So, here is my little Opel GT. She is a hot little car. My mother bought it new in 1972. It is been in several different little accidents and sat for extended periods of time between repairs. After my ex-wife and I split and she took the car I was driving, it seemed like the logical think to do to get the Opel running again. Well she is running and turning heads all the time. I will try to keep a log here, like I do with my Porsche about the steps of maintenance and restoration.
To get it back running this time, I had to replace the head which I did with the assistance of my ex's neighbor. We, mostly he, put a 2.0 head in to replace to 1.9 heads in which a hydraulic lifter had seized. I now have a "whir" noise because apparently the machine shop milled the head down slightly too far and so the timing chain rubs at low RPMs. I also replaced the water pump, fuel pump, and the master cylinder which went out shortly after getting it to run again. Then I replaced the front brake pads and installed a brake kit in the back to stop the brake leak. Following that, I installed the rear window seal, tinting the rear window while it was out, as well as the rear pop out windows and the doors. Up next is to replaces the seals around the windows that both act as a seal and help to hold the chrome time in place around the windows.
5-8-2004 - Well, my car smoked Friday night from the driver's side light and then from under the dash. Saturday, I opened up the headlight and FINALLY found the wires that were bad. The yellow and the black wire going to one of the micro-switches had the insulation completely gone and they were definitely the problem. I replaced the wires all the way back to the fuse box. From looking at the wiring diagram, I am pretty sure that is not exactly where they go. At some point it has been modified. When I have more time, I will correct that.
5-10-2004 - Still nervous about the wiring, I was testing the lights and accidentally left the parking lights on when I went to work. The battery went dead and after jumping it and trying it later, determined that it probably had a problem. I took the battery to Wal-Mart and has it tested. It failed so I got a new battery and installed it.
5-15-2004 - I replaced the oil, oil filter, and filled the transmission with gear oil. It runs MUCH, MUCH better. I had no idea it would make so much of a difference. I also didn't realize the transmission was that low. But, I know why. The reverse switch mounted in the transmission is leaking. I have a replacement ordered and will get that problem fixed this or next weekend. I also need to check the differential.
5-24-2004 - Received the Reverse switch. I will put it in this weekend hopefully. I replaced the under-hood rubber. I added the rubber piece that holds the hood holder when the bonnet is down. I replaced the missing metal clips that hold the cover of the air-filter on. I also replaced the rubber bumper under the hood and on each door that keep the metal from riding up against other metal. I have decided to start replacing the wiring through out the car as a long process. I already replaced a couple of wires to one of the headlights. When I replace the reverse switch, I'll go ahead and replace the wires to it as well.
5-29-2004 - Removed the reverse switch and let the gear box drain. Installed new reverse switch and filled gear box back up with new gear oil. I did not replaced the wires though. After looking at how the wires were routed, I determined that the driver's seat would need to be removed and the carpet pulled up when replacing the wires. I will wait to do that when I get the driver's seat recovered. I'll replace the carpet at the same time with a kit from Opel GT Source. I also, as per OGTS, removed the lowest bold on the differential to drain it. I then put the bolt back in and then removed the plug which is higher up on the back end passenger side of the car. I put as much gear oil as I had left. I didn't get it full but it has more than came out of it. I will cap it off in the next week or two.