IMPORTANT SAFETY NOTICE Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service procedures recommended by BUICK and described in this service manual are effective methods for performing service operations. Some of these service operations require the use of tools specially designed for the purpose. The special tools should be used when and as recommended. It is important to note that some warnings against the use of specific service methods that can damage the vehicle or render it unsafe are stated in this service manual. It is also important to understand these warnings are not exhaustive. BUICK could not possibly know, evaluate and advise the service trade of all conceivable ways in which service might be dbne or of the possible hazardous consequences of each way. Consequently, BUICK has not undertaken any such broad evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by BUICK must first satisfy himself thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects. / I / j BUICK MOTOR DIVISION GENERAL MOTORS CORPORATION IFLINT, MICHIGAN 48550 , 0 GENERAL MOTORS CORPORATION, 1972 Litho in U.S.A. 1973 GT OPEL 1900 MANTA TABLE OF CONTENTS SUBJECT CHASSIS I 1 I ELECTRICAL SERVICE I 2 I FRAME AND BUMPERS MANUAL I 3 I SUSPENSION AND STEERING This manual contains service information for the 1973 Opel 1900, Manta and GT 4 REAR AXLE models. Refer to the introduction for a I I description of the arrangement of this manual for locating desired information 5 BRAKES easily. I I All infotmation, illustrations and specifi- cations contained in this manual are based on the latest product information aveil- 6 ENGINE able at the time of publication approval. I I Therefore, the right is reserved to make changes at any time without notice. I 7 I TRANSMISSION I 8 I CHASSIS SHEET METAL I 9 I ACCESSORIES The 1973 Opel Chassis Service MayI has been completely revised with respect to layout, format and information content in a” attempt to provide you “The Technician” with a tiore logical and usable publication. An example of the new grouping layout 6 exhibited on the preceding _.page. _ Each wow is rubdivided as follows: Grouo 1 . Subiect I I Contents 0 General Information I General Information Lifting Maintenance and Lubrication 1 Electrical Battery Starting System lgriition System Charging System Washers and Wipers Lighting Systems Signal System Instrument Panel I Gauges Wiring Diagrams 2 Body and Bumpers : General Body Information I Frame & Body Mountings Windows & Window Moldings DONS Rear Compartment Lid Roof &Sun Roof Seat?., Interior Trim & Headlining Bumpers. 3 Suspension and Steering Front Suspension Steering Linkages 1 Front End Alignment Steering Gear Steering Column Rear Suspension Wheels and Tires 4 Propelley Shaft & Rear Axle Propeller Shaft & Central Joint Differential 5 Brakes ~ Power Booster and Master Cylinder Front Disc Brake I Rear Drum Brake 6 Engine Engine Mechanical and Mounts Cooling System Fuel System Exhaust Systems Carburetor and Throttle Linkage Emission Control Systems Tune-up 7 Transmission Clutch Manual Transmission Automatic Transmission B Chassis Sheet Metal Hood, Fenders and Grille 9 Accessol;ies Heater AirConditioning Radio INTRODUCTION The 1973 Opel Service Manual includes information on the Opel 1900, Manta and GT. It is organized to correspond with current servicing tech- niques. The various chassis components and systems have been classified into the nine (9) GROUPS. Every GROUP contains one or more SECTIONS. Each SECTION deals with a specific version of a component or system. The service information included in a SECTION is divided into five (5) basic DIVISIONS. The titles of each DIVISION are: Description and Operation Trouble Diagnosis Maintenance and Adjustments Major Repair SpLificaiions A DIVISION contains one or more PARAGRAPHS which can be identified by their specific headings. SUB-PARAGRAPHS are used when necessary for clarity or to provide distinc- tion between component procedures. SPECIAL TOOLS References are made throughout the Manual to special tool numbers, desig- nated by the prefix letter “J”. These tools are manufactured by the Kent- Moore Corporation, Inc. If equivalent special tools are not available locally, they may be obtained through: Kent-Moore Corporation, Inc. 28635 Mound Road Warren, Michigan 46092 LOCATING DESIRED INFORMATION To locate any desired information, locate the proper GROUP listed on the second page of the Manual. Bend the Manual until the black tab on the first page of the GROUP can be seen in line with the GROUP title on the second page. The first page of the GROUP lists the SECTIONS contained therein. Turn to the proper SECTION, locate the desired DIVISION and note the PARAGRAPH containing the information you are seeking. GROUP 0 Section Title Page OA General Information OA-1 GENERAL OB Vehicle Lifting Points 06-4 INFORMATION oc Maintenance and Lubrication. OC-5 GENERAL INt=ORMATION OA-1 GENERAL INFORMATION KEYS AND LOCKS Every key has a number engraved on one side which identities the key blank manufacturer. On the oppo- site side of GT keys, is a removable adhesive foil on which, the profile and cutting code letters and num- bers are imprinted. Attached to the protective key cover of Opel 1900 and Manta keys, is a tab on which the profile and cutting code letters and numbers are imprinted. Record the key cutting code letters and numbers before the adhesive foil or plastic tabs are discarded as this information is necessary to obtain replacement keys. In the event of lost keys and code records, one or more locks may be removed to obtain the code num- bers. The codes are stamped on the trunk and igni- tion lock cylinders and on the door lock plunger shaft. If a lock cylinder is damaged, it must be re- placed. This then means that the owner will have an additional key. Figure OA-2 Federal Certification Label Location REMOVE AND of the serial number represents the vehicle model. DOOR & IGNI KEY CODE LOCK. OPEL The remaining digits are the actual serial number. IGNITION LOCK GAS CAP LOCK GT GT Figure OA-1 1973 Keys Figure OA-3 Model Identification Plate FEDERAL CERTIFICATION LABEL In accordance with Federal Motor Vehicle Regula- Engine Number tions, a certification label is affIxed to all 1973 mod- els. The engine number is stamped in a machined boss on the upper left center of the engine block. The number The label has a certification statement, vehicle iden- starts with 1.9US which denotes the displacement in tification number, and month and year that the vehi- Liters and also that the engine is equipped with the cle was built. The label is attached vertically to the Opel Emission Control System. left front door inner panel lock facing. See Figure OA-2. Vehicle Identification Number VEHICLE IDENTIFICATION A new thirteen digit vehicle identification number is used on all Opel models imported for 1973. It is Model Identification Plate embossed on a narrow strip of metal which is at- The model identification plate as illustrated in Fig- tached to the left windshield post on Opel 1900 and ure OA-3 is attached to the inside right front inner Manta models and to the top of the left end of the fender panel on Opel 1900 and Manta and on top of instrument panel cover. In all cases the number is the right side of the cowl on the GT. The information visable when looking through the windshield from embossed on this plate includes such things as; type outside the vehicle. and model of vehicle, allowable front axle load, al- lowable maximum vehicle weight, allowable rear This new identification number includes; model axle load, paint color code and chassis serial number. designation, engine code, model year, assembly plant The key to identification is that the first two digits and the sequential number. See Figure OA-4. sOA- 1973 OPEL SERVICE MANUAL _ MODEL DESIGNATIONS OLll - OPEL 1900 2DR SEDAN OL60 - OPEL 1900 4DR SEDAN OL15 OPEL 1900 3DR WAGON MANTA 2 DR SPT. CPE. OL77 - MANTA 2DR RALLYE SPT. CPE. cMANTA LUXUS 2DR SPT. CPE. 1 OY07 GT 2DR SPT. CPE. 1 + VEHICLE IDENTIFICATION NUMbER OL77 N c9 123456 GM Model Designation I Engine Code Model Year Assembly Plant il GENERAL SPECIFICATIONS OVERAL MODEL AI(ID VVHEEL- FRONT REAR CURB NAME I BASE TREAD TREAD WEIGHT WIDTH LENGT, HElGHl 51. 2Dr Sedan 2138 = Opel 52.6 1900 53. 4Dr S+n 2183 * 164.6 54. 3Dr Wqgon 2227 l 53.3 57. 2Dr Spi. Cpe. 2183 l Manta 95.7 52.4 52 - 64.3 57R- 2Dr R&ye Spt. Cpe. 2205 l 171 51.3 Manta 57L. 2Dr Lu+sSpt. Cpe 2183 l LUXUS GT 77. 2Dr Splf. Cpe. 49.4 50.6 2120 * 62.2 161.9 47.4 I l Add 44 Ibs. for auto. trans. Figure OA-4 General Information PAINT Vehicle Identification Plate when that type of paint is used. Paint supplied by U.S. suppliers for repair Two types of paint are again useh for 1973, Enamel work is applicable on either type paint except that a and Acrylic. The word “Acrylic’! is embossed on the different match formula is required. / GENERAL INFORMATION OA-3 EXTERIOR PAINT MODELS coda Name 51 53 54 57 57L 57R 77 C Alpine White X X X X X X 0 strataStrato Blue X X X X X X F Glacier Blue X X X X X H Jade Mist X X X X X X Q Rallye Gold x. x X X X X R Flame Red X X X X X X T Antique Bronze X X X X X X Fire Glow X X X X X X Y Chrome Yellow X X X X X X .