt at lower end of steering shaft
U-joint.
6. With a floor jack under the center of the front
suspension cross member, raise car high enough for
wheels and suspension assembly to be rolled from
under car.
7. Position jack stands under both front jack brackets
on underbody to support car in this position.
8. Remove both front cross member support to frame
attaching bolts.
9. Remove brake pipe to brake hose retaining clips
at frame rails and disconnect brake hose from brake
pipes. Use an absorbent material or suitable con-
tainer for the brake fluid that will drain out.
10. Lower the front suspension assembly and remove
from under car.
11. Drain engine oil and remove oil pan and gasket.
Installation (Opel 1900 and Manta)1. Apply a light bead of sealer to the clean sealing
surfaces of the oil pan and affix a new gasket.
2. Bolt oil pan and gasket assembly to engine block.
3. Roll front suspension and floor jack under car and
raise into position careful to pilot the cross member
to frame rail attaching bolts and steering shaft to
their respective locations.
4. Install cross member’support to frame attaching
bolts and torque to 22 lb.ft.
5. Connect brake hose to brake pipes and install
retaining clips.
6. Bleed front brake system. Maintain brake fluid1Wd.
7. Remove jack stands and lower car.8. Install suspension to frame rail bolt retaining nuts.
9. Release and remove engine supporting device.
10. Install motor mount bracket to motor mount
retaining nuts.
11. Install steering shaft U-joint lower bolt and nut.
12. Replace engine oil.
Removal (GT Series)1. Support engine in vehicle using Tool J-23375. See
Figure 6A- 15.
Figure 6A-15 Engine Holding Fixture
Install tool by removing upper engine mount nut and
installing fixture. Replace nut and tighten. The en-
gine will now be supported by the tool, between the
frame rails. The front suspension need not be
removed on GT Models.
2. Drain oil.
3. Remove oil pan bolts and remove oil.
Installation (GT Series)1. Replace oil pan and bolts.
2. Remove engine holding fixture and replace engine
mounts.
3. Replace engine oil.

6A- 121973 OPEL SERVICE MANUALINTAKE AND EXHAUST MANIFOLD REMOVAL
AND
INSTALLATION
Removal1. Disconnect battery.
2. Remove air cleaner.
3. Disconnect throttle linkage at carburetor.
4. Disconnect vacuum advance line at carburetor.
5. Remove fuel line at carburetor inlet.
6. Remove positive crankcase ventilation hose at
rocker arm cover.
7. Disconnect E.G.R. lines from carburetor and in-
take manifold.
8. Disconnect exhaust pipe.
9. Remove six bolts attaching manifold assembly to
cylinder head and remove manifold and carburetor
as an assembly. Discard manifold gasket.
To separate intake and exhaust, manifold, remove
carburetor and four bolts using Tool J-23016, attach-
ing intake manifold to exhaust manifold. Always in-
stall a new manifold intermediate gasket when the
manifolds are separated.
Installation1. Install new manifold gasket and place manifold in
position.
2. Install manifold bolts. New manifold to cylinder
head gasket must be installed whenever a manifold
is removed.
3. When installing the manifold, start with the No.
1 and No. 2 bolts. See Figure 6A-16. Gradually
tighten both bolts until snug. Then continue with the
rest of the bolts in the sequence illustrated in Figure6A-16. Torque bolts to 33 lb. ft.
Figure 6A-16 Manifold
Bolt Tightening Sequence4. Connect parts removed in Steps 1 thru 8 above.
CYLINDER HEAD REMOVAL AND INSTALLATION
Removal1. Drain coolant from radiator and block. Loosen
drain plug on right side of engine to avoid coolant
entering into cylmder bores. Drain plug is located onthe right rear of cylinder block above oil pressure
switch.2. Remove hoses from thermostat housing. Collect
coolant as it contains anti-freeze.
3. Remove 6 intake and exhaust manifold attaching
bolts and swing assembly aside.
4. Remove spark plug wires from plugs.
5. Remove bracket bolt holding spark plug wires
away from cylinder head.
6. Remove rocker arm cover.
7. Remove 10 cylinder head bolts using 12 MM ser-
rated drive J-22915, and 2 cylinder head to timing
chain cover bolts with a 6MM hex head wrench. See
Figure 6A- 17.
Figure 6A-17 Serrated Bits
8. Remove three bolts attaching plate to front of
cylinder head.
9. Remove plastic screw from end of camshaft.
10. Remove 3 bolts attaching camshaft sprocket to
cylinder head. Slide sprocket off of camshaft and
remove head. Place head on bench supported at each
end by a block of wood to prevent damage to valves.
Installation1. Install in reverse procedure to removal, paying
particular attention to the following:

RECESSES VERTICAL FOR
REMOVAL OF LEFT ROW OF
CYLINDER HEAD BOLTS6A-16
Figure 6A-18 Recesses in Camshaft
2. Clean piston tops and combustion chambers.
Thoroughly clean all gasket surfaces on the cylinder
block and cylinder head.
3. Lightly lubricate cylinder walls with engine oil.
Install coolant passage rubber gasket ring in timing
case. See Figure 6A-19.I. TIMING CHAIN
2. CAMSHAFT SPROCKET
3. SPROCKET TIMING MARK
4. TIMING CASE5. SUPPORT TIMING MARK
6. SUPPORT
7. CYLINDER BLOCK
6. RUBBER GASKET RING6A-19
Figure 6A-19 Coolant Passage Rubber Gasket Ring in
Timing CaseENGINE MECHANICAL AND MOUNTS
6A- 13
4. Apply silastic sealer or equivalent to both sides of
the cylinder head gasket where the gasket mates with
the timing chain cover, place new cylinder head gas-
ket onto cylinder block.
5. Install cylinder head. Be careful to place head
squarely over guide pins.
Rotate camshaft so that recesses are in vertical posi-
tion to allow installation of left row of bolts.
6. Install 10 head bolts. Tighten the bolts a little at
a time in the sequence shown in Figure 6A-20. Give
bolts a final torque in the same sequence. Torque to
72 lb. ft. (cylinder head cold). Use same procedure
for cylinder head to timing chain cover bolts with
final torque at 17
lb.ft. See Figure 6A-20. These
torques apply to lightly oiled threads.
Figure 6A-20 Cylinder Head Bolt Tightening
sequence7. Slide camshaft sprocket with assembled chain onto
camshaft and guide pin and fasten with bolts. Install
nylon adjusting screw. After sprocket has been at-
tached to camshaft, recheck alignment to see that
chain has not slipped. Close front access hole.
8. Check camshaft end clearance between cover and
nylon screw with feeler gauge. Clearance should be
.004” - .008” Excess clearance can be eliminated by
carefully readjusting cover with a suitable drift.
Reconditioning Valves and Guides1. Remove cylinder head. Place on clean surface.
Place head on bench supported at each end by a
block of wood to prevent damage to valves.
2. Using suitable spring compressor, such as J-8062,
compress valve spring and remove cap retainers. Re-
lease tool and remove spring and cap. See Figure 6A-
21.3. Remove valves. Place valves in numerical order so
that they can be reinstalled in original location.
4. Remove all carbon from combustion chambers,
piston heads, and valves. When using scrapers or