Opel GT 1900 Manta - Service Manual - Repair Manual

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OPEL GT, 1900, MANTA - WORKSHOP, SERVICE, WORKSHOP MANUAL

- English Service Manual / Workshop Manual, for vehicles Opel GT 1900 Manta.
 

CONTENTS:

Group 0 - General Information
- 0A - General Information
- Keys and Locks
- Federal Certification Label
- Vehicle Identification
- Model Identification Plate
- Engine Number
- Vehicle Identification Number
- Model Designations
- Vehicle Identification Number
- General Specifications
- Paint
- 0B - Vehicle Lifting
- 0C - Lubrication & Maintenance
- Lubrication Chart
- Maintenance Schedule
- Lubrication and General Maintenance
- Safety Maintenance
- Emission Control Maintenance
- Services
- Lube and General Maintenance
- Engine Oil
- Engine Oil Filter
- Chassis
- Fluid Levels
- Tires
- Clutch
- Rear Axle
- Cooling System
- Wheel Bearings
- Automatic Transmission Fluid
- Safety Maintenance
- Brake Lines and Hoses
- Tires and Wheels
- Exhaust System
- Engine Drive Belts
- Suspension and Steering
- Safety Checks to be Performed by Owner
- Disc Brakes
- Parking and Drum Brakes
- Throttle Linkage
- Headlights
- Underbody
- Emission Control Maintenance
- Thermostatically Controlled Air Cleaner
- Carburetor Choke
- Timing, Dwell and Distributor
- Carburetor and Idle Speed
- Carburetor Fuel Inlet Filter
- Spark Plugs
- Spark Plug Wires
- Positive Crankcase Ventillation System
- Evaporation Control System
- Exhaust Gas Recirculation System
- Engine Compression
- Fuel Cap, Fuel Lines, and Fuel Tank
- Air Cleaner Element
Group 1 - Electrical
- 1A - Battery & Cables
- Description and Operation
- General Battery Information
- Registration of Battery
- Care of Wet Batteries in Storage
- Importance of Maintaining Electrolyte at Proper Level
- Importance of Keep Battery Properly Charged
- Care of Dry Batteries in Storage
- Preparing Dry Charged Batteries for Service
- Test After Batteries are Prepared for Service
- Diagnosis
- Battery and Cables - Trouble Diagnosis
- Quick Check of Battery and Cables
- Testing Resistance of Cables and Terminal Connections
- Undercharge Failure of Battery
- Overcharge Failure of Battery
- Maintenance and Adjustments
- Periodic Battery Inspection and Service
- Maintain Electrolyte Level
- Inspect Battery, Mounting and Cables
- Cleaning Cable Terminals
- 421 Battery Test
- 421 Test Procedure
- Hydrometer Test of Battery
- Hydrometer Test
- Use of Hydrometer
- Fusible Links
- Battery Recharging
- Slow-Charging
- Quick-Charging
- Major Repair
- Battery Removal and Installation
- Removal
- Installation
- Fusible Link Removal and Installation
- Specifications
- Battery Specifications
- 1B - Starting System
- Description and Operation
- Starting System Description
- Diagnosis
- Starting System Diagnosis
- Maintenance and Adjustments
- Starting System Checks
- Voltage Loss Checks
- Starter Current Draw - Lock Test
- Starter Current Draw - On Car
- Major Repair
- Starter Removal
- Starter Disassembly
- Cleaning and Inspecting Parts
- Replacing Field Coils
- Checking and Replacing Brushes
- Replacing Bushings
- Starter Assembly
- Starter Installation
- Specifications
- Starter Specifications
- 1C - Ignition System
- Description and Operation
- Ignition System
- Ignition Switch
- Ignition Coil
- Distributor
- Maintenance and Adjustments
- Contact Point Replacement
- Removing Contact Points
- Installing Contact Points
- Dwell Angle Adjustment
- Ignition Timing Adjustment
- Preliminary Timing (Engine Won't Run)
- Finish Timing
- Ignition Wire Inspection
- Check Ignition Output
- Check Distributor
- Check Spark Plugs
- Major Repair
- Distributor Overhaul
- Distributor Removal
- Disassembly
- Reassembly
- Distributor Installation
- Specifications
- Ignition Coil
- Distirbutor
- Spark Plugs
- 1D - Charging System
- Description and Operation
- Alternator
- Regulator
- Maintenance and Adjustments
- Alternator and Regulator Tests
- Test Current Output
- Test and Adjust Voltage Regulator Setting
- Major Repair
- Alternator Removal
- Alternator Disassembly
- Removing Diodes
- Positive Diodes
- Negative Diodes
- Installing Diodes
- Positive Diodes
- Negative Diodes
- Alternator Reassembly
- Alternator Installation
- Specifications
- Alternator
- Regulator
- 1E - Windsheild Wipers
- Description and Operation
- WIndshield Wiper Motor
- Diagnosis
- Windshield Wiper
- Preliminary Inspection
- Checking Wiper Operation
- Major Repair
- Wiper Transmission - 1900 & Manta
- Removal
- Installation
- Wiper Transmission - GT
- Removal and Installation
- Removal of Wiper Motor
- Disassembly
- Cleaning and Inspection of Parts
- Assembly of Wiper Motor
- Installation
- Specifications
- General Specifications
- Torque Specifications
- 1F - Lighting Systems
- Description and Operation
- Lighting Systems
- Headlight High-Low Beam Control and Passing Signal
- Fog Light Switch
- Courtesy Light
- GT Headlamp Mechanism
- Maintenance and Adjustments
- Headlamp Aiming
- Major Repair
- Opel 1900 & Manta
- Headlight Switch
- Removal
- Installation
- Fog Lamp or Heated Rear Window Switch
- Removal
- Installation
- Exterior Lights
- (Models 51-53-54) Headlamp Sealed Beam Unit
- Removal
- Installation
- (Models 57-57R) Headlamp Sealed Beam Unit
- Removal
- Installation
- Parking Light Housing or Lens
- Removal
- Installation
- (Models 51-53) Rear Stop, Tail, Directional Signal, or Back-up Lamp Housing
- Removal
- Installation
- (Model 54) Rear Stop, Tail, Directional Signal, or Back-up Lamp Housing
- Removal
- Installation
- (Model 57-57R) Rear Stop, Tail, Directional Signal, or Back-up Lamp Housing
- Removal
- Installation
- Rear License Plate Lamp Assembly
- Removal
- Installation
- Side Marker Lights
- Front
- Removal
- Installation
- Rear
- Removal
- Installation
- Interior Lights
- Courtesy Light
- Removal
- Installation
- Door Jam Switch
- Removal
- Installation
- GT
- Exterior Lights - GT
- Parking Light Housing
- Removal
- Installation
- Front Directional Signal Lamp
- Removal
- Installation
- Headlamp Sealed Beam
- Removal
- Installation
- Rear Directional Signal Lamp, Stop, and Tail Lamp
- Removal
- Installation
- Side Marker Lights
- Removal
- Installation
- License Plate Lamp
- Removal
- Installation
- Back-Up Lamp
- Removal
- Installation
- Headlamp Switch
- Removal
- Installation
- Door Jam Switch
- Removal
- Installation
- 1G - Signal Systems
- Description and Operation
- Directional Signal Lever
- Horn
- Hazard Warning Flasher
- Brake System Warning Light
- Diagnosis
- Signal System
- Major Repair
- Directional Signal Switch
- Horn
- Removal
- Installation
- Horn Contact
- Removal
- Installation
- Specifications
- Fuse Chart
- 1H - Instrument Panel
- Description and Operation
- Instrument Panel - Opel 1900 & Manta
- Headlight Switch
- Fog Light Switch (Rallye)
- Windshield Wiper Switch
- Electrically Heated Rear Window Switch (If Equipped)
- Instrument Panel - GT
- Headlight Switches
- Parking Light and Instrument Panel Light Switch Assembly
- Combined Windshield Wiper, Electrically Heated Rear Window and Heater Blower Switch
- Four Way Hazzard Warning Flasher Switch
- Major Repair
- Instrument Cluster Housing - Opel 1900 & Manta
- Removal
- Installation
- Windshield Wiper Switch
- Removal
- Installation
- Instrument Cluster Bulbs
- Removing
- Installation
- Instrument Cluster Housing - GT
- Removal
- Installation
- Combined Switch Assemblies
- Removal
- Installation
- Cigar Lighter
- Removal
- Installation
- 1I - Gauges
- Diagnosis
- Temperature and Fuel Gauge System - 1900 & Manta
- Temperature and Fuel Gauge System - GT
- Major Repair
- Opel 1900 & Manta
- Voltage Stabilizer
- Removal
- Installation
- Speedometer
- Removal
- Installation
- Electric Clock or Tachometer
- Removal
- Installation
- Temperature Indicator or Fuel Gauge
- Removal
- Installation
- Rallye Gauges
- Removal
- Installation
- Temperature Sending Unit
- Removal
- Installation
- Oil Pressure Sending Unit
- Removal
- Installation
- GT
- Speedometer
- Removal
- Installation
- Tachometer
- Removal
- Installation
- Temperature Indicator and Fuel Gauge Dash Unit
- Removal
- Installation
- 1J - Wiring Diagrams
- Windshield Wiper and Horn - Opel 1900 & Manta
- Windshield Wiper and Horn - Rallye
- Windshield Wiper and Horn - GT
- Turn Signal and Hazard Flasher - Opel 1900 & Manta
- Turn Signal and Hazard Flasher - GT
- Oil, Fuel, Temp, Tach, Stop and Brake Warning Light - GT
- Blower, Lighter and Backup Lights - Opel 1900 & Manta
- Blower and Lighter - GT
- Indicator Lights and Gauges - Opel 1900 & Manta
- Indicator Lights and Gauges - Rallye
- Dome Light and Buzzer - Opel 1900 & Manta
- Dome Light, Clock, and Buzzer - GT
- Headlamps - Opel 1900
- Headlamps - Manta
- Headlamp adn Fog Lights - Rallye
- Headlamps, Parking, Tail and Instrument Panel Lighting - GT
- Left Parking and Tail Lights - Opel 1900 & Manta
- Right Parking, Tail and Instrument Panel Lighting - Opel 1900 & Manta
- Starting, Ignition and Charging - Opel 1900 & Manta
- Starting, Ignition and Charging - GT
- Instrument Panel - GT
- A/C Generator and Regulator - All Models
- Seat Belt Warning System (Manual Transmission) - Opel 1900 & Manta
- Seat Belt Warning System (Automatic Transmission) - Opel 1900 & Manta
- Seat Belt Warning System (Manual Transmission) - GT
- Seat Belt Warning System (Automatic Transmission) - GT
- Heated Rear Glass - Opel 1900 & Manta
- Heated Rear Glass - GT
- Colored Wiring Diagrams (missing)
Group 2 - Body and Bumpers
- 2A - General Information
- Maintenance and Adjustments
- Paint Maintenance
- Chrome Maintenance
- Stain Removal
- Specifications
- Bolt Torque Specifications
- Special Body Tools
- 2B - Frame & Body Mountings
- Specifications
- 2C - Windows & Window Moldings
- Major Repair
- Removal & Installation
- Windshield Reveal Molding
- Windshield and Back Window
- Door Window
- Rear Quarter Window Molding
- Rear Quarter Window - 1900 & Manta
- Rear Quarter Window - GT
- Rear Quarter Window - Lock
- 2D - Doors
- Major Repair
- Front Door - Removal & Installation
- Door Lock Striker
- Window Regulator Handle
- Trim Pad
- Door Handle - Inside
- Reveal Molding
- Window Lifter
- Door Lock Cylinder
- Weatherstrip
- Door
- Rear Door - Removal & Installation
- Sash Window
- Window Regulator
- Tail Gate
- Door
- 2E - Rear Compartment Lid
- Major Repair
- Removal and Installation
- Weatherstrip
- Lock Cylinder
- Luggage Compartment Lid
- 2F - Roof and Sun Roof
- Diagnosis
- Sun Roof Diagnosis
- Maintenance and Adjustments
- Adjusting Height of Sun Roof
- Adjusting Front of Sun Roof
- Adjusting Rear of Sun Roof
- Major Repair
- Sun Roof Panel and Frame
- Removal of Sun Roof Panel
- Installation of Sun Roof Panel
- Removal of Sun Roof Frame
- Installation of Sun Roof Frame
- Velvet Strip and Weather Strip
- Removal of Velvet Strip On Sun Roof Opening
- Installation of Velvet Strip On Sun Roof Opening
- Removal of Velvet Strip and Weatherstrip On Rear of Sun Roof Panel
- Installing Velvet STrip and Weatherstrip On Rear of Sun Roof Panel
- Rear Guides and Cables
- Removal of Rear Guides and Cable
- Drive Pinion
- Water Drain Hoses
- Removal of Front Water Drainage Hose
- Installation of Front Water Drain Hose
- Removal of Rear Water Drain Hose
- Installation of Rear Water Drain Hose
- Luggage Rack
- 2G - Seats, Interior Trim & Headlining
- Major Repair
- Removal and Installation of Front Seat
- Removal and Installation of Rear Seat Back
- Removal and Installation of Glove Compartment Door Lock
- Removal and Installation of Front Side Panel Trim Pad
- Removal and Installation of Headlining
- Removal and Installation of Rear Side Panel Trim Pad
- 2H - Bumpers
- Description and Operation
- Protective Moldings
- Major Repair
- Removal & Installation of Front Bumper and Bumper Guards (1900 & Manta)
- Removal & Installation of Front Bumper Brackets (Opel 1900 & Manta)
- Removal and Installation of Rear Bumper and Guards (Opel 1900 & Manta)
- Removal and Installation of Front Bumper Assembly (GT)
- Removal and Installation of Rear Bumper Assembly (GT)
- Trailer Hitch Installation
- GT
- Opel 1900 Wagon
- Opel 1900 & Manta
Group 3 - Suspension & Steering
- 3A - Front Suspension
- Description and Operation
- Suspension Description
- GT
- Opel 1900 & Manta
- Maintenance and Adjustments
- Front Wheel Bearing Adjustments
- Major Repair
- Removal and Installation of Front Suspension
- Removal (GT)
- Removal (Opel 1900 & Manta)
- Installation (GT
- Installation (Opel 1900 & Manta)
- Upper Balljoint Removal and Installation
- Removal
- Installation
- Lower Balljoint Removal and Installation
- Removal (GT)
- Removal (Opel 1900 & Manta)
- Installation (GT)
- Installation (Opel 1900 & Manta)
- Upper Control Arm Removal and Installation
- Removal (GT)
- Removal (Opel 1900 & Manta)
- Installation (GT)
- Installation (Opel 1900 & Manta)
- Lower Control Arm Removal and Installation
- Removal (GT)
- Removal (Opel 1900 & Manta)
- Installation (GT)
- Installation (Opel 1900 & Manta)
- Steering Knuckle Removal and Installation
- Removal (GT)
- Removal (Opel 1900 & Manta)
- Installation (GT)
- Installation (Opel 1900 & Manta)
- Shock Absorber Removal and Installation
- Removal (Opel 1900 & Manta)
- Removal (GT)
- Installation (Opel 1900 & Manta)
- Installation (GT)
- Front Spring Removal and Installation
- Removal (GT)
- Removal (Opel 1900 & Manta)
- Installation (GT)
- Installation (Opel 1900 & Manta)
- Specifications
- Bolt Torque and Front End Alignment
- 3B - Steering Linkage
- Description and Operation
- Description and Operation of Tie Rods
- Major Service
- Removal and Installation of Tie Rods
- Removal
- Installation (GT)
- Installation (Opel 1900 & Manta)
- Disassembly and Reassembly of Tie Rods
- Disassembly (GT)
- Reassembly (GT)
- Specifications
- Tightening Specifications
- 3C - Front End Alignment
- Description and Operation
- Front Wheel Alignment
- Maintenance and Adjustments
- Inspection Before Checking Front Wheel Alignment
- Adjusting Caster (GT)
- Adjusting Caster (Opel 1900 & Manta)
- Adjusting Camber
- Adjusting Toe-in (GT)
- Adjusting Toe-in (Opel 1900 & Manta)
- Checking Theoretical King Pin Inclination
- Specificaitons
- Front End Alignment
- 3D - Steering Gear Assembly
- Description and Operation
- Description and Operation of Steering Gear Assembly
- Maintenance and Adjustments
- Adjustment of Steering Gear
- Major Repair
- Removal and Installation of Steering Gear Assembly and Tie Rods
- Removal (GT)
- Removal (Opel 1900 & Manta)
- Installation (GT)
- Installation (Opel 1900 & Manta)
- Disassembly and Assembly of Steering Gear With Tie Rods
- Disassembly (GT)
- Disassembly (Opel 1900 & Manta)
- Reassembly (GT)
- Reassembly (Opel 1900 & Manta)
- Specifications
- Tightening Specifications
- 3E - Steering Column Assembly
- Opel 1900 and Manta
- Description and Operation
- Description and Operation of Directional Signal Lever
- Description and Operation of Horn
- Description o f Steering Column Assembly
- Major Repair
- Removal and Installation of Steering Column Assembly
- Removal
- Installation
- Removal and Installation of Steering Wheel
- Removal
- Installation
- Removal and Replacement of Horn Contact Ring
- Disassembly and Reassembly of Directional Signal Switch
- Disassembly
- Reassembly
- Disassembly and Reassembly of Steering & Ignition Lock Cylinder & Electrical Switch from Mast Jacket Assembly
- Disassembly (GT)
- Disassembly (Opel 1900 & Manta)
- Reassembly
- Specifications
- Steering Column Tightening Specifications
- GT
- Description and Operation
- Description of Steering Column
- Major Repair
- Removal and Installation of Steering Wheel
- Removal
- Installation
- Removal and Installation of Ignition Lock Cylinder
- Removal
- Installation
- Removal and Installation of Steering Column Assembly
- Removal
- Installation
- Removal and Installation of Center Steering Shaft
- Removal
- Installation
- Removal and Installation of Ignition Switch and/or Steering Lock
- Removal
- Installation
- Removal and Installation of Upper Steering Bearing and/or Direction Signal Switch
- Removal
- Installation
- Removal and Installation of Steering Column Lower Bearing
- Removal
- Installation
- 3F - Rear Suspension
- Description and Operation
- Description and Operation of Rear Suspension
- Major Repair
- Rear Shock Absorber Removal and Installation
- Removal
- Installation
- Rear Spring Removal and Installation
- Rear Spring Removal
- Rear Spring Installation
- Lower Control Arm Replacement
- Removal
- Installation
- Stabilizer Rod Replacement
- Removal
- Installation
- Track Rod Replacement
- Removal
- Installation
- Specifications
- Tightening Specifications
- 3G - Wheels and Tires
- Diagnosis
- Car Roughness and Vibration
- Unbalance
- Runout
- Tire Grinding
- Tire Wear Irregularities
- Wheel Nut Torque and Tightening Specifications
- Summary of Diagnosis and Correction of Tire and Wheel Vibration
- Abnormal Tire Wear
- General Operation Conditions
- Shoulder or Underinflation Tread Wear
- Canter or Overinflation Tread Wear
- Cross or Toe Tread Wear
- Side or Camber Wear
- Cornering Tread Wear
- Heel and Toe Tread Wear
- Cupped or Scalloped Type Tire Wear
- Maintenance and Adjustments
- Demounting and Mounting Tubeless Tires
- Wheel and Tire Balance
- Specifications
- General Specifications
Group 4 - Propeller Shaft & Differential
- 4A - Propeller Shaft & Central Joint
- Description and Operation
- Propeller Shaft and Central Joint
- Major Repair
- Propeller Shaft Removal and Installation
- Removal
- Installation
- Disassembly and Assembly of the Central Joint
- Disassembly of Central Joint
- Assembly of Central Joint
- Specifications
- Tightening Specifications
- 4B - Rear Axle
- Description and Operation
- Rear Axle Description
- Diagnosis
- Rear Axle Trouble Diagnosis
- Major Repair
- Removal and Installation of Rear Axle Assembly
- Removal
- Installation
- Removal and Installation of Axle Shaft Assembly
- Removal
- Installation
- Disassembly and Assembly of the Differential
- Removal and Disassembly of Differential Case
- Removal and Disassembly of Drive Pinion
- Assembly and Installation of Drive Pinion
- Assembly and Installation of Differential Case (Opel 1900 and Manta)
- Assembly and Installation of Differential Case (GT)
- Specifications
- General Specifications
- Axle Ratios
- Adjusting end Fitting Specificaitons
- Torque Specifications
Group 5 - Brakes
- 5A - Power Brake Booster & Master Cylinder
- Description and Operation
- Power Brake Booster
- Master Cylinder
- Vacuum Control Valve
- Diagnosis
- Power Brake Unit Trouble Diagnosis
- Maintenance and Adjustments
- Checking Brake Booster Operation
- Brake Booster Filter Service
- Vacuum Control Valve Service
- Major Repair
- Brake Booster Removal and Installation
- Removal
- Installation
- Master Cylinder Overhaul - GT
- Removal of Master Cylinder
- Disassembly
- Cleaning and Checking
- Assembly
- Installation
- Master Cylinder Overhaul - Opel 1900 & Manta
- Removal of Master Cylinder
- Disassembly
- Cleaning and Checking
- Assembly
- Installation
- Specification
- General Specifications
- 5B - Disc Brakes
- Description and Operation
- Description
- Operation
- Diagnosis
- Disc Brake Trouble Diagnosis
- Maintenance and Adjustments
- Disc Brake Maintenance
- Checking Brake Fluid Level
- Friction Pad Adjustment
- Lubricating Front Wheel Bearings
- Checking Disc Brake Friction Pads for Wear
- Removal and Installation of Friction Pads
- Checking Brake Disc for Lateral Runout
- Major Repair
- Removing and Installing Brake Caliper
- Removing and Installing Brake Disc
- Removing and Installing Brake Disc Shield
- Removal
- Installation
- Disassembly and Assembly of Brake Caliper
- Specifications
- Disc Brake Specifications
- General Specifications
- Torque Specifications
- 5C - Drum Brakes
- Description and Operation
- Description of Brake Mechanism
- Wheel Brake Assemblies
- Parking Brake Control System
- Service Brake Control System - Standard Brakes
- Operation of Hydraulic Service Brake
- Diagnosis
- Brake Trouble Diagnosis Chart
- Maintenance and Adjustments
- Brake Adjustments
- Primary Checks
- Pedal Height Adjustment
- Adjustments at Wheels
- Parking Brake Adjustment
- Filling Brake Master Cylinder Reservoir
- Bleeding Brake Hydraulic System
- Sequence for Bleeding Wheel Cylinders or Calipers
- Bleeding Wheel Cylinder or Caliper
- Flushing Brake Hydraulic System

AND MORE....