1973 OPEL MANTA gear

ENGINE MECHANICAL AND MOUNTS6A- 9
The engine does not rest on the front suspension
cross member as in the Opel 1900 and Manta but on
a separate cross member. On removal and installa-
tion of the engine the front suspension cross member
need not be detached.
Fig. 6A-10 Right Front Engine Suspension with Cross
Member
(GT)1. Disconnect battery negative cable,
2. Remove air cleaner.
3. Drain radiator coolant by disconnecting lower
radiator hose. Disconnect upper radiator hose. See
Figure 6A-11. Radiator need not be disconnected.
4. Disconnect all electrical connections:
a. Coil wire to distributor.
b. Wires from alternator. Remove unit and bracket.
c. Battery positive cable at starter switch.
d. Oil pressure switch wires at cylinder block.
e. Wires from starter solenoid.
5. Remove vacuum hoses at tee mounted to intake
manifold. Remove tee from manifold to avoid inter-
ference during engine lowering.
6. Remove throttle linkage and carburetor.
7. Disconnect heater hoses.
8. Disconnect water valve bracket to manifold,
9. Remove gear shift lever.
10. Using suitable equipment lift up engine so that
front engine mounts are somewhat relieved.Figure 6A.1
1 Radiator Hose Clamp Location
11. Raise vehicle, both front and rear end. A two post
axle type hoist
IS recommended for this operation.
12. Disconnect fuel line at fuel pump and plug. Be
sure fuel line is disconnected from any engine and
transmission clips.
13. Disconnect speedometer cable from transmis-
sion.14. Disconnect clutch cable.
15. Disconnect drive shaft at rear universal joint and
remove.
16. Disconnect exhaust at manifold.
17. Remove tailpipe and mufIler hangers.
18. Remove ground strap from engine to side rail.
19. Detach transmission cross member from trans-
mission and frame. See Figure 6A-12.
20. Detach engine cross member from engine and
frame.21. Carefully lower engine and transmission and
remove from underneath vehicle.

ENGINE MECHANICAL AND MOUNTS6A- 251, CAMSHAFT SPROCKET
2. CAMSHAFT SPROCKET SUPPORT
3. LONG DAMPER BLOCK
4. CRANKSHAFT SPROCKET
5. CHAIN AND DAMPER BLOCK
IN PARALLEL
6. CRANKSHAFT KEY
7. PAINT MARK ON FRONT
8. TIMING CHAIN
9. MARK ON CAMSHAFT
SPROCKET SUPPORT
IO. MARK ON CAMSHAFT
SPROCKET
6A-41Figure 6A-4 1 Valve Timing Marks
Removal4. Lubricate new oil seal and place on installer
J-
22924.1. Remove cylinder head.
5. Place installer J-22924 on crankshaft. Using
crankshaft bolt and washer install seal into cover. See
Figure 6A-42.2. Loosen self-locking rocker arm nuts and swing
rocker arms off valve lifters.
6. Install crankshaft pulley, bolt and washer. Torque
bolt to 72
Ib.ft.3. Remove valve lifter. Place lifters in a suitable hold-
ing fixture so that they may be reinstalled in original
position.
7. Install belts and torque to proper tension 45
lb.ft.4. Remove cover from access hole on left side andFigure 6A-42 Installing Timing Chain Cover Oil Seal
Replacing Distributor Drive Gear
On Crankshaft1. Remove fan belt.
2. Remove fuel pump. Plug end of fuel line with a
suitable stop.
3. Remove spark plug wires, distributor hold down
clamp. Remove distributor.
4. Turn crankshaft so key is on top.
5. Pry oil seal out of timing chain cover.
6. Insert a screwdriver through opening for fuel
pump and push out distributor drive gear, which has
a push tit on crankshaft, through oil seal seat in
timing cover.
7. Install new gear. Be sure key tits in
keyway. When
installing components, use new gaskets as required.
8. Install new oil seal.
9. Connect parts removed in steps 1 thru 3.
CAMSHAFT

6A- 261973 OPEL SERVICE MANUAL
rear of cylinder head. Remove camshaft toward
front, supporting camshaft with one hand through
access hole and taking care not to damage bearing
surfaces. See Figure 6A-43.12345 6
I. OLD PRESSURE
4. COVER GASKET
RELIEF
~~- \SSEMBLY5. COVER 8 VALVE
ASSEMBLYVALVE I
2. TIMING CASE
6. COVER ATTACHING
3. OIL PUMP GEARS
SCREWS
123” 45Figure 6A-44 Oil Pump Components
1.CAMSHAFT
2. FRONT ACCESS HOLE
3. LATERAL ACCESS HOLE
4. CYLINDER HEAD
5. REAR ACCESS HOLEISA-43
Figure 6A-43 Removing Camshaft
Installation
1. Liberally lubricate camshaft journals and install
camshaft from front into cylinder head. Support
shaft through access hole in left side of head to pre-
vent damaging bearings.
2. Reinstall valve lifters, rocker arms and self- lock-
ing rocker arm nuts.
3. Install rear and side access plates.
4. Reinstall cylinder head.
OIL PUMP COVER AND GEARSRemoval and Installation of Oil Pump
Cover and Gears
1. Remove screws attaching oil pump cover assembly
to timing chain cover. Remove cover assembly and
slide out oil pump gears. See Figure 6A-44.
2. Wash off gears and inspect for wear, scoring, etc.
Replace any gears not found serviceable. Discard
pump covers scored by gear action. If pump housing
or distributor drive shaft bushing are worn (this is
only possible after a long service life), the timing case
together with all exchangeable pump parts have to be
discarded.In isolated cases, timing cases are installed in pro-
duction having
.008 in. oversize bores for pump gears
and shafts. Oversize bores may exist either for one or
both gears; these timing cases are identified by the
number “0.2” stamped into pump flange on left and-
/or right-hand side. Oversize replacement gears
should be selected according to Part Catalog specifi-
cations.
3. Liberally lubricate spindles and gear teeth and use
new cover gasket. Install oil pump cover.
If new gears are installed, their end clearance in a dry
pump housing should be checked with a straight
edge and a feeler gauge. The gears must not protrude
more than X04 in. over pump housing. See Figure6A-45.
FEELER
AUGESTRAIGHTIEDGE
Figure 6A-45 Checking Oil Pump Gear End Clearance

ENGINE MECHANICAL AND MOUNTS6A- 27
With feeler gauge, check gear backlash. It should be
between
.I?04 in. and .C!OS in. See Figure 6A-46.3. Remove (2) bolts holding pipe and screen assem-
bly to cylinder block. See Figure 6A-47.
FEELERGAUGE6A-46
Figure 6A-46 Measuring Oil Pump Gear Backlash
Checking Oil Pump Relief Valve
For Proper Functioning
1. Unscrew plug and check spring and relief valve
plunger in oil pump cover for dirt particles and free
operation. If required, carefully clean plunger and
seat. Pressure relief plunger sticking as a result of
foreign material or sludge build-up in the oil pump
cover can cause loss of oil pressure.
Removal and Inspection of Oil Pump
Pipe and Screen Assembly
1. Remove oil pan.
2. Clean oil pan. Make sure the gasket surfaces and
pan and block are clean.
Figure 6A-47 Installation of Pipe and Screen
Assembly4. Clean the screen and housing thoroughly in sol-
vent and blow dry with air stream.
Installation of Oil Pump and Screen Assembly
Install by reversing removal procedures, paying par-
ticular attention to the following points.
1. Make sure oil pump pipe flange gasket surface of
block is smooth and free of dirt.
2. Use a new gasket and install assembly.
3. Tighten pan bolts evenly. Do not over-tighten.
Torque to 5 lb. ft.
SPECIFICATIONSBOLT TORQUE SPECIFICATIONS
Use a reliable torque wrench to tighten all parts listed, to insure proper
tightness without straining or distorting parts. These specifications are for
clean and lightly-lubricated threads only; dry or dirty threads produce in-
creased friction which prevents accurate measurement of tightness.

GA. xl1973 OPEL SERVICE MANUAL
Valve Seat and Correction Angle in Cylinder Head
Intake
Valve Seat Angle ..,._,..__....,,..,,,..,.,.,.,..............,............................................................... 45”Outer Correction
.,,,.,,._.,._..___,,,.,,,,,.......,,.,..,...,,..,..,,..,,..,,,.............................................. 30”
Exhaust
Valve Seat Angle
,,,.,,.__,.__..___.,..,,..,...,,....,..,..,..,,..,..,...,..,,,...,,......................................... 45”
Outer Correction
.,,..,,...,._.,.__....,,,.....,,,........................................................................... 30”
Valve Face Angle
,,..,,,..,.__..__.._..,,,..,,...,,......,.,..,..,..,,.,,,..,..,,,..,,,..,,,...,,................................ 44”Valve Seat Width in Cylinder Head
Intake
. . . . . . . . . . .._..._._.................,,..,.....,,..,............,...,..,,,..,,..,,...,,...,,,..,..................049-,059 In.
Exhaust
.,..,,,..,,.___..,,..,,...,..,,,..,,...,,...,,...............,,..,,..........,,....,,...,..................... .063-,073 In.Valve Head Contact Area
,,..,,,..,,___.__.,,..,,..,.,,..........,...,,..,,............,,,...,....... Aim at Centricity
Valve Clearance at 176°F. Coolant and 140°F. to 176”
Oil Temperature
Intake and Exhaust
_.,,..,,,,,,..,,....,...,,,.,.,,,.,..........................,,,..,,,,.... Zero Plus One Turn
Cranking MechanismMax. Permissible Out-of-Roundness of Connecting Rod Bearing
Journals
.....................................................................................................................OC02 In.
Max. Permissible Taper of Connecting Rod and Crankshaft Bearing
Journals
.....................................................................................................................ooO4 In.
Max. Permissible Radial Runout of Center Main Bearing
JournalsWhenSupportedinEndBearings
...........................................................0012In.Max. Permissible UnparalYelism of Connecting Rod Bearing
Journals When Crankshaft is Placed in V-Blocks so That
Main Bearing Journals Next to Each Other Are Supported
................................0005 In.
Max. Permissible Runout of Crankshaft to Flywheel
Contact Area
...........................................................................................................0008 In.
Crankshaft End Play
.........................................................................................GOl7-.CO61 In.
MainBearingClearance
.....................................................................................ooO9-.@I25In.Connecting Rod Bearing Clearance
.................................................................ooO6-.0025 In.
Connecting RodEnd PlayonBearing Journal
...............................................0043-.0095In.Connecting Rod Bearing Length
.......................................................................7785-.7992 In.
CrankshaftThrustBearingLength
..............................................................................1.08In.
Valve MechanismCamshaft Bearing Clearance
.................................................................................OOl-,003 In.
Camshaft End Play
...............................................................................................004-038 In.
Max. Permissible Radial Runout of Camshaft Center Bearing
- Camshaft Supported in Outer Bearings................................................................,001 In.
ValveLifter Clearance in Cylinder HeadBore
...............................................0003-.OOl3In.
Engine Lubricating SystemOil Pump Gear Backlash
......................................................................................0%.008 In.
Oil Pump Gear End Play in Housing
........................................Gears Protruding Over Edge
of Housing: Not More Than
,004 In.
Clearance of Spindle in Bore of Oil Pump Driven
Gear
...............................................................................................................OCO3-.0015 In.
Clearance Between Oil Pump Drive Gear and
Bushing
.........................................................................................................00035-.OOl5 In.
Oil Pump Relief Valve Spring Pressure at a Spring Length
of
.8 In..................................................................................................................44-.66 Lbs.

7A- 21973 OPEL SERVICE MANUALDIAGNOSIS
CLUTCH TROUBLE DIAGNOSIS
ConditionPossible Cause
CorrectionFails to release (pedal
1. Improper cable1. Adjust cable.
pressed to floor
- shiftadjustment.
lever does not move
freely in and out of
“Reverse” gear.
2. Faulty pilot bearing.2. Replace bearing.
3. Faulty driven plate.3. Replace driven plate.
4. Yoke off ball stud.4. Install properly.
5. Clutch driven plate hub5. Repair or replace main drive
binding on main drive gear
gear.spline.
Slipping1. Improper adjustment (no1. Adjust cable.
lash).2. Oil-soaked driven plate.2. Install new driven plate and
correct oil leak at its source.
3. Worn facing or facing3. Replace driven plate.tofn from driven plate.
4. Warped pressure plate or4. Replace same.
flywheel.
5. Weak diaphragm spring.5. Replace cover assembly.
6. Driven plate not seated6. Make 20-50 normal starts.
in.7. Driven plate overheated.7. Allow to cool
- check lash.
Grabbing1. Oil on facing or burned1. Repair oil leak and install
or glazed facings.new driven plate.
2. Worn splines on main2. Replace transmission main drive
drive gear.gear.
3. Loose engine mountings.3. Tighten or replace mountings.
4. Warped pressure plate or4. Replace pressure plate or
flywheel.flywheel.
5. Burned or smeared resin5. Sand off if superficial, replace
on flywheel or pressureburned or heat checked parts.
plate.

7A- 61973 OPEL SERVICE MANUAL1. FIywheeI and Pressure PlateExamine friction surfaces of flywheel and pressure
plate for scoring or roughness. Slight roughness may
be smoothed with fine emery cloth, but if surface is
deeply scored or grooved the part should be re-
placed.
2.
CJutch Driven Plate
Inspect driven plate for condition of facings, loose
rivets, broken or very loose torsional springs.
If facings are worn down near rivets or are oily, the
plate assembly should be replaced. A very slight
amount of oil on clutch facings will cause clutch grab
and chatter. A large amount of oil on facings will
cause slippage. Removal of oil by solvents or by buff-
ing is not practical since oil will continue to bleed
from facing material when hot.
When oil is found on driven plate facings, examine
transmission drainback hole, pilot bushing, engine
rear main bearing and other points of possible oil
leakage.
Test the fit of driven plate hub on transmission main
drive gear for an easy sliding fit.
Regardless of whether the old plate or a new one is
to be installed, the plate should be checked for run-
out. Lateral run-out measured at disc circumference
should not exceed
.016 inch.
Inspect clutch release bearing for scoring or exces-
sive wear on front contact face. Test for roughness of
balls and races by pressing and turning front race
slowly. Inspect main drive gear pilot bushing in
crankshaft. If bushing is rough or worn it should be
Figure JA-3replaced. If replacement is necessary, remove bear-
ing with Tool J-21718 and Slide Hammer J-7004-1.
Install new bearing using J-21706. See Figure 7A-3
for removal procedure and Figure 7A-4 for installa-
tion.
\,,
Figure JA-4
Installation of Clutch1. Index alignment marks on clutch assembly and
flywheel. Place driven plate on pressure plate with
long end of splined hub facing forward toward the
flywheel. See Figure 7A-5.
2. Insert alignment Tool J-22934 through clutch
cover and driven plate.
3. Hold complete assembly against flywheel while
inserting end of Tool J-22934 into pilot bearing in
crankshaft.
4. Index the alignment marks and install four (4)
clutch cover to flywheel bolts finger tight. Complete
torquing bolts alternately and evenly one at a time.
5. Torque attaching bolts to 36 lb.ft. and remove
alignment tool.
6. Install release bearing.
7. Install flywheel housing and torque lower bolts to
36
lb.ft.8. Install flywheel housing lower cover.
9. Install clutch return spring and control cable.
10. Install transmission. See Manual Transmission
Section for procedure.
11. Adjust clutch control cable. Refer to paragraph7A-3.

7A- 101973 OPEL SERVICE MANUAL
Arrangement Of Clutch
1 Clutch release lever14 Clutch ossy. bolt, lockwasher
2 Slot in lever for control cable boll15 Hollow space under felt ring filled
endwith molybdenum disulfide paste
3Assembly marks
4Clutch assembly
5Flywheel
6 Flywheel ring gear
7Thrust pin
8Retaining spring
9Crankshaft
10 Clutch gear pilot bushing
11Oil seal
12Flywheel bolt
13Clutch housing
16 Felt ring
17 Clutch release bearing
18 Clutch gear ball beorirq
19 Clutch gear
20 Snap ring
21 Paper gasket
22 Clutch gear oil seal
23 Clutch release bearing sleeve
24 Clutch disc, long end of hub facing
forward.
?A-8Figure
7A-8 Arrangement of Clutch