1973 OPEL GT-R battery replacement

lA- 21973 OPEL SERVICE MANUAL
BATER~ AND CABLES
ALL/ MODELS
C+NTENTIiSubject
DESCRIPTION AND OPERATION:
GeneralBatteryInformation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS:
Battery and Cables
- Trouble Diagno:sis. . . . . . . . . . . . . . . . . . . .MAINTENANCE AND ADJUSTMENTS:
PeriodicBatteryInspectionandService. . . . . . . . . . . . . . . . . . . .421BatteryTest
. . . . . . . . . . . . ...! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydrometer Test of Batteiy
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FusibleLinks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BatteryRecharging
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
Battery
RemovalandInstallation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FusibleLinksRemovalandInstallation. . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:
BatterySpecifications
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1 A-2
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1 A-7lA-8
1 A-9
1 A-9
1 A-9
1 A-9
DESCRIPTION AND OPERATIONGENERAL BATTERY INFORMATION
Registration of BatteryUnited-Delco Battery dealers and distributors
$reprepared to carry out terms of the manufacturer’s
warranty on Delco-General batteries. In order that
Opel owners shall have the protection and benefit of
this warranty, it is necessary for the dealer or car
owner to register his battery with the local United-
Delco Battery dealer or distributor on all new car
deliveries, and on all deliveries of new replacement
Delco batteries. The Battery Owner’s Certificate is
located in the Owner’s Protection Plan Booklet..
Care of Wet Batteries in StorageBatteries in stored new cars, as well as batteries, in
stock, must be given regular attention to prevent
sulphation of plates that may result from inactivity
and self-discharge. All automotive wet batteries will
slowly discharge on standing idle, whether in stored
vehicles or in stock, and will self-discharge muchfaster when warm than when cold.
Batteriesin stock
should be rotated and the oIder ones used tirst.To minimize the extent of self-discharge always store
batteries fully charged and in a cool place where the
temperature does not go below freezing. Every 30
days check the level of electrolyte, add water as re-
quired and charge the batteries at a 5 ampere rate
until fully charged.
Batteries used for display purposes or standing in
cars in storage must be treated in the same manner
as batteries in stock.
When a new car, or a new replacement battery is
delivered, make certain that it is
fuIly charged and
the electrolyte is at
proper level.This is extremely
important because the delivery of a partially dis-
charged battery may not only lead to its return for
charging but may also result in shortened life of
battery.
Importance of Maintaining Electrolyte at PROPER
LevelWater is the only component of the battery which is

1 C- 18 1973 OPEL SERVICE MANUAL
IGNITIPN SYSTEM
CbNTENTS
Subject
DESCRIPTION AND OPERATION: Ignition System ..................................................................
Ignition
Switc,h....................................................................
Ignition Coil
..........................................................................\
Distributor
............................I...............................................
DIAGNOSIS: (Not Available)
MAINTENANCE AND ADJUSTMENTS: Contact PointReplacement ............................................
Dwell Angle Adjustment :
................................................
Ignition Timing Adjustment ..........................................
Ignition Wire Inspection :
..................................................
Check Ignition Output ......................................................
Check Distributor
..............................................................
Check Spark Plugs
............................................................
MAJOR REPAIR: Distributor Removal ..........................................................
Disassembly ........................
I...............................................
Reassembly
..........................I...............................................
Distributor Installation
....................................................
SPECIFICATIONS: /
Ignition
Coil ..........................................................................
Distributor
....‘........................i...............................................
Spark Plugs ........................................................................\
..
DESCRIPTION AND OPERATION
INGITION SYSTEM
The ignition system basically consists of an ignitipn
switch, ignition coil, distributor, battery and related
wiring. The ignition switch is located in the steering
column, the ignition coil is located left front inner fender
skirt and the distributor is located at the left
front of the engine.
IGNITION SWITCH
The combined ignition switch and steering lock ian
be switched to any one of the below listed positions.
Insert key with notch pointing upward.
Page No.
lC-18
lC-18
lC-19
lC-19
1 c-20
1 c-20
1 c-20
lC-21 r
lC-21
1 c-22
1 c-22
1 r-23
1 C-23
1 c-24
1 C-25
1 C-26
1 C-26
1 C-26
(Fully counterclockwise) Lock position. Ignition
locked, steering locked, only with key removed.
Electrical circuits disconnected except to main light-
ing switch and dome lamp. The
key can be removed.
0- (First position clockwise from lock) Garage posi-
tion. ‘The key and lock assembly must be pushed “in”
to reach this position from lock. The steering is un-
locked and the ignition is off. The electrical circuits
are the same as in lock position. The key cannot be withdrawn.
l- [Chposition.) All electrical circuits controlled by
ignition switch are completed through the switch.
The key cannot
be removed while switch is in drive
position.

I
,INSTRUMENT PANELlH-63Figure l;H-15 Removing Instrument Cluster AssemblyFibure1 H-l 6 Disconnecting Radio Wires
14. Disdonnect antenna lead-in at right lower corner
of radio!
15. Pull’ cluster housing out and turn sideways to
remove
&~y instrument gauge or switches.
I
lnstallaiion
CAUTlOI$ Fasteners in subparagraph B are impor-
tant attaching parts in that they coo/d
affect the
perform>nce of vital components and systems, and-
/or
cou!d result in major repair expense.They must
be
repraced with one of the same part number, or
with an equivalent part if replacement becomes
necessa?y. Do not use a replacement part of lesser
quality
br substitute design. Torque values must be
used as
&ified during reassembly to assure proper
retention of these parts.
1. Plug antenna lead-in cable and power source to
radio. I
2. Put i&trument cluster in position and replace six
(6) screbs in cluster.3. Connect speedometer cable.
4. Raise steering column into position and install hex
head
bolt% Be sure to install ground wire. Tighten
hex head bolts to 14 lb.ft.
5. Tighten tear lock bolts until hex head of bolt is
torn off.
6. Connect ignition and directional signal wire set
plugs.
7. Install flasher unit.
8. Replace screws in right and left lower instrument
panel and replace both access covers.
9. Connect battery cable.
Removal of Combined Switch Assemblies. GT1. Remove instrument cluster.
2. Turn instrument cluster to the side to remove
switch assembly.
3. Remove switch by removing two retaining nuts.
See Figure lH-17.
4. Remove wiring from switch.
Figure 1 H-l 7 Removing Switches
Installation1. Plug wiring into switch.
2. Install switch on panel.
3. Install instrument cluster.

OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY3E- 37
Figure 3E-5 Steering Column Assembly With Gear
replacement of steering column or steering ignition
lock parts.
Removal (Opel 1900 . Manta)1. Disconnect battery.
2. From underside of car, remove clamp screw of
upper steering mast out of universal joint flange. See
Figure
3E-6.Figure
3E-6 Upper Steering Mast Clamp Screw
3. Remove hex nut from steering mast jacket attach-
ment at front of dash panel. See Figure
3E-7.Figure
3E-7 - Steering Mast Jacket Attachment
4. Pull off signal switch, as well as steering and igni-
tion lock wire sets.
5. Unscrew slide-off base from underside of instru-
ment panel and remove steering column assembly
from car. See Figure
3E-8. Carefully put down as-
sembly. Avoid impacts and blows to steering column
assembly.
Figure
3E-8 - Slide-Off Base Attaching Nuts
Installation (Opel 1900. Manta)
CAUTION:
Fasteners are important attaching parts in
that they could affect the performance of
vital com-

3E- 38 ,1973 OPEL SERVICE MANUAL
ponents and systems, and/or could result in major
repair expense. They must be replaced with one or
the same part number or with
an equivalent part if
replacement becomes necessary. Do not use a
re-
placement part of lesser quality or substitute design.
Torque
values must be used as specified during reas-
sembly to assure proper retention of these parts.On installation, make sure steering wheel spokes
point downwards and steering gear is in high point.
1. Carefully insert steering mast into universal joint
flange.
2. Loosely attach slide-off base attaching nuts at un-
derside of instrument panel.
3. Attach steering mast jacket at front of dash, using
a notched hex nut.
4. Torque nuts at slide-off base to II
lb.ft.5. Tighten screw at steering mast clamp to 22
lb.ft.6. Reconnect wires to directional signal switch and
ignition switch.
7. Reconnect battery.
REMOVAL AND INSTALLATION OF
STEERING WHEELThis procedure may be performed with the steering
column assembly either removed or installed in the
car.
Removal
1. Disconnect battery.
2. Pry off horn cap and remove wires from cap. See
Figure
3E-3.3. Bend lockplate tabs down and take off steering
shaft nut and lockplate.
4. Install steering wheel remover J-21686 as shown
in Figure
3E-9 and pull off steering wheel.
Installation1. Before installing steering wheel, lubricate return
pin and sliding area on directional signal switch re-
turn cams and horn contact ring.
2. Make sure that clamp bolt in steering shaft flange
is on top.
3. Make sure notch on steering shaft face is in hori-
zontal position.Figure
3E-9 Removing Steering Wheel
4. With the steering wheel centered, place the steer-
ing wheel onto the steering shaft.
5. Install steering wheel lockplate and nut. Torque to
11
lb.ft.
CAUTION:
This steering wheeI to steering shaft fas-
tener is an important attaching part in that it could
affect the
performance of vital components and sys-
tems, and/or could result in major repair expense. It
must be repked
with one of the same part number
or with an equivalent part if replacement becomes
necessary. Do not use a replacement part of lesser
quality or substitute design. Torque
values must be
used as specified during reassembly to assure proper
retention of this part.6. Bend lockplate tabs up, connect horn cap wires
and replace cable and cap.
7. Reconnect battery.
REMOVAL AND REPLACEMENT OF HORN
CONTACT RING
1. Remove steering wheel.
2. Cut off defective contact ring at wire.
3. Strip wire approximately
l/8”.4. Install new part and solder connection with resin
core solder.
5. Lubricate contact ring with lubriplate, or equiva-
lent.
6. Reinstall steering wheel.

GT STEERING COLUMN ASSEMBLY3E- 45
loose must never be done. The only recommendation
for freeing frozen steering wheels is to use a penetrat-
ing lubricant.Installation1. Before installing steering wheel, lubricate return
pin and slide area on direction signal switch return
cams and horn ring contact.
2. With steering wheel properly aligned to shaft, in-
stall lockplate and nut. Torque nut to 15
Ib.ft.
CAUTION:
This steering wheel to steering shafi fas-
tener is an important attac&ng part in that it could
affect the performance of vital components and sys-
tems, and/or could result in major repair expense. It
must be
rep/aced with one of the same part number
or with an equivalent part, if replacement becomes
necessary. Do not use a replacement part of lesser
quality or substitute design. Torque values must be
used as specified during reassembly to assure proper
retention of this part.3. Bend up lockplate tab and install horn cap.
4. Reconnect battery.
REMOVAL AND INSTALLATION OF IGNITION
LOCK CYLINDER
RemovalThis procedure may be performed with the steering
column assembly either removed or installed in the
car.1. Remove steering wheel, as outlined previously in
this Group.
2. Position lock cylinder to run position.
3. Using suitable piece of wire, push in lock cylinder
retaining pin and remove lock cylinder. See Figure3E- 18.
Installation1. Insert lock cylinder into lock cylinder housing.
2. Install steering wheel, as outlined previously in
this section.
REMOVAL AND INSTALLATION OF STEERING
COLUMN ASSEMBLY
Removal1. Position steering so that front wheels are straight
ahead.Figure
3E-18 Removing Lock Cylinder
2. Loosen steering shaft upper universal joint lower
clamp bolt. See Figure
3E-19.3. Drill off heads of both tear bolts by first drilling
an 3/16 inch pilot hole and then inserting a
l/4 inch
bolt extractor to remove lockbolt.
4. Disconnect ignition (white) and direction signal
(black) wire set plugs.
5. Support steering column assembly and remove
both hex. head bolts.
6. Pull steering column assembly off center steering
shaft. Do not apply any force as plastic injections in
center steering shaft may be loosened and shaft
would then require replacement.
Installation
CAUTION:
Fasteners are important attachingparts in
that they
cooId affect the performance of vital com-
ponents and systems, and/or could result in major
repair expense. They must be replaced with one of
the same part number or with an equivalent part if
replacement becomes necessary. Do not use a re-
placement part of lesser quality or
substitute design.
Torque values must be used as specified during
reas-
sembIy to assure proper retention of these parts.1. Install steering column assembly onto steering
shaft and torque steering shaft upper universal joint
lower clamp bolt to 14
lb.ft.2. Install hex head bolts and torque to 14
lb.ft.
NOTE:
Be sure to install ground wire.

98-48 1973 OPEL SERVICE MANUALCondition3. Compressor being
replaced with a ser-vice replacement
compressor major
oil loss evident.
Amount of Oil Drained
From Compressora. More than 4 oz.Amount of 525 Oil to Install
In Compressor
a.
Same amount as drained from
compressor being replaced.4. Compressor being
rebuilt or repaired
-no major oil loss
evident.b. Less than 4 oz.
a. More than 1
l/2 oz.b. Install 6 oz.
a. Same amount a.s drained from
compressor, plus
1 oz. additional.
5. Compressor being
rebuilt or repaired
major loss of oil
evident.b. Less than 1
l/2 oz.
a. More than 4 oz.b. Install 7 oz.
a. Same amount as drained from
compressor, plus 1
ozadditional.If foreign material is noted in oil drained from sys-
tem or evidence of moisture is obvious in the compo-
nents removed, it is recommended that the entire
system be flushed and the receiver-dehydrator be
replaced. A full oil charge of 10 oz. of 525 viscosity
refrigeration oil should be replaced in the system. It
should be noted that all service replacement com-
pressors will be supplied with 10 pz. of oil. In most
cases it will be necessary to drain oil from service
replacement compressor and refill it with amount as
specified in the Oil Replacement Table.filter screen on the expansion valve should be re-
placed. If the evaporator assembly is flushed while
installed in the car, the temperature bulb on the
evaporator outlet pipe must be disconnected to keep
the expansion valve from closing at the inlet source.
FLUSHING THE SYSTEMIt is recommended that dry nitrogen be used as a
flushing agent due to the low cost involved. In addi-
tion, dry nitrogen will not cause a temperature drop,
as in the case of refrigerant-12, which results in
thickening of refrigerant oil. Dry nitrogen has the
additional advantage of removing moisture from thesystem.Flushing of the system may involve all the compo-
nents of the system or individual components in the
system. The components may be flushed while
mounted in the engine compartment or may be
removed for flushing. When a component is not
removed, disconnect all refrigerant lines or hoses
attached to component. To perform flushing operat-
ion, connect a cylinder of refrigerant-12 to the com-
ponent to be flushed, ,then invert the cylinder and
open the cylinder valve so that the liquid refrigerant
pours out and through the component. When liquid
Refrigerant-12 reaches atmospheric pressure, it im-
mediately drops to minus 21.7 degrees F. Insure that
area immediately surrounding outlet of component is
clear of anything that may be damaged by contact
because of the sudden drop in temperature.MAJOR REPAIR
REMOVAL AND INSTALLATION OF
COMPRESSOR
- OPEL 1900 - MANTA
Removal
I. Remove negative battery cable from battery.
2. Remove air cleaner and heat pipe. Cover the
carburetor to keep out dirt etc.
3. Discharge system. Refer to DISCHARGING
SYSTEM.
In all cases where a complete system flushing operat-4. While system is discharging remove sheet metal
ion is performed, the receiver-dehydrator and thecover. See Figure
9B-50.