1973 OPEL GT-R ECU

9B-44 1973 OPEL SERVICE MANUAL
Do not turn refrigerant drum upside down, as this
would allow liquid refrigerant to enter compressor
which may cause damage.
4. If line at center gauge fitting has not been purged
of air, loosen line at center fitting on gauge set and
crack valve on refrigerant drum to blow air from
line. Retighten line at center fitting and record exact
weight of refrigerant tank in water on the scales.
5. Open valve on refrigerant drum and both valves
on gauge set to allow refrigerant to flow into system.
Continue charging until the scales show that 2
Ibs.Opel 1900
- Manta and 2 l/4 lbs. GT, of refrigerant
have been transferred from refrigerant drum to sys-
tem.If full charge cannot be obtained, close both valves
on gauge set, start engine, and set temperature con-
trol knob to full cold position with blower in Max Hi.
Open low pressure valve on gauge set slowly and
leave open until full charge is added.
WARNING: Observe high pressure gauge while charg-
ing with compressor running. Shut
offengine ifpres-
sure exceeds 250 psi. A large fan placed in front
ol
the car wi// help reduce excessively high head pres-6. Close both valves on gauge set (high pressure valve
will already be closed if charging was completed by
running compressor) and close valve on refrigerant
drum.
If the engine was used to complete the charge into
the system, close valve on refrigerant drum to permit
compressor to draw any refrigerant left in the line
from the drum to the center fitting of the gauge set,
then close the low pressure valve on the gauge set.
7. Operate engine at 2000 RPM with temperature
control knob at full cold, blower speed in Max Hi.
After ten minutes of operation, observe appearance
of refrigerant in receiver-dehydrator. If bubbles are
observed, open low pressure gauge valve and valve
on refrigerant drum to allow more refrigerant to en-
ter system. Close valve when receiver-dehydrator
clears
up.If an air inlet temperature is below 70 degrees F.
when this check is made, bubbles may appear, even
though the proper amount of refrigerant is in the
system. Air inlet temperature must be 70 degrees F.
or above to make an accurate check.
8. When refrigerant has been installed, continue to
operate system and test for proper operation as ou-
tlined under “Operational Test”.
9. When satisfied that air conditioning system is op-
erating properly, stop engine, remove gauge set and
replace protective caps on compressor fittings.10. Using leak detector, check complete system for
leaks.Disposable Can Method
After having
depress&ed, repaired (if necessary)
and evacuated the refrigerant system, the system
may be charged as follows using refrigerant in dis-
posable cans:
1. Obtain three (3) 1
lb. cans or one 12 lb. can of
refrigerant.
2. If using 1 lb. cans, mount two (2) cans in J-6272-
02 (Multi-opener) or attach J-6271 (single-can
opener valve) on one can. If using the 12
lb. disposa-
ble can, attach J-23390 (disposable can control valve)
on can.WARNING: Make sure outlet valve on opener is
closed (clockwise) before installing opener.A. If the J-6272-02 multi-opener is used, raise lock-
ing lever, position three (3) cans of refrigerant and
force locking lever down to secure cans and at same
time puncture top of can to make it ready for charg-
ing.
B. If the J-6271 valve is used, back off the valve from
the can top retainer, slip the valve onto the can and
turn the valve into retainer until tight. DO NOT
open outlet valve during this operation, as turning
the valve into the retainer punctures top of can to
make it ready for charging.
3. Connect center flexible line of gauge set to fitting
on a can opener valve. If the line at center gauge
fitting has not been purged of air, loosen line at
center fitting on gauge set and “crack” valve at can
opener (for a second or two) to force air from the
line. Retighten line at center fitting.
4. Open valve at refrigerant source and at low and
high pressure valves on manifold gauge set. Leave
valve open at refrigerant source until all refrigerant
(when using 1 lb. can) has ‘entered the refrigeration
system or system is fully charged. Close valve on can.
A. If the system is charged using
1 lb. cans and the
J- 627 1 valve, disconnect valve from can. Leave valve
closed to flexible line to the center fitting of the
manifold gauge set. Install valve on a new and full
disposable can of refrigerant.

REFRIGERANT COMPONENTS ALL MODELS9t3- 45
B. If system is charged using J-6272-02, close the
valve of opener after all cans are empty. Release the locking lever and discard the three (3) empty cans.
If this tool will be used to complete the charge with
additional cans to provide the required refrigerant
charge, leave the empty cans in position, locate one
full can and lock the lever into place. These empty
cans balance the assembly and prevent the loss of
refrigerant through the open “series” passage. Align
the pierced hole in the empty can with the punch in
the cover of the tool.
If the J-6271 valve for single cans is available, com-
plete charging as explained in 4a above.
5. Close high side valve on manifold gauge set,
WARNING: Prior to starting up engine, the high side
valve on the charging manifold must be closed due
to excessive pressure
bui/d-up which can result in
bursting of the container(s) causing serious injury. If
you are inexperienced in the use of this procedure, seek professional assistance.
6. Operate engine at 2000 RPM with temperature
control knob at full cold position and blower speed
on Max Hi. If air inlet temperature at the condenser
is below 70 degrees F. when this check is made,
bubbles may appear, even though the proper amount
of refrigerant is in the system. Air inlet temperature
must be 70 degrees F. or above to make an accurate
check.
7. When refrigerant has been installed, continue to
operate system and test for proper operation as ou-
tlined
under “Operational Test”.
8. When satisfied that the air conditioning system
is operating properly, stop engine, remove gauge set
and replace protective caps on suction and discharge
fittings.
from thegauge fitting to prevent damage-or injury to
personnel.
9. Using a leak detector, check complete system for
leaks.
Charging Station Method
INSTALLING J-8393-02
-
1. Be ceitain compressor hand shut-off valves to
gauge fittings are closed (counterclockwise).
2. Be certain all valves on charging station are
closed.
3. Connect high pressure gauge line to compressor
high pressure gauge fitting.
4. Turn high pressure hand shut-off valve one turn
clockwise, and high pressure control one turn coun-
terclockwise (open). Crack open low pressure con-
trol and allow refrigerant gas to hiss from low
pressure gauge line for three seconds, then connect
low pressure gauge line to low pressure gauge fitting
on compressor adapter fitting. (Place J-9459 adapter
on hose, then attach adapter to gauge fitting.)
FILLING CHARGING CYLINDER
1. Open Control valve on refrigerant container.
2. Open valve on bottom of charging cylinder, al-
lowing refrigerant to enter cylinder.
3. Bleed charging cylinder to valve (behind control
panel) only as required to allow refrigerant to enter
cylinder. When refrigerant reaches desired charge
level, close valve at bottom of charging cylinder and
be certain cylinder bleed valve is closed securely.
While filling the cylinder, it will be necessary to close
the bleed valve periodically to allow boiling to sub-
side so that refrigerant level in the charging cylinder
can be accurately read.
CHARGING THE SYSTEM USING J-8393-02
1. With charging station connected, as previously
described, remove low pressure gauge line at com-
pressor adapter fitting.
2. Crack open high and low pressure control valves
on station and allow refrigerant gas to purge from
system. Purge slowly enough so, that oil does not
escape from system along with refrigerant.
3. When refrigerant flow nearly stops, connect low
pressure gauge line to
compress& adapter fitting.
4. Turn on vacuum pump and open vacuum control
valve.
5. With system purged as
abovk, run pump until
26-28 inches of vacuum is obtained Continue to run
pump for 15 minutes after the system reaches 26-28
inches vacuum.
In all evacuating procedures, the specification of
26.
28 inches of mercury vacuum is used. These figures
are only attainable at or near sea level. For each 1000
feet above sea level where this operation is being
performed, the specifications should be lowered by 1
inch. For example, at 5000 feet elevation, only 21 to
23 inches vacuum can normally be obtained.
6. If 26-28 inches vacuum (corrected to sea level)
cannot be obtained, close vacuum: control valve and

REFRIGERANT COMPONENTS ALL MODELSSB- 51
3. Remove two (2) screws securing receiver-dehy-
drator within support bracket and lift out receiver-
dehydrator.
InstallationIf the receiver-dehydrator has been exposed to the
atmosphere for any amount of time, (more than five
(5) minutes), the receiver-dehydrator should be re-
placed, since the life of the dessicant is probably
expended.
1. Install receiver-dehydrator. Using new o-rings
during installation. Lubricate o-rings prior to instal-
lation using No. 525 viscosity oil.
Figure 98.56 Pipes, Hoses and Compressor Wire
Location
- Opel 1900 Manta2. Evacuate and charge system. Refer to CHARG-
ING AND DISCHARGING SYSTEM.
Figure 98.57 Receiver Dehydrator Support Bracket.
Opel 1900
- Manta
Figure 98-59 Receiver Dehydrator O-Ring and Drain
Hose Location
- Opel 1900 - MantaFigure 9B-60 Receiver Dehydrator Hoses and
O-Rings Opel 1900 Manta
Figure 9B-61 Removing Left Side Distributor Duct

REFRIGERANT COMPONENTS ALL MODELS99.55pipes and tape closed the open ends of refrigerant
lines, and also the open ends of the inlet and outlet
pipes of the condenser.
10. Remove two (2) top retaining screws.
Figure
9,S-73 Condenser Retaining Screws - Opel
1900
- Manta
11. Remove radiator grille and two (2) condenser to
body mounting screws. See Figure 98.74.
Figure 98-74 Condenser Assembly and Attachments.
Opel 1900
- Manta
12. Remove condenser.
Installation
If refrigerarit circuit or condenser has been exposed
to the atmosphere and moisture may be present in
the circuit, the system and/or component must beFigure 98-75 Condenser Assembly Mounting Brackets
Opel 1900 Manta
flushed prior to installation. Refer to FLUSHING
THE SYSTEM.
1. Install comjenser into car and install 2 condenser
to body mounting screws. See Figure 98-74. Install
radiator grill.
2. Install 2 top retaining screws.
3. Remove tape from the condenser pipes and re-
frigerant hoses and install hoses using new o-rings on
lines lubricated with No.
525 viscosity oil.
4. Evacuate system. Refer to EVACUATING SYS-
TEM.
5. While system is being evacuated, install radiator
into engine compartment and secure lower attaching
nut.
Figure 98.76 Clearance Between Lower Radiator
Tank and Fan Blades
- Opel 1900 Manta
6. On vehicles with automatic transmissions, fasten

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.
.

REFRIGERANT COMPONENTS ALL MODELS9s. 59
2. If the receiver-dehydrator has been exposed to
the atmosphere for any amount of time, (more than
5 minutes), the receiver-dehydrator should be re-
placed, since the life of the dessicant is probably
expended.
3. Evacuate and charge system. Refer to CHARG-ING AND DISCHARGING SYSTEM.
REMOVAL AND INSTALLATION OF EVAPORATOR
AND EXPANSION VALVE. GTRemoval
1. Disconnect negative battery cable.
2. Discharge system. Refer to, DISCHARGING
SYSTEM.3. While system is discharging, remove attaching
screws and lift out luggage tray. See Figure
9B-87.Figure 98.88 Evaporator Cover Assembly and
Attaching Screws GT
Figure 98.87 Luggage Tray
4. Remove all evaporator cover screws and removecover. See Figure
9B-88.
5. Remove electrical plug connector from the resis-tor assembly and unplug blower motor connection
and remove ground wire. See Figure
9B-90.6. From underneath evaporator housing, discon-
nect two (2) drain hoses. See Figure
9B-91.
7. From under car remove 4 nuts securing
evapora-Figure 96.90 Electrical Connections, Ground Wire
GTtar mounting bracket to floor. See Figures
9B- 92
and
9B-93.8. Remove inlet and outlet pipes from evaporator
and tape closed the refrigerant lines and also the
open ends of the inlet and outlet pipes of the evapora-tor. See Figure
9B-94.

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.

REFRIGERANT COMPONENTS ALL MODELSSB-632. Install condenser into car and secure with 4 at-
taching screws. See Figure
9B-101.3. Untape discharge line and pipe and install using
new o-rings lubricated with No. 525 viscosity oil.
Figure
99.102 Condenser - Receiver - Dehydrator
O-Rings. GT
4. Untape and install inlet and outlet pipes into the
receiver-dehydrator using new o-rings lubricated
with No. 525 viscosity oil.
Figure
98-103 Condenser Assembly - GT
5. Evacuate system. Refer to EVACUATING SYS-
TEM.
6. While system is being evacuated, install the char-
coal cannistor, washer jar, battery tray and battery
and connect negative battery cable.
7. Charge system. Refer to CHARGING SYS-
TEM.
DISASSEMBLY AND REASSEMBLY OF CLUTCH
DRIVE PLATE AND SHAFT SEALIt is not necessary to remove the compressor or dis-connect refrigerant lines to remove or install clutch
parts on the GT, however, the compressor must be
removed from the Opel 1900
- Manta.
Disassembly
1. Firmly clamp holding fixture (J-9396) in a vise
and attach compressor assembly to fixture (see Figwe
9B-104).
-_ .s -Figure SE-104 Removing or Installing Shaft Nut
2. Hold hub of clutch drive plate with wrench
(J-9403). Using special thin wall 9/16 inch socket
(J-9399) and 3/g inch drive, remove shaft nut.
3. Install threaded hub puller (J-9401) onto hub of
clutch drive plate (see Figure
9B-105). Hold body of
hub puller with wrench, tighten center screw of hub
puller, and lift off clutch drive plate and woodruff
key.Figure SE-105 Removing Clutch Drive Plate