1973 OPEL GT-R service

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

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.

9B-84 1973 OPEL SERVICE MANUALtCOMPRESSOR
CONDENSEREVAPORATOR
q H.P. VAPORq H.P. LIQUIDq 1.p. LIQUIDq L.P. VAPORq H.P.T.X.V. POWER ELEMENTFigure 96-l 61 Cycle of Operation

REFRIGERANT COMPONENTS ALL MODELS9B- 87
SUCTION,011 INLET T”BE
REAR CYLINDER
’ REAR NEEDtE”q.PRESSURE RELIEF VALVE
THRUST BEARlNG
/IT DISCHARGE VALVE PLATE
fFRONT HEAD
,-SEAL SEAT O-RING
I,-SHAFT SEAL
~&SHELL TOHEAD O-RING
I,IPORTFRONT
CYLINDE<\., -I\,VALVE PLATE[SERVICE ONLYI(SERVICE ONLY1.TION VALVE REED DISC
Figure 96-l 64 Compressor Exploded View

98-88 1973 OPEL SERVICE MANUAL
Figure gB-165 Special Tools

System controls are the AIR knob controlling the
three speed blower motor switch and the TEMP
knob which controls the setting of the thermostatic
switch. When operating this system, the heater must
be off for maximum cooling.DIAGNOSIS
TROUBLE DIAGNOSIS GUIDE
Air Knob
Insufficient CoolingTurning the AIR knob clockwise operates the three-
speed blower motor.CHECK AIR FLOW9B-90 1973 OPEL SERVICE MANUAL
AIR CONDITIONER SYSTEM
OPEL 1900
- MANTA
CONTENTS
Subject
DESCRIPTION AND OPERATION:
General Description of System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...”Operation of Controls
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .DIAGNOSIS:
DiagnosisGuide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..“................... . . . . . . . . .MAINTENANCE AND ADJUSTMENT:
Adjustment of Thermostatic Switch
. . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Removal81InstallationBlowerSwitch. . . . . . . . . . . . . . . . . . . . . .Page No.
9B-90
9B-90
9B-90
9B-91
98-92Removal
& Installation Temperature Control Switch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal
& Installation Resistor Assembly. . . . . . . . . . . . . .Removal
& Installation Blower Motor Assembly . .
SPECIFICATIONS:
Specifications
.,...,,.,,..~.,.,..,,......,.,....,.,........,......,........ ,, . . . . . . .
98-92
98-92
98-92
98-96
DESCRIPTION AND OPERATION
GENERAL DESCRIPTION OF SYSTEMThe air conditioner is intended to give maximum
cooling comfort within the vehicle. To do this, care-
ful attention must be given to the following Sections.
The system operates on recirculated air only and is
entirely independent of the vehicle heater.
Temp KnobThis knob may be regulated to control the degree of
cooling desired. Fully clockwise provides maximum
cooling; however, turning the knob to the center de-
tent position provides adequate cooling for highway
operation.
When maximum cooling is required, outside air
should not be admitted to the car.
Recirculated inside air is drawn into the unit, passed
through the evaporator core and into the car through
the adjustable outlets in the evaporator case.
Operation of ControlsWhen the unit is set for maximum cooling and the
vehicle is being driven continuously at highway
speeds or at elevations of
4,OOC!ft. or more, there is
a possibility of the formation of ice on the evaporator
core fins.

98-92 1973 OPEL SERVICE MANUAL
MAJOR REPAIR
REMOVAL AND INSTALLATION OF BLOWER
SWITCH
Removal
I. Remove the face plate retaining screws and
remove the face plate assembly. See Figure 9B-172.
Figure SE-172 Face Plate Retaining Screws andcontrots
2. Remove the blower switch retaining screws and
remove switch.
Installation
1. Install the blower switch and retainer screws.
2. Install the face plate and secure with the retainer
screws. See Figure
9B-372.
REMOVAL AND INSTALLATION OF
TEMPERATURE CONTROL SWITCH
Removal
1. Remove the face plate retaining screws and
remove the face plate assembly noting the position of
the air sensing capillary so that it can be reinstalled
in the same location as when removed. See Figure
9B- 173.
2. Remove the temperature control switch retaining
screws and remove switch.
AIR SENSING CAPILLARY,yT,,ERMOSTATIC SWITCH
!IBUMPERBLOWER SWITCH98-136
Figure SB-173 Location of Air Sensing Capillary
Installation
1. Install the temperature control switch and secure
with the retaining screws.
2. Position the air sensing capillary in the exact
location as was noted when removing.
3. Install the face plate and secure with the retain-
ing screws. See Figure
9B-172.
REMOVAL AND INSTALLATION OF RESISTOR
ASSEMBLY
Removal
1. Disconnect the negative battery cable.
2. Remove the glove box assembly. 3. Disconnect the electrical plug from the resistor
assembly. See Figure
9B-176.
4. Remove two (2) screws and remove resistor as-
sembly.
Installation
1. Install the resistor assembly and secure with two
(2) screws.
2. Install the electrical plug onto the resistor assem-
bly. See Figure
9B-176.
3. Install the glove box assembly.
4. Connect the negative battery cable.
REMOVAL AND INSTALLATION OF BLOWER
MOTOR ASSEMBLY
REMOVAL
1. Remove the negative battery cable from the bat-
tery.