1973 OPEL MANTA oil pressure

REFRIGERANT COMPONENTS ALL MODELS9s. 41
BIower Operating Normal Check for the following:Restriction or leakage in air ducts, A/C outlets not
opening.2. Do not carry cylinder in passenger compartment
of car.3. Do not subject cylinder to high temperatures.
MAINTENANCE AND ADJUSTMENTS4. Do not weld or steam clean on or near cylinder.
5. Do not fill cylinder completely.
GENERAL SERVICE INFORMATION AND SAFETY
PRECAUTIONS6. Do not discharge vapor into area where flame is
exposed or directly into engine air intake.
General InformationAll subassemblies are shipped sealed and dehy-
drated. They are to remain sealed until just prior to
making connections, and should be at room tempera-
ture before uncapping. This prevents condensation of
moisture from air that enters the system.
All precautions should be taken to prevent damage
to fittings or connections. Even minute damage to a
connection could cause it to leak. Any fittings with
grease or dirt on them should be wiped clean with a
cloth dipped in alcohol.
Do not clean fitting or hoses with solvents because
they are contaminants. If dirt, grease or moisture
gets inside the pipes or hoses and cannot be removed,the pipe or hose is to be replaced. Use a small amount
of clean refrigeration oil on all tube and hose con-
necting joints, and lubricate the
“0” ring gasket with
this oil before assembling the joint. The oil will help
in effectitig a leak-proofjoint and assist the
“0” ring
to slip into the proper location without being cut or
damaged. Always use new
“0” rings.
When tightening joints, use a second wrench to hold
the stationary part of the connection to prevent
twisting and to prevent hose kinking. Kinked hoses
are apt to transmit noise and vibration. Tighten all
connections in accordance with recommended
torques (see Division VI, Specifications).7. Do not expose eyes to liquid
- WEAR SAFETY
GOGGLES whenever discharging, charging or leak
testing system.
CHARGING AND DISCHARGING SYSTEMRemoval of any part in the refrigerant circuit will
require discharging of the entire system.
Discharging the System1. Remove caps from gauge fittings on the compres-
sor adapter fitting on the compressor.
2. With both valves on manifold gauge set (J-5725-
04) closed (clockwise), attach manifold to the com-
pressor adapter fitting on the compressor, using
J-5420 valve adapter at suction gauge fitting and
J-9459 valve adapter at discharge gauge fitting. See
Figure
9B-41.3. Fully open high pressure valve on manifold gauge
set to allow escape of refrigerant from system
through the manifold gauge set and out the center
fitting and hose. (Place end of hose in clean container
to collect oil loss due to rapid discharge of system).
4. When hissing ceases, indicating all refrigerant
has escaped, close high pressure valve on manifold
gauge set by turning valve clockwise.
Do not connect receiver-dehydrator assembly until
all other connections have been made. This is neces-
sary to itisure maximum moisture removal from sys-
tem.It is important that air conditioning hoses do not rest
on or contact body sheet metal except where neces-
sary. Because of the high frequency at which the
compressor operates, the passenger compartment is
susceptible to transfer of noise.
Evacuating the SystemWhen the refrigeration system is depressurized and
opened for service, some air will enter the lines, re-
gardless of how quickly openings are capped. In
or-der to remove this air and as much as possible of the
moisture it contains, the complete system must be
evacuated. Evacuating is merely the process of
removing all air from the system, thereby creating a
vacuum in the system.
Safety PiecautionsThe following safety precautions should always be
followed~,when servicing refrigerant charged compo-nents:Under no circumstances should alcohol be used in
the system in an attempt to remove moisture,
regard-less of the successful use of alcohol in other refrigera-
tion systems.
Preparations for Evacuating Complete System
1. Do not leave Refrigerant-12 cylinder uncapped.
1. Check the low pressure gauge for proper calibra-

98-42 1973 OPEL SERVICE MANUAL
SCHRADER VALVE
ADAPTER J-54201COMPRESSOR(TOP VIEW)[/--DISCHARGE LINE
ILOW PRESSURE\ GAUGE
MANIFOLD AND
-GAUGE SET
J-5725-01
rGAUGE LINES
(5) J-541899-31
Figure 98.41 Set-Up For Discharging System
tion. With the gauge disconnected from the refrigera-
tion system, be sure that the pointer indicates to the
center of zero. Lightly tap gauge a few times to be
sure pointer is not sticking. If necessary, calibrate as
follows:
A. Remove cover from gauge.
B. Holding gauge pointer adjusting screw firmly with
one hand, carefully force pointer in the proper direc-
tion in proper amount to position pointer through
the center of
“0” position. Tap gauge a few times to
be sure pointer is not sticking. Replace gauge cover.
2. If gauge is not already connected to compressor,
connect as follows:
A. Close hand shut-off valves on gauge set by turning
clockwise.B. Remove caps from gauge fittings on the compres-
sor adapter fitting.
C. Attach valve adapter (J-5420) to end of the hosefrom the low pressure gauge and connect thisadapl:er fitted hose to suction gauge fitting.
D. Attach valve adapter (J-9459) to end of hose from
the high pressure gauge and connect this adapter
fitted hose to the discharge fitting.
3. Attach a flexible gauge hose to center fitting of
the gauge set and attach the other end of this hose
to vacuum pump (J-5428-03).
Evacuating Complete System
1. Turn hand shut-off valve on low pressure gauge
of gauge set to full clockwise position.
2. Slowly turn valve on high pressure gauge coun-
terclockwise from full clockwise position, letting any
pressure build-up escape completely. Close high
pressure valve.
3. Check oil level in vacuum pump and, if neces-
sary, add refrigeration oil. Make sure dust cap on
discharge side of pump has been removed.

REFRIGERANT COMPONENTS ALL MODELS9B- 43
4. Start the vacuum pump and slowly open low and
high pressure sides of manifold gauge set to avoid
forcing oil out of refrigeration system and pump,
Pressure is now being reduced on both sides of the
refrigeration system. If oil is blown from the vacuum
pump, it should be refilled to the proper level.
5. Observe low pressure gauge and operate vacuum
pump until gauge shows 28-29 inches vacuum. In all
evacuating procedures, specifications of 28-29 inchesof vacuum is used. This evacuation can only be at-
tained at or near sea level.
For each 1000 feet above sea level where this operat-ion is being-performed, the specification should be
lowered by one inch of mercury vacuum. At 5000
feet elevation, only 23 inches to 24 inches of vacuum
can normally be obtained.
If vacuum cannot be pulled to the minimum specifi-
cation for the respective altitude, it indicates a leak
in the system or gauge connections or a defective
vacuum pump. In this case, it will be necessary to
check for leaks as described under “Leak Testing
Refrigerant System”.
When specified vacuum level (28-29 inches at sea
level) is obtained, continue to run vacuum pump for
ten (10) ‘additional minutes. During these ten (10)
minutes:
A. Prepare for charging the system. If using a charg-
ing station, till charging cylinder. If using manifold
gauge set, make all preparations for charging system
as described under “Disposable Can Method” or
“Refrigerant Drum Method”.
B. Measure oil loss collected as a result of rapid
discharge.
C. Uncap compressor oil injector (J-24095) and open
valve. Flush J-24095 with refrigerant, close valve and
insert pick-up tube into graduated container of clean
refrigerant oil.
D. Con&ct J-24095 to suction fitting at the compres-
sor adapter fitting. When valve on J-24095 is opened,
the vacuum applied to the discharge side of the sys-
tem will suck oil into system from container. There-
fore,
close observation of oil level in the container is
necessary.E. Note level of oil in container. Open valve on
J-24095
u+il oil level in container is reduced by an
amount equal to that lost during discharge of system,
then shut valve. Take care not to add more oil than
was lost. ,,
F. Disconnect J-24095 and attach pick-up tube fit-
ting to schraeder fitting to cap tool. See Figure 9B-
42.J-24095
-98.32
Figure 98.42 Oil Injector J-24095
6. Turn hand shut-off valves at low and high pressure
gauges of gauge set to full clockwise position with
vacuum pump operating, then stop pump. Carefully
check low pressure gauge approximately for two (2)
minutes to see that vacuum remains constant. If
vacuum reduces, it indicates a leak in the system or
gauge connections.
Charging the SystemThe system should be charged only after being eva-cuated as outlined in “Evacuating the System”.
Refrigerant orurn Method
1. Connect center flexible line of gauge set to refriger-ant drum.
2. Place refrigerant drum in a pail of water which has
been heated to a maximum of 125 degrees F.
WARNING: Do not allow temperature of water to ex-
ceed I25
degrees E High temperature will cause
safety plugs in the refrigerant drum. It may not be
necessarv to use hot water if a /arae drum is used(over
ap)roximateIy 100 lbs.).-I3. Place refrigerant drum (in pail of water) on scales
(bathroom or commercial, perferably commercial).

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

98-46 1973 OPEL SERVICE MANUAL
shut off vacuum pump. Open refrigerant control
valve and allow some refrigerant to enter system.
Locate and repair all leaks.
7. After evacuating for 15 minutes, add l/2 lb. of
refrigerant to system. Purge this
l/2 lb. and reevacu-
ate for 15 minutes. This second evacuation is to be
certain that as much contamination is removed from
the system as possible.
8. Only after evacuating as above, system is ready
for charging. Note reading on sight glass of charging
cylinder. If it does not contain a sufficient amount
for a full charge, till to proper level.
9. Close low pressure valve on charging station.
Fully open station refrigerant control valve and al-
low all liquid refrigerant to enter system. When full
charge of refrigerant has entered system, turn off
refrigerant control valve and close both hand shut-
off valves.
10. If full charge of refrigerant will not enter system,
close high pressure control and refrigerant control
valves. Start engine and run at low idle with com-
pressor operating. Crack refrigerant control valve
and low pressure control on station. Watch low side
gauge and keep gauge below 50 psi by regulating
refrigerant control valve. Closing valve will lower
pressure. This is to prevent liquid refrigerant from
reaching the compressor while the compressor is op-
erating. When required charge has entered system,
close refrigerant control valve and close low pressure
control.
11. System is now charged and should be perform-
ance- tested before removing gauges.
Adding Refrigerant
The following procedure should be used in adding
small amounts of refrigerant that may have been lost
by leaks or while opening system for servicing the
compressor. Before adding refrigerent to replace that
lost by leaks, check for evidence of oil loss and add
oil if necessary.
This procedure will only apply if the air inlet temper-
ature is above 70 degrees F. at the condenser.
1. Remove caps from compressor gauge fittings.
Attach gauge set to gauge fittings, making sure
adapter (J- 5420) is between low pressure gauge hose
and suction gauge fitting, and J-9459 is between high
pressure gauge hose and discharge gauge fitting.
2. Start engine, turn air conditioning temperature
control knob to full cold position, blower switch to
Max Hi. Operate for ten
(IO) minutes at 2000 RPM
to stabilize system.
3. Observe the refrigerant through the sight glasscover of receiver-dehydrator with the system operat-
ing,
IO see if there are any bubbles evident.
a. If no bubbles are evident, then bleed system slowly
through the discharge valve until bubbles appear in
the receiver-dehydrator. Add 1 lb. of refrigerant as
explained under “Charging the
ISystem”.b. If bubbles are visible in the receiver-dehydrator
with the temperature control krlob in the full cold
position and the blower at MAX speed, it indicates
a partial or complete plug in a line, a shortage of
refrigerant, or both. Correct condition. Add refriger-
ant
u~ntil the sight glass clears, then add another 1 lb.
of refrigerant.
4. Attach flexible hose from center fitting of gauge
set loosely to refrigerant drum or on disposable can
valvxs. Open high and low pressure valves on the
gauge set slightly to purge pressure gauge lines of air.
Tighten fitting of refrigerant drum or can when satis-
fied ihat all air has been removed from gauge lines.
Close (clockwise) both hand shut-off valves or gauge
set.5. Partially charge system.
REFRIGERANT DRUM METHOD:
A. Place pail containing hot water that does not have
a temperature exceeding 125 degrees F. on scales,
place refrigerant drum in pa” containing water, note
weig,ht and only open low pressure valve on gauge
set.B. Start engine, turn temperature control knob to full
cold position and place blower switch in Max Hi.
Operate engine for 10 minutes at 2000 RPM to sta-
bilize system.
C. With compressor operating, slowly open valve on
refrigerant drum and allow refrigerant to flow into
system (through manifold gauge set) until liquid in-
dicator clears up and immediately shut off valve ai
gauge set or on refrigerant drum. Check weight of
refrigerant drum and pail of water. Then slowly open
valve on gauge set (or refrigerant drum) and add one
more lb. of refrigerant. Note total amount of refriger-
ant added.
DISPOSABLE CAN METHOD:
A. Make sure the outlet valve on the J-6271 valve is
fully clockwise and attach the J-6271 to a 1 lb. can
of refrigerant by backing off the valve from the top
of the retainer, slipping the valve onto the can and
turning the valve into the retainer until tight. DO
NOT accidentally open outlet valve during this oper-
ation, as turning the valve into the retainer punctures
the top of the can to make it ready for charging.
.

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.

REFRIGERANT COMPONENTS ALL MODELS96-66Figure 98.109 Removing or Installing Shaft Seal
SEAL SEAT
-Figure 98-l 10 Removing Seal Seat O-Ring
assembly engages the flats on the shaft and is seated
in place. Disengage the tool by pressing downward
and twisting tool counterclockwise.
4. Coat ihe seal face of the new seal seat with clean
refrigeration oil. Mount the seal seat on Tool J-9393
and install it in the compressor neck, taking care not
to dislodge the seal seat
“0” ring and being sure the
seal seat makes a good seal with the “0” ring.FRONT
L’HEAD
\Figure 96-l 11 Installing Seal Seat O-Ring
5. Install the new seal seat retainer ring with its flat
side against the seal seat, using No. 21 Truarc pliers
(J-5403). Use the sleeve from
Top1 J-9393 to press in
on the seal seat retainer ring so that it snaps into its
groove. Remove seal protector
Jz22974 from the end
of the shaft.
6. Install Compressor Leak Test Fixture (J-9625)
on rear head of compressor and connect gage charg-
ing lines as shown in Figure
9B-112. Pressurize suc-
tion side of compressor with Refrigerant-12 vapor to
drum pressure. Temporarily install the shaft nut and,
with compressor horizontal and oil sump down,
ro-tate the compressor shaft in nornial direction of rota-
tion several times by hand. Leak, test the seal with a
propane torch type leak
detectot; in good condition.
Correct any leak found. Remove and discard the
shaft nut.
7. Remove any excess oil, resulting from installing
the new seal parts, from the shaft and inside the
compressor neck.8. Install the new absorbent sleeve by rolling the
material into a cylinder, overlapping the ends, and
slipping it into the compressor neck with the overlap
at the top of the compressor. Using a small screw-
driver or similar instrument, carefully spread the
sleeve so that in its final position, the ends butt
together at the top vertical centerline. Install the new
sleeve retainer so that its flange face will be against
the front end of the sleeve. Using the sleeve from
Tool J-9393, press and tap with a mallet, setting the
retainer and sleeve into place, until the outer edge of

REFRIGERANT COMPONENTS ALL MODELS96.69
J-9481\J-8092
/BEARING
Disassembly of Rear Head, Oil Pump, Rear
Discharge Valve Plate, and Rear Suction Valve
Reed Disc
If compressor is not going to be disassembled any
further than removal of rear head, oil pump, rear
discharge valve plate, or rear suction valve reed disc,
omit Steps “1, 2 and
4”.
1. Disassemble clutch drive plate and shaft seal.
2. Disassemble pulley assembly, and coil and hous-
ing assembly.
3. Clean surface of compressor shell and dry with
compressed air.
4. Remove compressor from holding fixture
(J-
9396), unscrew drain screw. Drain, measure and re-
cord amount of oil in compressor.
Figure
98-121 Installing Bearing into Pulley Assembly 5. Reinstall compressor in holding fixture (J-9396)
positioned as shown in Figure 9B-123.
Figure SB-122 Installing Pulley Assembly
6. Reassemble clutch drive plate.
DISASSEMBLY AND REASSEMBLY OF INTERNAL
PARTS OF COMPRESSOR AND LEAK TESTING
COMPRESSOR
A clean work area and a place for each part removed
is required to properly disassemble and reassemble compressor. The internal parts of the compressor
must be kept free of dirt or foreign material.
When working with compressor, under no circum-
stances should compressor be rested on pulley end.
PRESSURE
Figure 96.123 Compressor Installed in Holding
Fixture
6. Unscrew and discard four lock nuts from rear of
compressor, and lift off rear head by tapping it with
a mallet. If Teflon sealing surface is damaged (see
Figure
9B-124), replace rear head. Clean or replace
suction screen as necessary.
7. Pencil mark top side of both oil pump rotors and
lift out rotors. Replace both oil pump inner and outer
rotors if one or both are damaged or worn.