1973 OPEL MANTA battery

CHARGING SYSTEMlD- 29
REGULAiOR DESCRIPTION
The regulator contains only one unit - a double con-
tact voltage regulator. See Figure
lD-2.
I Figure 1 D-2 Voltage Regulator
Since th< alternator field is grounded inside the alter-
nator, the voltage contacts are in series with the field.
Field
&rent is supplied from the D- terminal of the
alter”@, goes through a small red wire to the volt-
age contacts in the regulator, comes out of the
regulator through a brown wire, into the DF termi-
nal of the generator, and through the field winding to
grouqd inside the generator. See Figure lD-3.
:
,
!
/ I
’ A I
j
/ I
-
IF
O?
i 2
j
:
:
k
I
I
.i
A = REGULATOR
B = CHARGING
INDICATOR LAMP
C = BATTERY D = DIODES
E =STATOR
I
I F
=ROTOR301D3
kigure
lD-3 Charging Circuit Diagram
The diodes in the alternator, since they act like one-
way check valves, make a cutout relay unnecessary;
battery current can flow only as far as the diodes, but
cannot discharge through the alternator. However,
whenever alternator voltage is higher than battery
voltage, current flows freely through the diodes in
the other direction to charge the battery.
A current-regulator is not necessary. Any alternator
is limited by its design in regard to maximum current
output. Regardless of current need, an alternator
cannot put out more than its rated current output
and, therefore, cannot overheat and damage itself
due to excessive output.
MAINTENANCE AND ADJUSTMENTS
ALTERNATOR AND REGULATOR TESTS
Test Current Output
1. Check alternator belt condition and tension. Ad-
just to 45 lbs. using Gauge J-23600.
2. Install a battery post adapter at the positive post
of the battery.
3. Connect ammeter leads to adapter with red lead
toward generator and black lead toward battery posi-
tive post. Connect ground
lead to battery negative
post. See Figure
lD-4.
BATTERY POST
ADAPTER
SOID
Figure lD-4 Connecting Ammeter Leads
4. Connect voltmeter across the battery: red lead at
generator side of battery post adapter and black lead
to battery negative post.
5. Connect a tachometer to ignition system.

i
1 D- 301973 OPEL SERVICE MANUAL
6. Make sure all electrical accessories are turned (lff.
Start engine with battery post adapter switch closed;
open switch as soon as engine
iS: started.
7. Adjust engine speed to 2500 RPM.
8. Turn tester control knob to “LOAD” position
aid
adjust knob to obtain highest possible ammeter r&d-
ing. Output must be 30 amperes minimum. If
outcut
is okay, proceed to voltage regulator test below. j
/.9. If output is low, defect may be in alternator or m
regulator. To eliminate regulator, supply field &-
rent direct to cause full alternat,or output. Unplug
three-way connector from regulator and plug in a
jumper between the red and black leads. See Figure
lD-5. Retest as described in Steps 7 and 8. If output
is still low, generator is faulty and must be
remov&d.
301D5 :
Figure lD-5 Alternator Ouiput Check I
10. If output (using field jumper) is now okay, defect
is in the regulator or wiring harness. Check all wiring
connections. If all wiring is okay, try
replac/~g
regulator; if output now tests okay (without
uslpg
field jumper), you have found the trouble. Always
follow-up with a voltage regulator test.
Test and Adjust Voltage Regulator Setting
1. Always test alternator output first, as describedlin
subparagraph a above. Leave all test
instrumeqts
connected, but make sure field
jumper is removed; if
used.
2. With engine speed at 2500 RPM, turn tester con-
trol
knob to “l/4 OHM” position. Make sure ill
electrical accessories are turned off. After volt&e
reading stabilizes, any reading between 13.5 and 14.5
volts is okay.
3. If voltage reading is out of limits, remove regulator cover and adjust voltage regulator armature spring
tension to obtain a middle reading of 14.0 volts. If
reading fluctuates, voltage contacts are dirty.
4. Replace regulator cover and recheck voltage set- ting. A steady voltage reading between 13.5 and 14.5
volts means voltage regulator is okay.
5. Adjust engine speed to specified idle. Reseal volt-
age regulator cover carefully, using electrical tape.
MAJOR REPAIR
ALTERNATOR OVERHAUL
Always disconnect battery ground cable before mak-
ing any electrical repairs.
Alternator Removal
1. Disconnect battery ground strap.
2. Unplug wiring connector from alternator. 3. Disconnect battery lead from alternator.
4. Remove adjusting brace bolt, lockwasher, plain
washer and nut.
5. Loosen pivot bolt. Push alternator inward and
remove belt from pulley.
6. Drop alternator down and remove pivot bolt, nut,
lockwasher and plain washer.
7. Remove alternator.
Figure 1D-6 Removing Alternator Pulley

CHARGING SYSTEMlD- 35
’Figure lD-25 Installing Diode
I
7. Instail rotor together with drive end frame intostator and assemble generator in reverse order ofdisasse+bly. Make sure marks made during disas-
sembly
+-ire aligned.
8. Insta!l pulley and fan. Tighten nut to 30 lb.ft.
9. Test benerator on test bench, if available. If not,
install alternator on car and test.
Alternator Installation
1. Hold /alternator in position and install pivot bolt,
plain washer, lockwasher and nut finger tight.
2. Install alternator belt.
3. Install adjusting brace bolt, lockwasher, plain
washer and nut finger tight.
4.
Posit& a belt tension gage such as Gage J- 23600Figure 1 D-26 Alternator Installation
on belt. Pull alternator outward until gage reads 45
Ibs., then tighten adjusting brace bolt.
5. Tighten alternator pivot bolt.
6. Connect battery lead to alternator.
7. Plug three-way wiring connector into alternator
and engage safety catch.8. Connect battery ground strap.SPECkICATIONS
ALTERNATOR
35, AMPAlternatorNumberRated
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kl 14V35AZOOutputinVolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14ContinuousRatedOutputinAmperes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Test Output in Amperes at
2000 Engine RPM. . . . . . . . ..__.._...........................................23 Min.RksistanceofFieldCoilinOhms
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4.4Resistanceof StatorWindingsinOhms
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-29AlternatorPulleyNutTorqueinLb.Ft.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
BfltTensioninPounds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
REGULATORRegulatorNumber
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ADl/14V
Regulator Setting in Volts at 2500 Engine R.P.M.
. . . . . . . . . . ..___................................14 f .5

WINDSHIELD WIPERSlE- 37WINDSHEILD WIPERS
ALL MODELS
CONTENTS
Subject
DESCRIPTION AND OPERATION:
Windshield Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS:
Windshield Wiper
. . . . . . . . . . . . . . . . . . . , , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAINTENANCE AND ADJUSTMENTS: (Not
Applicable)
MAJOR REPAIR:Wiper Transmission
- 1900 and Manta. . . . . . . . . . . . . . . . . . . .W/per Transmission
- GT. . . . . a.* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly of Wiper Motor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning and Inspection of Parts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly of Wiper Motor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:
GeneralSpecifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torque Specifications
. . . . . . . a.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTIOfV AND OPERATION
GENERAL;DESCRlPTlDNThe two-sbeed wiper consists of a round shaped per-
manent magnet type motor and speed reduction gear
box. IOPERATldN
=The wipei motor is controlled through a dash
mounted &itch on all cars. The Rallye and GT, in
addition tb the dash mounted switch, also have a
switch moimted in conjunction with the windshield
washer fodt pump. Depressing the washer pump will
allow the bipers to operate while the pump is de-
pressed. i
DIAGNO;SIS
PRELIMINj9RY INSPECTION
1. Make
c&in of firm wire connections at wiper
motor fuse block and wiper switch.
Page No.
1 E-37
1 E-37E-38
E-38
E-40
E-41
E-4 1E-42
1 E-43
1 E-432. Check to see that the fuse is not blown.
3. Be sure wiper motor is not loose on fire wall.
4. With the yellow wire disconnected from terminal
No. 53 on the
wi@er motor, turn the ignition switch
and wiper switch to the on position and check volt-
age available to the wiper motor. There should be 12
volts available at the durple wire with a properly
charged battery.
Checking Wiper Operation1. Turn ignition switch on and engage wiper switch
to see if wiper motor will operate.
2. If wiper action is slow or inoperative, turn swit-
ches off and detach wiper control
inn from crank
arm.3. Operate wiper manually checking for excessive
bind in linkage. Correct if necessary.

1 E- 381973 OPEL SERVICE MANUAL
4. Turn switch on to see if wiper niotor will function
with wiper linkage’detached. If wiper motor will ndt
run, disconnect connector at wiper motor and co?-
nect hot lead from battery to terminal No. 53 onwiper motor. If wiper motor runs, the wiper switch
is faulty or there is an break in the lead wire. If wiper
motor still will not run, remove and bench test.
MAJOR REPAIRWIPER TRANSMISSIONS
Removal (1900 and Manta)1. Remove wiper blade (2).
2. Remove the wiper transmission retaining nut,
washer, and rubber seal ring. See .Figure lE-1.
Figure lE-1 Crank Arm Retaining Nut3. Remove instrument cluster housing.
If only left wiper transmission is to be serviced, it can
be done without removing any ‘other instrument
panel components. If the right side, or both, trans-
missions are to be serviced, then
it will be necessary
for complete instrument panel removal. On the Ral-
lye models, the gauge carrier must also be remove&Qn all
1900 and Manta Models the defroster ducts
are secured to the instrument panel cover, by two (‘2)
spring clips, and should not be removed from
dayhcover. Remove cover and duct as, a unit.
4. Remove retaining clips from transmission co;-netting rod pins. Pull connecting rods off pins. See
Item “A”, Figure lE-2.
5. Remove the screws securing the wiper transmis-
sion to the inner side of the cowl (Items “B”, Figuie
13), and remove the transmission assemblies.I
Figure lE-2 Connecting Rod Retaining Clips
Installation1. Place wiper transmissions into position at cowl
and install holding screws.
2. Push connecting rods onto transmission cranking
arm pins and install retaining clips. See Figure lE-2,
Item “A”.
3. Reinstall dash and instrument cluster parts.
4.
1nst:all the rubber seal ring, washer, and transmis-
sion retaining nut. See Figure IE-1.
5. Install wiper blades and check the position of the
blades in the park position. See Figure lE-3.
Figure lE-3 Wiper Blades in Park Position
Removal and Installation of GT W/per Transmission1. Remove nuts and remove both wiper
arms. See
Figure lE-4.
2. Remove three (3) bolts from each windshield

I
LIGHTING SYSTEMSlF- 53
/Removal if Back-Up Lamp1. Remode back-up lens.
2.
Remo+ lamp housing.
3. Discodnect electrical wires. See FigurelF-20
Removal of Headlamp Switch1. Completely remove left headlamp and headlamp
housing.
2. Remove switch from base plate. See Figure lF-21.
Fibure lF-20 Removal of Back-Up Light
Interior djght RemovalI
1. Disco@ect battery.
2. Remohe lens.
3.
RemoF base plate by removing two (2) screws.
4. Unplulg wires.
I
I
InstallationI
1. Connect wires to proper plugs.
2. Install! base plate.
3. Install! lens.
4. Con&t battery.
I
,Figure
1 F-2 1 Light Switch Positions
Installation1. Install switch to base plate.
2. Install left headlamp and housing.
Door Jam Switch Removal1. Remove door jam switch attaching screws.
2. Remove switch and disconnect wire.
Installation1. Connect wire to switch.
2. Replace switch on door jam with attaching screw.

Tigure lG-2 Horn Button and Contact
HAZARD; WARNING FLASHER
The hazard warning flasher is operated by the button
on the
toi, of the steering column. When the button
is
press&@ down and released, all four turn signal
lights
WIU flash. To turn the flasher system off, press
down
oni the button and release. When the hazard
warning
hystem is operating, a flashing light in the
iristrumeht cluster will operate. The hazard warning
flasher
&itch is part of the directional signal switch.
BRAKE $YSTEM WARNING LIGHT
The brak; system warning light is located in the left
side of
tpe instrument cluster assembly. The light
will
come on when the brake pedal is depressed and
the ignition is on if there is a hydraulic leak in the
brake system. The light will go out when the foot is
removed!from the brake pedal. The light will also
glow with the parking brake applied and the ignition
on. (On
Iautomatic transmission equipped vehicles,
light is
a! reminder to release parking brake; and on
manual
fransmission equipped vehicles, light glows
when
the clutch pedal needs adjustment,)
I
DlAGNfXlS
SIGNAL SYSTEM
The indiLator light on the dash will show defects in
the directional signal system as follows:
1.
Indic One of
tie switched-on directional signal lamp bulbs
is defective. The other signal lamp will continue to
flash.
Thi most common defect is a burned out bulb.
2.
Indicdtor light on dash stays on when directional
signal
leier is switched to either side. Check flasher
unit. I
SIGNAL SYSTEMSlG- 55
MAJOR REPAIR
Removing and Installing Directional Signal Switch
Proceed as outlined in Group 3, Section E.
HORN REMOVAL
1. Remove grille (GT only).
2. Remove horn bracket attaching bolt.
3. Disconnect wires and remove horn.
Installation
1. Install horn with bracket attaching bolt.
2. Connect horn wire.
3. Install grille (GT only).
Removing Horn Contact
1. Disconnect battery.
2. Remove horn cap.
3. Bend lockplate tabs down and remove steering
wheel nut, lockplate, and washer.
4. Mark shaft and wheel hub for reassembly align-
ment.
5. Remove steering wheel using Wheel Puller
J-
21686.
6. Remove horn contact from wheel.
installation
1. Replace horn contact.
2. Before installing steering wheel, lubricate return
pin and slide area on directional signal switch return
cams and contact ring.
3. With steering wheel properly aligned to shaft, in-
stall washer, lockplate, and nut. Torque nut to 15
lb.ft.
4. Bend up lockplate tab and install horn cap.
5. Connect battery.

/
I
IINSTRUMENT PANELlH- 59
Figure 1 H-2
- GT Instrument and Switch Arrangement
The Wihdshield Wipers have two-speed operation.
By pushing the lower half of the switch inward to the
first stop, the wipers will operate at half speed and
by deprbssing to the second stop will provide full
speed oieration. When the switch is returned to the
off posit/on, the wiper blades automatically return to
their park position.
I
The El standarFf whether or not the vehicle is equipped with
this optlpn. The engine must be running before
suffi-cient current can be generated to energize this circuit
even th6ugh the switch is depressed to the “ON”
position! When the window is being heated, a warm-
ing light’on the instrument panel will glow. This light
is locate? below the left ventilation inlet.
The
Heiter Blower Switch is a three position switch.
By depressing the lower half of the switch to the first
stop,
th& blower will operate at low speed. Whendepressdd to the second stop, the blower will operate
at high ipeed.
Four Way Hezrerd Warning Flasher SwitchThe
hazard warning flasher switch is located below
the heater controls in the center console. By
depress-ing the lower half of the switch, all four turn- signal
lamps flash at the same time. Although this system
makes use of the regulat turn signal system, it has a
separate feed wire to the switch which allows for its
operation even with the ignition switch and doors
locked. No vehicle should be driven with this system
in operation because of its universal meaning “This
Vehicle Is Not Moving”. To turn the system off,
simply depress the upper half of the switch.
MAJOR REPAIR
Removal of Instrument Cluster Housing Assembly.Opel 1900 Manta
Before starting any instrument panel repair, always
disconnect battery ground cable first.
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