1973 OPEL MANTA heat shield

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IINSTRUMENT PANEL
lH- 57
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/SubjectPage No. INSTRUMENT PANEL
CONTENTS
DESCRIPTION AND OPERATION:
Instrument Panel
- Opel 1900 - Manta. . . . . . . . . . . . . . . . . . . . . .Instrument
Panel-GT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS:
MAINTENANCE AND ADJUSTMENTS:
MAJOR REPAIR:
Instrument Cluster Housing
- Opel 1900 - Manta . .
Windshield Wiper Switch
. , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .InstrumentCluster
Bulbs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .InstrumentCluster
Housing-GT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Combined Switch Assemblies
. . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CigarLighter
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS: (Not Applicable)
I H-57
1H-58
1H-59
1H-61
lH-61
1H-61
1H-63
1H-64
DESCF(lPTlON AND OPERATION2. The fog light toggle switch lower half is pushed in.INSTRUFENT PANEL (OPEL 1900. MANTA)
Headligl$ Switch
3. The parking lights and/or low beam headlights are
on.The thr& position light switch controls the head-
lights, @lights, parking lights, side marker lights,
license
plate light and instrument panel lights and is
located
4t the lower left on the instrument panel.
With thk switch knob pulled outward to the first
stop,
thi parking lights, side marker lights, license
plate
ligiit and instrument panel lights will light. Theinstrumdnt panel lights can be turned off by turning
the
lightSwitch knob counterclockwise past the first
detent. IThe fog lights are automatically turned off if the
ignition switch is on and the headlights are on high
beam.
Windshield Wiper Switch
The windshield wiper switch is located on the instru-ment panel to the right of the headlight switch.
By pull&g the lightswitch knob out all the way, the
headlights will also be turned on.
IBy pushing the lower half of this switch in to the first
stop, the wipers will operate at slow speed. By push-ing in to the second stop, the wipers will operate at
fast speed.
Fog
Ligh) Switch (Rallye)The fog
iight toggle switch is located in the instru-
ment cluster to the left of the temperature and fuel
gauge
cl+ster. The fog lights can be turned off at any
time by
t,he toggle switch, but can only be turned on
when: ,
Electrically Heated Rear Window Switch (If
Equipped)The heated rear
wind&v switch is located in the
instrument panel to the right of the clock opening.
1. The ignition switch is on or the engine running.
ITo operate (only possible with the engine running),
push in on the lower half of the switch. When the
rear window is being heated, the switch will
belighted.

1 H- 581973 OPEL SERVICE MANUAL
/-FOG LIGHT SWITCH IRALLYEi
\HEADLIGHT HIGH BEAM INDICATOR
-HAZARD WARNINGFLASHERINDICATORSYSTEM WARN,NGLlGHT
LWINDSHIELD WIPER SWlTCH -1 LFUEL&,UGELHEATER-DEFROSTER CONTROL
CHARGING INDICATOR LlGHTHEATER’ TEMPERATURE CONTROLHEATED REAR GLASS SWITCH1
301H1Figure 1 H-l
- 1900 lnstrumellt Arrangement
INSTRUMENT PANEL
(GT)I
Headlight SwitchesThere are two headlight switches, one for turning on
the headlights and the other operates an indicator
light on the instrument panel. Both switches are
located behind the left headlamp assembly.
When the headlamp lever is @shed forward,’ the
operating mechanism rotates the headlights to open
position, tuins the headlight and instrument panel
indicator light switches on until the headlamps are
locked in full open position at which time the indica-
tar lamp switch is turned off.
Along with the headlights, the headlight switch,also
turns on the parking lights, taillights, license plate
lights and rear side marker lights.
Parking Light and instrument Panel Light SwitCh
AssemblyThe left switch of this assembly is the Parking Light
Switch. By pushing inward on the lower half of thisswitch, the parking lights, taillights, license plate
lights and rear side marker lights are turned on and
can be turned off by pushing inward on the upper
half of the switch providing the headlights are not
turned on.
The center portion of this switch assembly is inopera-
tive and controls nothing.
The switch on the right end of this assembly is the
Instrument Panel Light switch. By pushing inward
on the lower half of the switch turns on the instru-
ment panel lights. The brightness of the instrument
panel lights can be adjusted by movement of the
switch. If either the Parking Light or Instrument
Panel switch becomes defective, the switch assembly
must be replaced.
Combined Windshield Wiper, Electrically Heated
Rear Window and Heater Blower SwitchThis switch assembly is located to the right of the
cigar lighter. If any one of these switches should fail,
the complete switch assembly must be replaced.

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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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IINSTRUMENT PANELlH- 61Figwe 1 H-7
- Disconnecting Cluster Wires
4. Install instrument cluster trim plate and replace
two screw and plugs.
5. Con&t speed0 cable by turning coupling clock-
wise. 1
6. Install light
.switch button and heater control
knobs. I
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7. Con+ct battery cable.
Removidg Windshield Wiper Switch - Opel 1900Manta I
1.
Rem* instrument cluster trim plate.
2. Corndress retaining clips and remove switch. See
Figure iH-8.
I
Figure lH-8 . Removing Windshield Wiper Switch3. Disconnect wiring connector.
Installation1. Connect wiring to switch.
2. Snap switch back into panel.
3. Replace instrument cluster trim plate.
Removing Instrument Cluster Bulbs - Opel 1900.
Manta1. Remove instrument cluster assembly.
2. Replace bulbs from back ofcluster. See Figure
lH-
9.Figure lH-9 Removing Instrument
Clu’ster Bulbs
Installation1. Replace bulbs in cluster.
2. Replace instrument cluster assembly.
Removing and Installing Ignition SwitchRefer to Group 3, Section F.
Removal of Instrument Cluster Housing Assembly.
GTDisconnect battery before making any electrical re-
pairs.
1. Disconnect battery cable.
2. Remove right access cover and remove screw. See
Figure lH-10.

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GAUGES1 I- 67I
I Condition
Car
&s out of gas with
gauge indicating fuel in
tank. 1
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IPossible Cause
1. Tank unit misadjusted
2. Defective voltage
stabilizer.Correction
1. Follow corrective action as
stated above (obtain empty
reading on dash)
1. See corrective action above.
Temperature gauge not1. Loose dash gauge1. See corrective action above.
Iattaching nut.
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I2. Defective temperature1. Install 40 ohm resistor
Isending unitbetween temperature sneding
Iunit and ground (disconnect
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from unit). If dash unit reads
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full scale, replace temperature
Isending unit.
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I3. Open wiring.1. Follow corrective action as
Istated above (connector socket
Iwith blue wire).Tempkrature gauge indicates
hot when engine temperature1. Incorrect temperature1. Check for correct sending unit
sending unit
normal.(white porcelain) replace if
incorrect.
2. i>efective temperaturesending unit.1. See corrective action above.
3. Dkfective voltage
stabilizer.
1. See Corrective action above.
GAS
GdUGE TROUBLE DIAGNOSIS - GT4. Disconnect the tank unit lead wire (light blue with
black tracer) from the tank unit.
An inoperative gas gauge reading can normally be
found to result from a poor grounding condition
within the circuit. Using the procedure as outlined
below may lead to the correction of the inoperative
reading without replacement of either the tank unit
or the
dph unit.5. Connect ihe stock tank unit; ground unit, and
operate manually.
6. If the dash unit shows a correct reading, then
replacement of the tank unit is required as the cor-
rection.
1. Makelcertain the gas tank (ground) strap is prop-
erly secured.A correct reading will be one which resembles the
movement of the manually-operated tank unit.
2. Make’certain the ground wire (brown in color) for
gasoline/ and temperature gauges is properly con-
nected tb the windshield wiper motor and is secured.
(This
gl?ound wire is also common for the heater
blower
etor.)7. If the dash unit does not show a correct reading,
then its replacement is necessary.
If the adove procedure does not produce a satisfac-
tory gaube reading, an attempt to isolate the defec-
tive
par<, i.e. tank or dash unit should be made.
3. Rem&e a tank unit from parts stock.MAJOR
AEPAIR
OPEL 1900. MANTA
Removing Voltage Stabilizer1. Remove instrument cluster housing assembly.

WINDOWS AND WINDOW MOLDINGS2c-9WINDOWS AND WINDOW MOLDINGS
CONTENTS
Subject
DESCRIPTION AND OPERATION: (Not Applicable)
DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS: (Not
Applicable)
MAJOR REPAIR:
Removal and Installation
Windshield
RevealMolding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Windshield
andBackWindow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DoorWindow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Quarter Window Molding
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Quarter Window
-1900 -Manta. . . . . . . . . . . . . . . . . .RearQuarterWindow
-GT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RearQuarterWindowLock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS: (Not Applicable)Page No.
2c- 9
2c-10
2c-11
2c-11
2c-12
2c-12
2c-12
MAJOR REPAIR
REMOVAL AND INSTALLATION OF WINDSHIELD3. With Tools J-2 1828 and J-2 1549, insert new reveal
REVEAL MOLDINGmolding and install escutcheon.
1. Remove reveal molding escutcheon. Starting at
one end, pull molding out of rubber channel. See
Figure
2C-2.Figure ZC-2 Removing Reveal Molding
Figure ZC-3 Pushing Windshield Out 2. Prior to installation, place molding in water and
heat up to approximately 113
- 122 degrees F.

6A- 8 1973 OPEL SERVICE MANUAL
Actual adjustment is made by backing off adjusting
nut at the rocker arm until clearance exists between the valve stem, rocker arm, and lifter. Then slowly
tighten adjusting nut until clearance is eliminated.
When clearance is eliminated, turn adjusting nut one
full turn (clockwise). This positions the hydraulic
piston of the hydraulic lifter mid-point in its total
available travel, and no further adjustment is re-
quired.
MAJOR REPAIR
ENGINE ASSEMBLY REMOVAL AND
INSTALLATION
Removal (Opel 1900 and Manta)’
The engine assembly on the Opel 1900 and Manta
can be removed together with the transmission
through the top of the engine compartment.
1. Remove hood (scribe hood hinge to hood mount-
ing location).
2. Disconnect battery negative cable.
3. Drain coolant at lower radiator hose.
4. Remove upper and lower radiator hoses.
5. Remove radiator and fan
shrbud.
6. Disconnect heater hoses.
7. Disconnect brake booster
vacuum hose.
8. Remove air cleaner.
9. Disconnect electrical connections and accelerator
linkage. 10. Remove console.
11. Remove shift lever boot, plate, and shift lever.
12. Raise car on hoist.
13. Disconnect fuel line at pump.
14. Remove front stone shield.
15. Disconnect speedo-cable, back-up light switch,
and clutch cable.
16. Remove drive shaft. I
17. Disconnect exhaust pipe
ar$l bell housing sup-
port.
18. Disconnect transmission support. See Figure
6A-7. 19. Remove engine mount bolts. See Figure
6A-8.
20. Attach hoist chains.
21. Lift engine and transmission assembly out of car.
Figure 6A-7 Transmission Support Bolts . Opel 1900
and Manta Series
Figure
6A-B Engine Mount Bolts - Opel 1900 and
Manta Series
Removal (GT)
The removal and installation of the 1.9 liter engine is only possible towards the floor and from below
Fig, 6A-9 Left Front Engine Suspension with Cross
Member (GT)

AUTOMATIC TRANSMISSION 7C- 95
12. Place suitable jack under transmission and
remove transmission support bolts.
13. Lower transmission enough to remove detent
cable and modulator vacuum line.
14. Remove speedometer cable.
15. Remove selector lever.
16. Mark flywheel and converter for reassembly in
same position, and remove converter to flywheel
bolts. See Figure 7C-106.17. Remove converter housing to engine bolts and
tiller tube.
18. Pry transmission loose from engine.
19. Keep rear of transmission lower than front to
prevent converter from falling and install converter
holding fixture J-21366. Lower transmission and
move to bench.
Installation. Opel 1900 and Manta1. Assemble transmission to suitable jack and raise
transmission into position. Rotate converter to per-
mit coupling of fly wheel and converter with original
relationship. Remove J-21366.
2. Install tiller tube and converter housing to engine
block bolts. Torque to 35 lb. ft. DO NOT over
torque.
3. Install flywheel to converter bolts. Torque to 30 lb.
ft.4. Install detent cable to transmission.
5. Connect oil cooler lines.
6. Install lower bolt on starter. Torque to 40 lb. ft.
7. Connect shift linkage to transmission.
8. Connect modulator line.
9. Connect speedometer cable.
10. Install transmission support.
11. Install drive shaft. Torque U-Bolts to 18 lb. ft.
12. Install flywheel cover pan. Torque to 15 lb. ft.
13. Install engine support brackets.
14. Reconnect exhaust system.15. Attach stabilizer supports and tighten stabilizer
bolts in lower control arms.
16. Lower car.
17. Install starter bolts. Torque to 40 lb. ft.
18. Reconnect battery.
19. Fill transmission with fluid as described in
Specifications. Check selector lever and detent cable
adjustment.
Removal GT1. Disconnect battery.
2. Remove dipstick.
3. Pull throttle control rod off ball pin.
4. Remove screws from fan shroud.
5. Raise car and provide support for front and rear.
6. Remove heat protection shield from right side to
make room for exhaust pipe removal.
Figure 7C-957. Detach exhaust pipe from manifold flange.
8. Unhook damper rings on front muffler and tail
pipe from brackets on body floor panel. Place ex-
haust pipe assembly onto rear axle. See Figure 7C-
96.9. Remove propeller shaft. Make sure that spring in
front universal joint does not get lost.