1973 OPEL MANTA battery

96-54 1973 OPEL SERVICE MANUAL
valve. The filter screen at the inlet port may be re-
placed. Remove screen by threading a lo-32 NF
screw into old filter screen. With a washer and a nut
on the screw arranged to work as a puller screw, hold
the body of the screw and turn the nut. Insert the
new filter screen into the inlet port and lightly tap
screen only enough to seat.
1. Install expansion valve using new o-rings during
installation. Lubricate o-rings prior to installation
using No. 525 viscosity oil.
2. Install evaporator assembly and case attaching
screws. See Figure 9B-70.3. Install blower motor assembly into case and se-
cure with attaching screws. See Figure
9B-69.4. Install finger guard shields and fan housing case.
See Figure
9B-69.5. Install resistor assembly and electrical connector.
Install blower motor connector. See Figure
9B-69.6. Install assembly into car carefully guiding
evaporator pipes up through cowl opening. See Fig-
ure
9B-71.Figure 93-7 1 Inlet and Outlet Pipes and O-Rings
-Opel 1900 Manta
7. Install two (2) upper attaching evaporator at-
taching nuts. See Figures 9B-66 and
9B-67.8. Install two (2) attaching case mounting bracket
to instrument panel screws. See Figure
9B-67.9. Connect two (2) drain hoses underneath evapora-
tor.10. Install evaporator inlet and outlet pipes retainer
and rubber grommet. See Figure
9B-65.11. Connect vacuum cut-off switch and electrical
wiring, making sure the delay restrictor and checkvalve hoses are installed correctly. See Figures
9B-63and 64.
.gB-72 Delay Restrictor and Check Valve Hose.Assembly
12. Install refrigerant hoses and pipes using new
o-rings on line fittings and evacuate system. Refer to
EVACUATING SYSTEM.
13. While system is being evacuated, install in-line
fuse and left side of distributor duct. See Figure 9B-
61.14. Install glove box.
15. Install negative battery cable and charge system.
Refer to CHARGING SYSTEM.
REMOVAL AND INSTALLATION OF CONDENSER
ASSEMBLY -OPEL 1900. MANTA
Removal
1. Remove negative battery cable from battery.
2. Remove air cleaner.
3. Discharge system. Refer to DISCHARGING
SYSTEM.
4. While system is discharging, remove lower radia-
tor hose from radiator and drain coolant into a suita-
ble container.
5. Remove fan shroud.
6. On vehicles with automatic transmission, un-
screw oil lines from connectors on lower radiator
tank and plug lines. It is essential that no dirt enters
the oil lines. When unscrewing oil lines, hold connec-
tors on lower radiator tank with pliers to avoid leak-
ages. Ensure that no dirt enters oil cooler.
7. Remove upper radiator hose from radiator.
8. Remove lower attaching nut and slide radiator
upward and out of engine compartment.
9. Remove inlet and outlet hoses from condenser

98-56 1973 OPEL SERVICE MANUAL
oil cooler lines to lower radiator tank. It is essential
that no dirt enters the oil lines. When tightening oil
lines hold connectors on lower radiator tank with
pliers to avoid leakages. Ensure that no dirt enters oil
cooler. Torque to 11-15 Ibs. ft.
7. Install fan shroud.
8. Install upper radiator hose.
9. Install lower radiator hose and add collected coo-
lant.
All Opel
1900’s and Manta’s are provided with a
radiator initial fill of an anti-freeze solution contain-
ing corrosion inhibitor. The anti-freeze has either a
glycol or glycerin base and protects the engine
against freezing, down to minus 22 degrees F. (minus
30 degrees C.). Before the start of the cold season,
coolant must be checked with a hydrometer and if
necessary, brought to the necessary specific gravity
by adding anti-freeze. Anti-freeze added, must have
a glycol or glycerin base. As the specific gravities of
all anti-freeze solutions having a glycol or glycerin
base are practically the same, the hydrometer can be
used for all these types. Because of the tolerances of
the hydrometer, or slight differences in specific
gravity, variations of plus or minus 5 degrees can be
expected. Coolant must be checked at a temperature
of plus 68 degrees F. (plus 20 degrees C.).
IO. Install negative battery cable and air cleaner.
11. Charge system. Refer to CHARGING SYS-
TEM.
Figure 99.80 Location of Idler Pulley and Bracket
Assembly
- GTFigure 99.81 Idler Pulley and Bracket Assembly and
Support Bracket GT
REMOVAL AND INSTALLATION OF
COMPRESSOR. GT
I. Removenegative battery cable from battery.
Figure 98-82 Compressor Adapter Fitting, Ground
Wire. and Front and Rear Mounting Bolts
- GT
Figure 99.83
Elecirical Connector and Ground Wire
GT

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

98-92 1973 OPEL SERVICE MANUAL
MAJOR REPAIR
REMOVAL AND INSTALLATION OF BLOWER
SWITCH
Removal
I. Remove the face plate retaining screws and
remove the face plate assembly. See Figure 9B-172.
Figure SE-172 Face Plate Retaining Screws andcontrots
2. Remove the blower switch retaining screws and
remove switch.
Installation
1. Install the blower switch and retainer screws.
2. Install the face plate and secure with the retainer
screws. See Figure
9B-372.
REMOVAL AND INSTALLATION OF
TEMPERATURE CONTROL SWITCH
Removal
1. Remove the face plate retaining screws and
remove the face plate assembly noting the position of
the air sensing capillary so that it can be reinstalled
in the same location as when removed. See Figure
9B- 173.
2. Remove the temperature control switch retaining
screws and remove switch.
AIR SENSING CAPILLARY,yT,,ERMOSTATIC SWITCH
!IBUMPERBLOWER SWITCH98-136
Figure SB-173 Location of Air Sensing Capillary
Installation
1. Install the temperature control switch and secure
with the retaining screws.
2. Position the air sensing capillary in the exact
location as was noted when removing.
3. Install the face plate and secure with the retain-
ing screws. See Figure
9B-172.
REMOVAL AND INSTALLATION OF RESISTOR
ASSEMBLY
Removal
1. Disconnect the negative battery cable.
2. Remove the glove box assembly. 3. Disconnect the electrical plug from the resistor
assembly. See Figure
9B-176.
4. Remove two (2) screws and remove resistor as-
sembly.
Installation
1. Install the resistor assembly and secure with two
(2) screws.
2. Install the electrical plug onto the resistor assem-
bly. See Figure
9B-176.
3. Install the glove box assembly.
4. Connect the negative battery cable.
REMOVAL AND INSTALLATION OF BLOWER
MOTOR ASSEMBLY
REMOVAL
1. Remove the negative battery cable from the bat-
tery.

AIR CONDITIONER SYSTEM -OPEL 1900 - MANTA9B- 95
Figure 96.185 Evaporator Inlet and Outlet Pipes andO-Rings
7. Connect the 2 drain hoses underneath evapora-
tor.
8. Install evaporator inlet and outlet pipes retainer
and rubber grommet. See Figure
9B-178.
9. Connect vacuum cut-off switch and electrical
wiring,, making sure the delay restrictor and check
valve hose are installed correctly. See Figure
9B-180.
10. Install refrigerant hoses and pipes using new o-
rings on line fittings and evacuate system. Refer to
EVACUATING SYSTEM.
Il. While system is being evacuated install the in-line
fuse and left side of distributor duct. See Figure
9B-
174.
12. Install the glove box.
Figure 98.186 Delay Restrictor and Check Valve Hose
Assembly
Figure 9B-187 Fuse Block Connections
13. Install negative battery cable and charge the sys-
tem. Refer to CHARGING SYSTEM.