1973 OPEL GT-R Service Manual

8A.41973 OPEL SERVICE MANUAL
Figure SA-5 Location of Fender Attaching Bolts
9. Fit new fender and apply a sealing compound, as
required, to joint. See Figure
SA-6.Figure 8A-6 Sealing Location
10. Coat fender inside with a dampening compound.
REMOVAL AND INSTALLATION OF HEADLAMP
COVERING (OPEL
1900. MANTA)
Removal1. Remove radiator grille.2. In engine compartment unscrew headlamp cover-
ing.
Se:e Figure SA-7.Figure 8A-7 Headlamp Covering Attaching Bolts
Installation1. Install headlamp covering. See Figure
SA-7.2. Install radiator grille.
REMOVAL AND INSTALLATION OF HEADLAMP
ASSEMBLY
(GT)1. Move headlamp to open position and remove
headlamp cover. See Figure
SA-8.Figure EA.8 Removing Headlamp Cap

HOOD, FENDERS, AND GRILLEBA- 5
2. Remove headlamp assembly and remove multiple
plug from wire set.
3. Disconnect Bowden control wire(B). Loosen link-
age at the clamp screw (A) and disconnect linkage in
direction of arrows. See Figure SA-9.Figure EA.9 Disconnecting Linkage
4. Mark support plate at its circumference and
remove it. The marking facilitates the adjustment on
reinstallation. See Figure
SA-2.5. Mark swivel plate at its circumference and remove
it. See Figure
8A-3.Figure EA.10 Removing Headlamp Assembly6. To avoid damage cover headlamp upper and lower
edges with tape.
Turn headlamp 90 degrees and carefully remove
headlamp housing in direction of arrow. See Figure
8A-10.7. Through access hole on fender underside, remove
the two attaching screws and the screw at the upper
deflector panel. See Figure
8A-11.Figure EA.1 1 Locking Mechanism Attaching Screws
8. Prior to removing, mark the individual single
plugs (left headlamp only) and remove lock assem-
bly. See Figure
8A-12.Figure EA.1 2 Headlamp and Headlamp Indicator
Switches

8A-61973 OPEL SERVICE MANUAL
9. On installation make sure that the gaps between
headlamp housing in closed position and headlamp
opening is equal all round and housing is flush in its
height with the body.
REMOVAL AND INSTALLATION OF HEADLAMP
CABLE ASSEMBLY
Removal1. Remove cotter pin. See Figure
EA-13 “CL”2. Remove trunion block and nut. See Figure SA-13
“D.”
3. Remove outer adjusting nut and pull cable
through bearing. See Figure 8A-13 “B.”
4. Pull cable through front chassis support.
5. Hoist car.
6. Remove wire clip and unsnap ball seat at control
lever. See Figure 8A-14 “A.”
7. Remove ball-socket and lock nut. See Figure SA-
14
“B.”8. Remove rear adjusting nut. See Figure 8A-14
“CL”9. Remove cable from retainers.
Figure SA-13 Removing Headlamp Trunion Block
Installation10. Thread cable through bearing and clip retainers.Figure 8A-14 Removing Ball Seat at Control Lever
11. Install adjusting lock nut approximately
l/2” on
thread. See Figure 8A-13 “B.’
12. Install lock nut and ball stud on end of cable. See
Figure 8A-14 “B.”
13. Connect ball stud to control lever with clip. See
Figure 8A-14 “A.”
14. Adjust lock nut under vehicle for maximum cable
length. See Figure 8A-14
“CL”15. Thread cable through proper openings in body
and install adjusting lock nut, trunion lock nut, trun-
ion, and lock clip.
16. Adjust cable length for proper headlight operat-
ion.
REMOVAL AND INSTALLATION OF RADIATOR
GRILLE
(GT)
RemovalRemove screws securing grille screen to opening.
InstallationInstall grille screen to opening and secure with
screws.
REMOVAL AND INSTALLATION OF
RADIATOR GRILLE EXTENSIONS
(GTI
Removal
1. Remove hex head screw and washer holding grille
extension to baffle plate.

HOOD, FENDERS, AND GRILLE8A- 72. Remove two plastic caps and phillips screws from
outer end of grille extension.
3. Remove grille extension,
Installation1. Install grille extension and secure with Phillips
screws and two (2) plastic caps.
2. Install hex head screw and washer holding grille
extension to baffle plate.
REMOVAL AND INSTALLATION OF RADIATOR
GRILLE
(OPEL 1900. MANTA)
A. Removal (Model 57)1. Remove the
five (5) radiator grille attaching
screws. See Figure
8A-15.Figure 8A-15 Radiator Grille Attaching Screws
2. Remove radiator grille towards the top so that the
lower guide pins do not break off. See Figure 8A- 16.Figure 8A-16 Removing Radiator Grille
Installation (Model 57)
1. Install radiator grille, aligning guide pins into
lower panel. See Figure
8A-16.2. Secure grille with five (5) attaching screws. See
Figure 8A-2.
Removal (Models 51.53, and 54)
1. Remove the three (3) radiator grille attaching
screws. See Figure
8A-17.Figure 8A.17 Location of Radiator Grille AttachingSCWWS
2. Remove radiator grille towards the top SO that the
lower guide pins do not break off.

GROUP 9
ACCESSORIESSectionTitlePage No.HEATER
9AGT,9A-2Opel
1900-Manta. 9A- 10
AIR CONDITIONING
Refrigerant
Components9B- 179B
Air Conditioner System
Opel
1900~Manta.9B- 90
Air Conditioner System
GT.
OB- 97
RADIO
9cGT..............9c-105Opel
1900~Manta. PC-109

9A-2 1973 OPEL SERVICE MANUALHEATER SYSTEM
- GT
CONTENTS
Subject
DESCRIPTION AND OPERATION:
Flow-ThroughVentilationSystem................................
Heater System Description............................................
HeaterSystemOperation................................................
DIAGNOSIS:
Heater and Defroster........................................................
MAINTENANCE AND ADJUSTMENTS:
Control
CableAdjustment..............................................
MAJOR REPAIR:
Removal
81 Installation Instrument Panel
FreshAirOutlet..............................................................
Removal
& Installation Kick Panel Fresh
AirOutlet..........................................................................
Removal&InstallationBlowerSwitch......................
Removal&InstallationHeater......................................
Removal&InstallationDefrosterOutlet..................
Removal
81InstallationHeaterValve........................
SPECIFICATIONS:
Specifications......................................................................Page No.9A-29A-29A-49A-49A-49A-59A-59A-59A-59A-09A-99A-9
DESCRIPTION AND OPERATION
FLOW-THROUGH VENTILATION SYSTEMA separate ventilation system for direct intake of
outside air is controlled by two plastic fresh air inlet
nozzles in the side kick panels and two lever operated
inlet nozzles located on either end of the instrument
panel assembly.
The air allowed to enter the passenger compartment
will exit through outlets on both sides of the back
glass. See Figure 9A-1.
HEATER SYSTEM DESCRIPTIONThe GT heater system consists of two components
assemblies: (1) heater assembly, and (2) control as-
sembly. The heater assembly consists of the heater
housing and air valves; heater core and blower motor
and fan assembly.Figure
9A-1 GT Air Flow
The flow of air enters the car through the cowl;
passes through the blower fan, through or around the
heater core, past the air inlet door and is then di-
rected to either the floor outlets or defroster outlets
or both depending on the position of the defroster
door.

HEATER SYSTEM. GT9A- 3
Figure 9A-‘2 Heater Assembly-Rear View
The heater-defroster air door directs the air to the
floor outlets, defroster outlets, or apportions the air
flow to both outlets depending on the position of the
door. A manual water valve regulates the flow of
coolant through the heater core, thereby varying the
temperature of the air flow past the core. The blower
motor is located in the forward portion of the heater
housing. See Figure 9A-2.
Opening and closing of the heater defroster air door
and manual water valve is accomplished by bowden
cables connected to the heater control. The heater
controls function as follows:
Air Inlet-Defroster Control (Upper Lever) Thiscontrol (See Figure 9A-4) opens and closes the air
inlet and heater-defroster air door which channels
the air flow to either the heater outlets or to defroster
outlets, or to both outlets simultaneously, depending
on the position of the control.
Temperature Control (Lower Lever)
- This lever
regulates the flow of coolant through the heater core
and the amount of air that can by-pass heater core
thereby increasing or decreasing the air temperature
proportionate to its travel (toward red square-warm;
toward blue square-cold). Unheated air may be cir-
culated through the car by leaving the temperature
control in the OFF position (blue square).
Figure 9A-3 Heater Assembly-Front View