1973 OPEL GT-R maintenance

TUNE-UP
ALL MODELS
CONTENTS
Subject
DESCRIPTION AND OPERATION:
Purpose of a Tune-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS:
EngineTune-UpMechanicalOperations. . . . . . . . . . . . . . . . . . . .
EngineTune-UpInstrumentChecks. . . . . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR: (Not Applicable)
SPECIFICATIONS:
Tune-Uo Soecifications and Adjustments
. . . . . . . . . . . . . . . .Page No.6G-65
6G-6566-6766-68
DESCRIPTION AND OPERATION
PURPOSE OF TUNE-UP
The purpose of an engine tune-up is to restore powerand performance that may have been lost through,
loss of adjustment, wear, corrosion, or deterioration
of one or more parts or units. In the normal operat-
ion of an engine, these changes take place gradually
at quite a number of points so that it is seldom advis-able to attempt an improvement in performance by
correcting one or two items only. Time will be savedand more lasting results will be assured by following
a definite and thorough procedure of analysis and
correction of all items affecting power and perform-
ance. Because of Federal laws, limiting exhaust emis-sions, it is even more important that the engines
tune-up is done accurately, using the specifications
listed and the tune-up sticker found in each engine
compartment.
Economical, trouble free operation can better be as-sured if a complete tune-up is performed at first 4
months or
6,ooO miles of operation - then at 12
month or 12,000 mile intervals.
The parts or units which affect power and perform-
ance may be divided, into three groups (1) compres-sion, (2) ignition and (3) carburetion. The tune-up
procedure should cover these groups in the order
given. While the items affecting compression and
ignition may be handled according to individual
preference, correction of items in the carburetiongroup should not be attemplcu
ulllll all items in
compression and ignition have been satisfactorily
corrected.
MAINTENANCE AND ADJUSTMENTS
ENGINE TUNE-UP OPERATIONS
CompressionTo make sure hydrocarbon and carbon monoxide
emissions will be within limits, it is very important
that the adjustments be followed exactly.
The suggested procedure for engine tune-up is as
follows:1. Remove all spark plugs.
2. Position throttle and choke valve in full open posi-tion.
3. Connect jumper wire between distributor terminalof coil and ground on engine to avoid high tension
sparking while cranking engine.
4. Hook up starter remote control cable and turn
ignition switch to “on” position.
5. Firmly insert compression gage in spark plug port.Crank engine to obtain highest possible reading.

CLUTCH7A. 1
CLUTCH
CONTENTS
Subject
DESCRIPTION AND OPERATION: Clutch andClutch
PedalMechanisms
. . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS:
Clutch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . .
MAINTENANCE AND ADJUSTMENTS: Clutch LashAdjustment (GTOnly)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Adjustment (All 1.9 Engines Except GT). . . .
Control CableAdjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . .
MAJOR REPAIR:
Clutch Removal and Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Control Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS:
Specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page No.
7A-
1
7A-2
7A-4
7A-4
7A-4
IA-5
7A- 7
7A-7
DESCRIPTION AND OPERATION
CLUTCH PEDAL MECHANISM GT Only
The pedal lever pivots on a tubular steel shaft and
operates the clutch release yoke thru a sheathed ca-
ble attached directly to the upper end of the pedallever. Pedal return is accomplished thru the cable by
the clutch yoke return spring at the transmission.
The pedal return stop
is a nonadjustable rubber
bumper inserted through the upper end of the pedal leverjust below the cable attaching point. The clutch
cable is sheathed in woven steel and weather pro-
tected by a plastic and fabric covering. An eyelet is
wedged on the upper end and fits over a formed
hook on the upper end of the pedal. The lower end
is provided with a
wedged ball stud arrangement
that slips into a slot in the clutch release lever. See
Figure
7A-6.
Opel 1900 and Manta
The pedal lever pivots on a tubular steel shaft and
operates the clutch release yoke through a sheathed
cable attached directly to the upper end of the pedal
lever. Pedal return is accomplished through a spring
attached to the pedal below the pivot shaft and to the
pedal assembly mounting bracket at the bulkhead. Clutch actuation works without pedal-free travel and
a warning device is provided which actuates an in-
dicator lamp in the instrument panel indicating
necessity of clutch adjustment. The clutch cable is
sheathed in
woven steel and weather protected by a
plastic fabric covering. An eyelet is wedged on the
upper end and fits over a formed hook on the upper
end of the pedal. The lower end is provided with a
wedged ball stud arrangement that slips into a slot in the clutch release lever. See Figure
7A-7.
Clutch Mechanism
The clutch assembly is enclosed in the bell housing.
The clutch release bearing and release fork are of
conventional design, with the fork pivoting on a ball
stud located opposite the control cable attaching
point. The bearing flange tits over two vertical pins
which are riveted to and extend into the eye of the
yoke.
The clutch pressure plate is similar in design to the
Buick Century pressure plate. A radially slotted dia-
phragm pivoting on two steel wire rings is retained
to the clutch cover by eight rivets. The clutch driven
member is a
6-3/4 inches diameter single plate dry
disc with torsional damper springs and spring leaves
between facings to cushion application. Dampener
springs in clutch disc assembly are
preloaded.

7A- 41973 dPEL SERVICE MANUALConditionPossible CauseCorrectionHeat-blued driven plate
and pressure plate
assembly.
1. Improper pedal1. Replace only driven plate, and
adjustment.adjust clutch pedal and cable.
Grab and chatter with
oil present on clutch
assembly.1. Oil leak.1. Correct oil leakage, clean
pressure plate in solvent, replace
driven plate and adjust pedal lash.
MAINTENANCE AND ADJUSTMENTS
CLUTCH LASH ADJUSTMENT
GTPedal lash, free pedal travel must be adjusted occa-
sionally to compensate for normal wear of the clutch
facings. As the driven plate wears thinner, pedal lash
decreases. Adjust clutch pedal free travel only with
ball stud located on right side of clutch housing if
cable length is not to be changed. To adjust pedal
lash proceed as follows:
1. Loosen lock nut on ball stud end located to the
right of the transmission on the clutch housing. Posi-
tion ball stud so that the outer end protrudes 3/4
inches out of housing and finger tighten lock nut. See
Figures
7A-1 and 7A-6.
2. Adjust ball stud, pivoting clutch release fork, to
obtain 3/4 to
l-1/4 inches pedal lash, free pedal. See
Figure 7A-6.
Opel 1900 and MantaThe clutch actuation works without clutch pedal free
travel. A readjustment of the clutch is only required
if the indicator lamp at the instrument panel lights
up.In synchronism with the gradual wear of the clutch
linings the clutch pedal travels from its basic adjust-
ment position upwards,
ie., towards driver. If the
clutch lining wear has reached such an extent that
the clutch pedal rests against switch, the indicator
lamp at the instrument panel lights up.
This is an indication that the clutch pedal position
has to be corrected to ensure proper clutch operat-
ion.
To
&~sure proper clutch operation, observe the fol-
lowing adjustment instructions.. For all adjustment
dimensions, refer to Figure 7A-7.
1. If the parking brake is provided with an indicator
lamp, the parking brake has to be disengaged, other-wise the same indicator lamp as for the clutch lights
UP.2. Carry out adjustment only with ball stud on clutch
housing whereby the distance (Item 20, Figure 7A-7)
between clutch housing contacting surface and
clutch release lever has to be adjusted in the rear to
4
l/4 inches.
Clutch Control Cable Adjustment(Only on
Installation of a New Clutch Disc or
Bowden
Control Wire)
GT1. Adjust ball stud so that outer end protrudes ap-
proximately 3/4 inches out of clutch housing.
2. Adjust distance between release lever and clutch
housing face at eye for control cable to approxi-
mately 4
l/4 inches. See Figure 7A-6. Hold cable in
this position and place E-ring two grooves ahead of
washer on rubber grommet. Clutch pedal free travel
is now between 3/4 and 1
l/4 inches and clutch
release bearing has proper clearance from pressure
plate.
Opel 1900 and Manta1. Adjust ball stud on clutch housing to basic dimen-
sion of approximately 3/4 inch. With lower end ofbowden control wire unhooked, push clutch release
lever towards the front so that the clutch release
bearing rests against clutch spring. Now, adjust ball
stud so that the dimension (Item 20, Figure
7A-7)between clutch housing contacting surface and
clutch release lever amounts in the rear to 4
l/4
inches.2. Pull reattached bowden control wire out of dash
panel so that clutch pedal rests against switch (in-
dicator lamp lights up).
3. In this position, install lockwasher at upper con-
trol wire attachment three grooves towards the front,
thereby completing control wire adjustment.

7B- 121973 OPEL SERVICE MANUAL
MANUAL TRANSMISSION
CONTENTS
Subject
DESCRIPTION AND OPERATION:
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power
Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS:
Adjusting
ReverseGearshiftBlocker. . . . . . . . . . . . . . . . . . . . . . . . . .Shift Lever Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ServicingGearshift
Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Transmission
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation
ofTransmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing and Installing
Speed0 Driven Gear
(Transmission
Removed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ReplacingBushinginSelectorLever. . . . . . . . . . . . . . . . . . . . . . . . . .Transmission
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:
Specifications ..,....._....,......,.....,......,.,.....,,.,..,......,.,....,........
Page No.
78-12
7B-13
78-1978-l
9
7B-19
78-22
78-22
78-23
78-23
78-23
78-28
78-33

MANUAL TRANSMISSION76.19
DIAGNOSIS
MANUAL TRANSMISSION DIAGNOSIS
ConditionPossible CauseNoisy in Forward Speeds1) Low lubricant level.
2) Incorrect lubricant.
3) Transmission misaligned or loose.
4) Front main bearing worn or damaged.
5) Mainshaft bearing worn or damaged.
6) Countergear or bearings worn or damaged,
7) Main drive gear worn or damaged.
8) Synchronizers worn or damaged.
Noisy in “Reverse”1) Reverse sliding gear or shaft, worn or damaged
Hard Shifting1) Clutch improperly adjusted.
2) Shift shafts, or forks worn.
3) Incorrect lubricant.
4) Synchronizers worn or broken.
Jumping Out of Gear1) Partial engagement of gear.
2) Transmission misaligned or loose.
3) Worn pilot bearing.
4) End play in main drive gear (bearing retainer
loose or broken, loose or worn bearings on
main drive gear and mainshaft).
5) Worn clutch teeth on main drive gear and/or
worn clutch teeth on synchronizer sleeve.
6) Worn or broken blocking rings.
7) Bent mainshaft.
Sticking in Gear1) Clutch not releasing fully.
2) Low lubricant level.
3) Incorrect lubrication.
4) Defective (tight) main drive gear pilot
bearing.
5) Frozen blocking ring on main drive gear cone.
6) Burred or battered teeth on synchronizer
sleeve and/or main drive gear.
MAINTENANCE AND ADJUSTMENTS
ADJUSTING REVERSE GEARSHIFT BLOCKER1. Engage second speed.
2. Adjust selector ring (a) so that ball on lower end
of shift finger has an equal clearance on both sides
when seated into the transmission case extension bolt
hole. See Figure
7B-7.3. Back off selector ring an additional
l/4 of a turn
and tighten lock nut (B). See Figure
7B-7.SERVICING GEARSHIFT LEVER
Removal1. Unscrew console from floor panel, on small con-
sole remove three (3) attaching screws, on large con-
sole remove four (4) attaching screws. The fourth
screw is accessible after removal of the ash tray. See
Figure
7B-8.2. Remove rubber bellows from cover plate and from
below unbutton protective cap arranged around in-
termediate shift lever.

7C- 361973 OPEL SERVICE MANUAL
CONTENTS
Subject
DESCRIPTION AND OPERATION:
Description of the Opel Three-Speed Automatic,Transmission....................................................................
Principles of Operation....................................................
ComponentOperation
andLocation............................
Mechanical Operation......................................................
Hydraulic Control Units and Valves............................H,y&aulic Operation..........................................................
DIAGNOSIS:
Sequence for Trouble Diagnosis..................................
Checking
Procedures........................................................
ExternalOil
Leaks..............................................................
Trouble
DiagnosisChart..................................................
Hydraulic Pressure
Checks............................................
MAINTENANCE AND ADJUSTMENTS:
Detent Cable Adjustment..............................................
ServicingSelector
Lever..................................................
MAJOR REPAIR:
Transmission Removal and Installation
AllModels........................................................................
Removalof
OilPan............................................................
RemovalofValveBody....................................................
Removalof
ServoPiston................................................
Removalof
Selector
LeverandShaft........................
RemovalofModulatorAssembly..................................
RemovalofDetentValveAssembly............................
RemovalofExtensionHousing......................................
Removal of Speedometer Drive Gear, Governor
Body and Governor Hub..............................................
Removal of Converter Housing, Oil Pump, Reverse
and Second Clutch Assembly..................................
Removal of Third Clutch Assembly, Planetary
Carrier Assembly, Reaction Sun Gear and Drum
Assembly and Low Bank............................................
Disassembly, Inspection and Reassembly of
Converter Housing, Oil Pump and Reverse Clutch
Disassembly, Inspection and Reassembly of
SecondClutch
................................................................
Disassembly, Inspection and Reassembly of
ThirdClutch....................................................................
Disassembly, Inspection and Reassembly of
Planetary Carrier
............................................................Page No.7c- 377c- 387c- 447c- 487c- 487c- 64
7C- 81
7C- 81IC- 817c- 827c- 877c- 917c- 937c- 947c- 99.7c- 99
7c-1007c-loo
7&l 01
7c-102
7c-102
7c-103
7c-103
7c-104
7c-105
7c-111
7c-114
7c-118

AUTOMATIC TRANSMISSION 7C- 91
MAINTENANCE AND ADJUSTMENTS
DETENT CABLE REPLACEMENT AND
ADJUSTMENT
The reliability of the detent bowden control cable is
greatly dependent upon the proper adjustment of the
wire whenever installation is being made. It is impor-
tant to remember that the free end of the wire is not
kinked, as individual strands will break due to the
continuous bending during operation. To avoid this
situation, it is important that the bowden control
cable be properly installed. Although replacement
and adjustment procedures on various models are
identical, the location of the upper, or throttle, end
of the detent cable may vary. For proper model iden-
tification, see Figures
7C-61, 7C-62, 7C-63, and 7C-
64.Figure JC-79 Opel 1900 and Manta
Figure
7~80 Opel 1900 and MantaFigure JC-81 GT Models
Figure JC-93 GT Models
Removal
I. Detach retainer at detent cable to accelerator link-
age.2. Loosen rear transmission crossmember from body
and remove right side bolt. See Figure
7C-84, Callout
” A ”3. Insert block of wood between floor pan and right
rear corner of transmission to expose detent cable
bracket at transmission. See Figure
7C-85.4. Unscrew detent cable connecting retainer from
transmission and pull cable out of transmission. See
Figure
7C-86.

8A-2 1973 OPEL SERVICE MANUAL
HOOD, FENDERS, AND GRILLE
CONTENTS
Subject
DESCRIPTION AND OPERATION:
GTHeadlampOperation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS
GTHeadlampMechanism
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Removal and Installation
Hood (1900
- Manta). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fender(1900-Manta). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlamp Covering (1900
- Manta). . . . . . . . . . . . . . . . . . . . . . . .Headlamp Assembly
(GT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlamp
CableAssembly(GT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grille
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS: (Not Applicable)
DESCRIPTION AND OPERATION
DESCRIPTION AND OPERATION OF GT
HEADLAMP MECHANISMThe concealed headlamps are moved mechanically.
Pushing actuating lever on left side of console opens
headlamps, pulling lever closes headlamps. Two
meshing gear segments convert the movement of the
lever to a rotation of 180 degrees. The pivots of the
headlamps lie below the centerline so that with head-
lamps in closed position the headlamp housing is
flush with front sheet metal.
A white indicator lamp in the instrument panel lights
if the headlamps are not completely opened and
locked. The switches of the headlamp electrical sys-
tem are located behind the left headlamp operating
mechanism.
MAINTENANCE AND ADJUSTMENTS
ADJUSTMENT OF HEADLAMP MECHANISMBoth headlamp assemblies must operate in unison in
order to lock in either the open or closed position.
Page No.
8A-2
8A-2
8A-3
8A-3
8A-4
8A-4
8A-6
8A-61. Adjust headlamps to be parallel in any position by
changing length of right headlamp operating rod.
For adjustment loosen clamp bolt (A). See Figure
8A-1.Figure
8A-l Headlamp Operation Adjustments