1973 OPEL 1900 rod

3A. 141973 OPEL SERVkE MANUAL
Figure 3A-22 Caliper Removed and Hung by Wire
steering knuckle. Swing steering arm and tie rod to
the side.7. Remove castle nut cotter pin, unscrew nut and
pull steering knuckle off lower control arm ball joint.
Installation GTCAUTION: Fasteners are important attachingparts in
that they could affect the performance of
viral com-
ponents and systems, and/or could result in major
repair expense. They must be replaced with one of
the same part number or with an equivalent part if
replacement becomes necessary. Do not use a re-
placement part of lesser quality or substitute
desig.Torque values must be used as specified during reas-
sembly to assure proper retention of these parts.
1. Always replace paper gasket when installing dust
shield on steering knuckle. Lightly coat both surfaces
of paper gasket with chassis lubricant before installa-tion and torque attaching bolts to 47
lb.ft.2. Install lower ball joint in steering knuckle. Torque
castle nut to 54
Ib.ft. Install new cotter pin.
3. Attach shock absorber at lower end. Torque boltsto 30 lbs. ft.
4. Install upper ball joint. Torque castle nut to 29
lb.ft. Install new cotter pin.
5. Remove spring compressor.6. Install hub and disc on spindle and tighten spindle
nut as stated under MAINTENANCE AND AD-
JUSTMENTS in this section.
7. Install caliper on steering knuckle and torque boltsto 72
lb.ft. See Figure 3A-21.8. Install wheel and torque wheel nuts to 65
lb.ft.
Installation Opel 1900
- MantaCAUTION: Fasteners are important attachingparts in
that they could
affit the performance of vital com-
ponents and systems, and/or could result in
ma&repair expense. They must be replaced with one of
the same part number or with equivalent parts, ifrepfacement becomes necessary. Do not use a re-
placement part of lesser quality or substitute design.
Torque values must be used as specified during reas-
sembly to assure proper retention of these parts.
1. Attach steering knuckle to lower control arm ball
joint. Torque castle nut to 54
lb.ft.
2.
Atl,ach brake cover plate and steering arm to steer-ing knuckle. If required, install new paper gasket
between cover plate and steering knuckle. Care for
proper seat of T-head bolts. See Figure
3A-23.Figure 3A-23 Attaching Brake Cover Plate
3. Install front wheel hub and brake caliper.
4. Attach steering knuckle to upper control arm ball
joint. Torque castle nut to 40
lb.ft.5. Steering arm to steering knuckle
_ 58 lb.ft.6. Brake caliper to steering knuckle
- 72 lb.ft.7. Adjust front wheel bearing clearance.
8. Remove stands and lower car

3A- 161973 OPEL SERVICE MANUAL
SPECIFICATIONS
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 maasurement of tightness.
LocationFront Suspension Crossmember to Front Frame
Clamp, Steering Mast to Steering Mast Flange
(GT)
........................................................................................
Clamp, Steering Mast to Steering Mast Flange(1900
-Manta)..................................................................
Clamp,UpperUniversalJoint(GT)..................................Clamp, Lower Universal Joint (GT)
..................................
WheelNuts............................................................................Lower Control Arm Shaft to Lower Control Arm
..........Lower Control Arm Ball Joint to Steering Knuckle
......Upper Control Arm Ball Joint to Steering Knuckle
(GT)........................................................................................Upper Control Arm Ball Joint to Steering Knuckle
(1 900 Manta)
..................................................................Upper Control Arm Ball Joint to Upper Control Arm
ShockAbsorbertoLowerControlArm..........................Steering Arm to Steering Knuckle (1900
- Manta)......
Brake Backing Plate or Brake Disc Shield andSteering Arm to Steering Knuckle
(GTJ
Hex Head Bolt M 10......Hex Head Bolt M 8
......
Brake Backing Plate to Steering Knuckle(1900 Manta)
..................................................................
Brake Caliper to Steering Knuckle.................................
Lower Control Arm to Front Spring Eye (GT)................
Brake Disc to Front Wheel Hub........................................Upper Control Arm to Crossmember (1900
- MantajLower Control Arm to Crossmember (1900
- Manta)
Steering Gear Housing to Front Suspension
Crossmember (GT)
............................................................
Steering Gear Housing to Front SuspensionCrossmember (1900
- Manta)........................................Stabilizer Bar to Lower Control Arm
(Opel 1900
- Manta)........................................................Tie Rod Clamp Bolts
(GTJ....................................................
CastleNut,TieRodtoSteeringArm..............................Upper Control Arm Shaft to Shock Absorber Support
and Upper Control Arm (GT)
..........................................
CrossMember to
BodySupport Attachment................
FrontSuspensionAssemblytoFrame............................Front End Alignment Specifications
Torque
Lb.Ft.36
1522
14
22
6540
5429
ii30
5847
18
58
72
1836
40
43
1830
87
:i33
58
47ModelCaster’
Camber”1900‘3
l/2-6 l/2GT
3+1-:%+*Permissible deviation from left to right wheel
- Max. 1’.
Toe-In”Min.-Max.
l/8-3/ 16
l/32-1/8Outer Wheel
When Inner
Wheel at 20
19
l/418
l/2

STEERING LINKAGE38.19STEERING LINKAGE
CONTENTS
Subject
DESCRIPTION AND OPERATION:
Description
andOperationofTieRods. . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS: (Not
Applicable)
MAJOR REPAIR:
RemovalandInstallationofTieRods. . . . . . . . . . . . . . . . . . . . . . . .Disassembly
andReassemblyofTieRods. . . . . . . . . . . . . . . .SPECIFICATIONS:
Tightening Specifications ..,.............................................Page No.
38-193B-1938-21jB-21
DESCRIPTION AND OPERATION2. Using remover J-21687, pull outer tie rod ball
studs out of steering arms. See Figure
3B-2.DESCRIPTION AND OPERATION OF TIE RODS
Tie rods on the GT are connected to both rack ends
by means of a ball joint. Two rubber bellows between
ball joint and steering gear housing protect rack and
ball joints against dirt, dust and mud. The ball joints
of the tie rods do not require service.
Tie rods on the Opel l&O and Manta are connected
to both rack ends by means of a axial joint. Two
rubber bellows between the axial joint and steering
gear housing protect the rack and axial joints against
dirt, dust, and mud. The ball joint of the tie rod ends
on the Opel 1900 and Manta are maintenance free
and must not be disassembled.
MAJOR REPAIRREMOVAL AND INSTALLATION OF TIE RODS
38-2
RemovalFigure
38-2 Removing Ball Stud
In order to avoid the possibility of dirt entering the
steering gear assembly via the rack, it is recom-
mended that rods and area immediately surrounding
the gear assembly be wiped free of loose dirt prior to
removal.3. Remove clamp securing one end of rubber bellows
to tie rods and slip bellows off tie rods to expose nut
or lock plates. See Figure
3B-3.1. Remove cotter pins securing nuts on tie rod ends
and remove nuts. Discard cotter pins.4. On the GT, bend up round edges of lock plate
from tie rod ball studs and unscrew ball studs From
rack. See Figure
3B-4.

Figure 38-3 Bellows Removed From Tie Rod GT
5. On the Opel 1900 - Manta, unscrew tie rod from
axial joint. It is important that rack be held secure
with open end wrench to prevent damage to rack
teeth.
38. 201973 OPEL SERWCE MANUAL
Figure 38.4 Removing Tie Rods. GT
Installation . GT
CAUTION:
Fasteners are important attaching parts in
that they could affect the performance of vital com-
ponents and systems, and/or
coo/d result in major
repair expense. They must be replaced with one of
the same part number or with an equivalent part if
replacement becomes necessary. Do not use a
re-
placement part or lesser
quaJity or sub.Mute design.
Torque
vaJues must be used as specified during reas-
sembJy to assure proper retention of these parts.1. Install new lock plates onto tie rod ball studs and
screw ball studs into rack while holding bent tab of
lock plates against flat on rack. Torque ball studs 43lb.ft. See Figure
3B-5. It is important that rack be
held secure with open end wrench to prevent damage
to rack teeth.
Figure 38-5 Bending Lock Plate Over Ball Stud
- GT
2. Bend round edges of lock plate over
flat on ball
stud
‘to lock ball stud in position.
3. Position rubber bellows and hose clamps over tie
rods and adjust clamp so that wire ends are pointing
in same direction as adjusting screw. Check that bel-
lows are not twisted and will compress and expand
properly.
4. Connect outer tie rod ball stud to steering arm,
torque castle nut to 29
lb.ft., and lock in position
with new cotter pin.
Installation Opel 1900. Manta
CAUTION:
Fasteners are important attachingparts in
that they could ah% the performance of vital com-
ponents and systems, and/or
couJd reslllt in major
repair expense. They must be replaced with one of
the same part number or with an
equivalenr part if
repJacement becomes necessary. Do not use a re-
placement part of lesser quality or substitute design.
Torque valves must be used as specified during
reas-
sembfy to assure proper retention of these parts.1. Screw tie rod into axial joint.
2. Attach tie rod end to steering arm and torque nut
to 29 lb.ft. Install new cotter pin.
3. Adjust toe-in and then torque lock nut of both tie
rods to 47 lbft.

STEERING LINKAGE38-21
4. Attach rubber bellows to axial joint using hoseClamp.DISASSEMBLY AND REASSEMBLY OF TIE RODS
The ball joint of the tie rod end on the Opel 1900
_Manta is maintenance free and must not be disassem-
bled.
Disassembly - GT
?. Loosen tie rod clamp bolt and unscrew outer tie
rod ball stud from tie rod. See Figure
3B-6.2. Remove retainer ring from outer ball stud of tie
rod and take off rubber sealing cap.
Reassembly GT1. Install rubber sealing cap and retainer ring onto
outer ball stud.
2. Screw outer tie rod ball stud into tie rod and
tighten clamp bolt.
CAUTION: Fasteners for tie rods are important
attaching parts in that they could affect the per-
formance of vital components and systems, and-
TIE ROD rCLAMPOUTERy BALL STUD
RETAINER RING
SEALING RINGFigure
38-6 Tie Rod and Outer Ball Stud
/or could result in major repair expense.They must
be replaced with one of the same part number or with
an equivalent part if replacement becomes necessary.
Do not use a replacement part or lesser quality or
substitute design. Torque values must be used as
specified during reassembly to assure proper reten-
tion of these parts.
SPECIFICATIONSTIGHTENING SPECIFICATIONS
Location
Ball Stud to Rack (GT)Ball Stud to Steering Arm (GT)
Tie Rod End to Steering Arm (1900 . Manta)
Tie Rod Lock Nut (1900
- Manta)
Torque
Lb.Ft.
4329
29
47

3C-24 1973 OPEL SERVICE MANUAL
NOTE:
FRONT OF CAR
4Figure
3C-3 Upper Control Arm Shaft and Bushingsx.3
Figure
3C-4 Supporting Vehicle at Both Lower
Control Arms(B) (rear) between upper control arm and shock ab-
sorber support. See Figure
3C-5.5. One
.24” thick washer each is installed in produc-
tion on each car side. Consequently, only two adjust-
ments are possible by adding washers of different
thickness.
6. One
.12” in front and one .36” in the rear (caster
increase of 1 degree) or one
.36” in front and one. 12”
in the rear (caster decrease of 1 degree). Never addFRONT OF CAR
3G5
Figure
3C-5 Caster Adjustment Washer Location -Opel 1900 - Manta
several washers in one place. The washers B installed
in production have a larger outer diameter than the
washer A. For service, the Parts and Accessories
Department supplies only larger washers with an
outer diameter of 1.57”.
7. Insert control arm shaft from front towards the
rear into upper control arm and shock absorber
SUP-port. Observe that the crown of both plate washers
shows inwards. See Figure
3C-5.8. Torque hex nut of control arm shaft to 40 ft.lbs.
Always use new self-locking nut.
9. Torque wheel nuts to 75
ft.lbs.10. Recheck caster setting.

FRONT END ALIGNMENT 3C-25
Figure 3C-6 Adjusting Toe-In (GT)ADJUSTING CAMBER
Camber is adjusted by turning the upper ball jointflange 180 degrees. This means that only two possi-
ble camber adjustments can be made. At the factory
camber is set at the smallest possible positive camber
setting for GT and smallest possible negative camber
for Opel
1900 - Manta. Rotating the flange will make
camber more positive on GT and more negative on
Opel
1900 - Manta.
1. Raise front end of car using wood block on jack
to prevent damage to front cross member.
2. Support car below lower control arm and remove
front wheel on side to be adjusted.
3. Remove ball joint from upper control arm and
front steering knuckle.
4. Lift upper control arm and turn the ball joint
flange through 180 degrees.
5. First tighten both ball joint attaching bolts on
upper control arm and then the ball stud castle nut.
Torque to 29 ft. lbs. on GT and 44
ft.lbs. on Opel
1900 - Manta. Install new cotter pin.
6. Install front wheel and torque wheel nuts to 72
lb.ft. on GT and 75 Ib.ft. on Opel 1900 - Manta.
7. Recheck camber.
ADJUSTING TOE-IN
(GT)Toe-in is adjusted by rotating the tie rod sleeves.
Refer to Figure
3C-6.1. Recheck caster and camber before proceeding
with toe-in adjustment. If correct, adjust toe-in.2. Set wormshaft and ball nut to steering gear high
point by turning steering wheel half way from one
stop to the other, noticing the following:
(a) With the steering wheel hub button removed, the
“marking” on the steering shaft end should be in a
horizontal position.
(b) The steering wheel spokes should also be in a
centered position.
3. Remove wire clamps on left and right tie rod and
push back bellows.
4. Loosen clamp bolts and tie rods. See Figure
3C-4.5. The toe-in should be
l/32” - l/8”.When adjusting toe-in, never grip tie rod on inner
ball stud joint. To avoid ball stud resting against
inside of hole in tie rod outer end, center outer end
of each tie rod to the ball stud.
6. Pull bellows over tie rods and attach with wire
clamps. The bellows must not be twisted and wire
ends must show towards steering gear adjusting
screw opening.
7. Torque clamp bolts to 12
Ib.ft.8. After toe-in adjustment, turn steering wheel sev-
eral times completely towards the left and right to
determine whether bellows are properly attached to
the tie rods and steering gear housing.
ADJUSTING TOE-IN (OPEL 1900. MANTA)
The adjustment of the toe-in has always to be carried
out on both tie rods.

3C-26 1973 OPEL SERVICE MANUAL
1. Loosen lock nut of left and right tie rod and
slacken back nut.
2. Remove hose clamp for rubber bellows attach-
ment from respective axial joint and adjust toe-in by
turning axial joint. When doing this, observe that the
rubber bellows, having a tight seat on thejoint, is not
twisted. If necessary, lubricate seat of bellows and
hold back bellows when turning. See Figure 3C-7.Figure
3C-7 Adjusting Toe-In Opel 1900 Manta
3. Toe-in should be l/S”
- 3/16”.
4. Torque lock nut of left and right tie rod to 47
ft.lbs.5. Attach respective rubber bellows with hose clamp,
making sure that clamp bolt points towards the
front. The rubber bellows must not be twisted, i.e.,
SpecificationsFRONT END ALIGNMENTthe individual grooves of bellows must be in vertical
position.
6. After adjustment, turn steering several times to the
left and right to determine if a proper attachment of
both rubber bellows to the steering gear housing is
warranted.
CHECKING THEORETICAL KING PIN
INCLINATION
When checking theoretical king pin inclination, car
must be on a level surface, both transversely and fore
and aft, must have trim heights within limits, and
must be at curb load.
With camber known to be within specitied limits,
theoretical king pin inclination should check to 8.5
degrees for Opel 1900
- Manta, and 6 degrees for GT.
If camber is incorrect beyond limits of adjustment
and theoretical king pin inclination is correct, or
nearly so, a bent steering knuckle is indicated.
There is no adjustment for theoretical king pin incli-
nation as this factor depends on the accuracy of the
fronts suspension parts. Distorted parts should be re-
placed with new parts.
The practice of heating and bending front suspension
parts to correct errors must be avoided as this may
produce soft spots in the metal in which fatigue and
breakage may develop in service.
MODELCASTER
’CAMBER ’TOE-INOUTER WHEEL
MIN.. MAX.WHEN INNER
WHEEL AT 20
’1900‘3
l/2-61/2-1?1/2I/% - 3/1619 l/4GT3+1
1+1/2l/32 - l/818 l/2* Permissable deviation from left to right wheel
- maximum 1”.