1973 OPEL GT-R wheel bolts

FRONT SUSPENSION3A- 15
SHOCK ABSORBER REMOVAL ANDINSTALLATION
Removal
Opel 1900. Manta1. Raise car and support with stands.
2. Remove upper attaching nuts from shock ab-
sorber.3. Remove lower attaching nut, lockwasher, and
bolt.
4. Compress shock absorber and remove from car.
Removal GT1. Remove air cleaner. See Figure 3A-24.
Figure 3A-24 Removal of Air Cleaner
2. Remove plastic cover over shock absorber upper
attachment.
3. Raise car and support with stands.
4. Remove upper attaching nuts from shock ab-
sorber.5. Remove lower attaching nut, lockwasher, and
bolt.
6. Compress shock absorber and remove from car.
Installation Opel 1900. Manta1. Inspect shock absorber for damage and seal leaks.Always replace the upper and lower rubber grom-
mets when replacing a shock absorber.
2. Install the lower grommet retainer and grommets
on shock absorber. Compress shock absorber and
place in position.
3. Install lower attaching bolt and nut. Torque to 30
lb.ft.4. Install nuts on upper attaching studs. Tighten nuts
until distance from top of nut to stud is approxi-
mately
l/2 inch. See Figure 3A-25.5. Install plastic cover.
Installation GT1. Inspect shock absorber for damage and seal leaks.
Always replace the upper and lower rubber grom-
mets when replacing a shock absorber.
2. Install the lower grommet retainer and grommets
on shock absorber. Compress shock absorber and
place in position.
3. Install lower attaching bolt and nut. Torque to 30
lb. ft.
4. Install nuts on upper attaching studs. Tighten nuts
until distance from top of nut to stud is approxi-
mately
l/2 inch. See Figure 3A-25.5. Install plastic cover.
6. Install air cleaner.
FRONT SPRING REMOVAL AND INSTALLATION
Removal (GT)1. Raise car and support at rear of front frame rails
with stands.
2. Remove front wheels.
3. Remove cotter pin from castle nut on lower ball
joint studs and back off castle nut two (2) turns. Hit
ball stud a sharp blow to break it loose. Do not
remove nut.4. Install J-21689 spring compressor and compress
the spring until 3-l/8” clearance is obtained between
spring and compressor.
5. Disconnect both shock absorbers at their lower
attachment. Compress both shock absorbers.
6. Support the rail of J-21689 Spring Compressor
with a jack. Remove lower control arm to cross
member attaching nuts and bolts.

3A- 161973 OPEL SERVICE MANUAL
INNER RUBBERSTUD.1 /2”\E
/
PLASTIC COVER
DAMPENING RING
RETAINERRUBBER DAMPENING RING-
-zSELF-LOCKING NUT
UPPER RUBBER
GROMMET RETAINERLOWER
RUBIGROMMET RETAINER
WHEEL HOUSE
SHOCK ABSORBER
SHOCK ABSORBERSA-25Figure
3A-25 Shock Absorber Upper Attachment
7. Remove lower ball joint stud nuts. Slightly lower
jack so that the spring and lower control arm assem-
bly is removed from the front cross member and
steering knuckle.
8. Lower jack, spring compressor, and front spring
and control arm assembly. Remove lower control
arm to spring nuts.
9. Relieve tension on spring compressor and remove
control arm attaching bolts and control arms.
Removal (Opel 1900 - Manta)1. Prior to raising car, install upper control arm
hooks J-23697.
2. Raise car and stipport with stands. Hoist should
be left in the raised position to maintain pressure on
lower control arm.
3. Remove front wheel.
4. Detach both stabilizer supports from cross mem-
ber to body support.5. Remove shock absorber.
6. At lower control arm ball joint, remove castle nut
cotter pin and remove nut.
7. With suitable drift, detach lower control arm ball
joint from steering knuckle.
8. Loosen nut that retains lower control to front
cross member.
9. Slowly lower hoist to release spring tension.
10. Swing lower control arm downwards and remove
front spring.
Installation (GT)
CAUTION:
Fasteners are important attachingparts in
that they could at&t
the performance of vital 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 oflesser quality or substitute design.

FRONT SUSPENSION3A- 17Torque values must be used as specified during reas-
sembly to assure proper retention of these parts.1. Attach lower control arm to front spring eye.
Torque bolts to 18
lb.ft.2. Install spring compressor on spring and compress
spring to appropriate length.
3. Raise jack with spring compressor, spring and
control arm assembly into position under the car.
4. Install lower ball joints and torque nuts to 54
Ib.ft.Install new cotter pin.
5. Attach lower control arms to frame cross member
using new lock nuts.
6. Attach both shock absorbers. Torque bolts to 30
lb.ft.7. Remove spring compressor.
8. Install front wheels.
On replacement of the damper bushings on the front
springs, only the one-part damper bushing is in-
stalled for either the two-leaf or three-leaf spring.
For proper location of the marking lugs, see Figure3A-26.
Installation (Opel 1900. Manta)
CAUTION: Fasteners are important attachingparts in
that they
co&d affect the performance of vital 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 design.
Torque values must be used as specified
during reas-
sembly to assure proper retention of these parts.1. Properly seat spring between lower control arm
and cross member.
2. Raise jack and place lower control into position.CROSS SECTION
SA-26Fig. 3A-26 Front Spring Damper Bushing.
3. Attach lower control ball joint to steering knuckle
and torque nut to 54
lb.ft.4. Tighten lower control arm to cross member bolt
to 43 lb.ft.
5. Attach stabilizer bar to cross member to body
support.
6. Install shock absorber and torque lower attaching
nut and bolt to 30
lb.ft.7. Install nuts on upper shock absorber attaching
studs. Tighten nuts until a distance from top of nut
to stud is approximately
l/2 inch.
8. Install front wheels and tighten nuts to 65
lb.ft.9. Remove stands and lower car.
SPECIFICATIONSBOLT TORQUE AND FRONT END ALIGNMENT

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

3C-22 1973 OPEL SERVICE MANUAL.
FRONT END ALIGNMENT
CONTENTS
SubjectPage No.
DESCRIPTION AND OPERATION:
FrontWheelAlignment
. . . . . . . . . . . . . . . . . . . . . . ..“...........................DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS:
Inspection Before Checking Front Wheel Alignment
AdjustingCaster
. . . . . . . . ...’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Camber
. . . . . . . . . . . . . . . . . . . . . . . . . . * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjusting Toe-In
. . . . . . . . . . . . . . * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .King Pin Inclination
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR: (Not Applicable)
SPECIFICATIONS:3C-223C-223C-233C-253C-253C-26
Wheel Alignment Specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3C-26
DESCRIPTION AND OPERATIONFRONT WHEEL ALIGNMENT
Wheel alignment is the mechanics of adjusting the
position of the front wheels in order to attain the
least steering effort with a minimal amount of tire
wear.handling, but require only reasonable accuracy to
provide normal tire life. With the type of front sus-
pension used, the toe-in adjustment is much more
important than caster and camber are as far as tire
wear is concerned.
Correct alignment of the chassis is essential to proper
alignment of front and rear wheels. Briefly, the es-
sentials are that the frame must be square in plain
view within specified limits, that the top and bottom
surfaces of the front cross member must be parallel
fore and aft, and that the upper and lower control
arm must be at correct location in respect to shafts
and the front cross member. All bushings, ball joints
and bolts must be of proper torque and in usable
condition.Caster and camber adjustments need not be consid-
ered unless visual inspection shows these settings to
be out, or unless the car gives poor handling on the
road. In the majority of cases, services consisting of
inflating tires to specified pressure and interchanging
tires at recommended intervals, balancing all wheels
and tires, adjusting steering gear and setting toe-in
correctly will provide more improvement in car han-
dling and tire wear than will other front end align-
ment adjustments.
Wheel and tire balance has an important effect on
steering and tire wear. If wheels and tires are out of
balance, “shimmy” or “tramp” may develop or tires
may wear unevenly and give the erroneous impres-
sion that the wheels are not in proper alignment. For
this reason, the wheel and tire assemblies should be
known to be in proper balance before assuming that
wheels are out of alignment.The correct use of accurate front end alignment
equipment is essential to determine whether front
suspension parts have been damaged by shock or
accident, and to obtain correct alignment settings
after new parts have been installed.
MAINTENANCE AND ADJUSTMENTS
Inspection Before Checking Front Wheel AlignmentClose limits on caster, front wheel camber, andBefore making any adjustment affecting caster, cam-
theoretical king pin inclination are beneficial to carber, toe-in, theoretical king pin inclination, or
steer-

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.

STEERING GEAR ASSEMBLY30-292. Loosen clamp securing flexible coupling to steer-
ing shaft.
4. Remove stop bolt (see Figure 3D-4) from under-
side of steering column (secures steering shaft bush-
ing to mast jacket), and pull steering wheel rearward
approximately three inches.
Figure
3D-4 Stop Bolt
4. Remove cotter pin located on left and right tie rod
ends and unscrew nut.
5. Using remover J-21687, press ball studs out of
steering arms (see Figure
3D-5).
IJ-21 68’Figure 3D-5 Removing Ball Stud6. Remove four attaching bolts securing steering gear
to front suspension cross member (see Figure 3D-6)
and lift off steering gear assembly and tie rods.
Figure
3D-6 Steering Gear Assembly Attaching Bolts
Removal (Opel 1900. Manta)1. Remove splash shield from lower deflector pa:
and both side members. See Figure
3D-7.nel
Figure
3D-7 Removing Splash Shield
2. Remove clamp bolt securing flexible coupling to
steering shaft. See Figure
3D-8.

3D- 301973 OPEL SERVICE MANUALFigure 3D-8 - Removing Clamp Bolt3. Remove cotter pin located on left and right tie rod
end and unscrew nut.
4. Using Tool J-21687, press tie rod ends out of
steering arms.
5. Disconnect steering gear housing from front sus-
pension cross member and remove steering gear
together with tie rods.
Installation . GTCAUTION: Fasteners are important attaching parts in
that they could affect the performance of vital 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 design.
Torque values must be used as specified during reas-
sembly to assure proper retention of these parts.
1. Position steering gear on front suspension cross
member and torque attaching bolts to 18
lb.ft.2. Position tie rod ball studs in steering arms; install
nuts and torque to 29 lb.ft. Lock in position with new
cotter pins.
3. Fully turn steering wheel so that flat or cutout
surface on lower portion of steering shaft is parallel
to flexible coupling bolt hole.
4. Install the lower end of steering shaft to the flexi-
ble coupling and adjust dimension between steering
wheel hub and direction signal switch housing cover
to
l/8 and 3/32 inch. Maintain adjustment by tight-
ening flexible coupling bolt and nut to 15 lb.ft. Lock
the bolt and nut in position with lock-plate tabs.5. Reinstall stop bolt into steering column.
6. Full turn steering wheel both right and left. If any
resistance is noticeable, it will be necessary to remove
the sleering column and correct the cause.
D. Installation (Opel 1900. Manta)CAUTION: Fasteners are important attachingparts in
that they could affect the performance of vital com-
ponents and systems, and/or could result in
maJbrrepair 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 oflesser
quaky or substitute design.
Torque values must be used as specified during reas-
sembly to assure proper retention of these parts.
1. Prior to installation, set steering gear to high
point. The steering wheel spokes point downwards in
an oblique angle. The elongated cutout of the lower
steering mast must coincide with the clamp bolt hole
of the pinion flange.
2. Position steering gear on front suspension cross
member and torque attaching bolts to 29 lb.ft.
3. Position tie rod studs in steering arms. Install nuts
and torque to 29
Ib.ft. Lock in position with new
cotter pin.
4. Install the lower end of the steering shaft to flexi-
ble coupling and torque clamp bolt to 22
lb.ft.5. Attach guard plate to both side members and
lower deflector panel.
DISASSEMBLY AND ASSEMBLY OF
STEERING GEAR ASSEMBLY WITH TIE RODS
Disassembly - GT1. Carefully clamp gear assembly in soft jaw vise and
slip clamps and rubber bellows off gear housing to
expose area where ball joint screws into rack.
2. Bend up round edges of lockplates from tie rod
ball studs and disconnect tie rod ball studs from rack.
See Figure
3D-9). It is important that rack be held
secure with open end wrench to prevent damage to
rack teeth.
3. Loosen adjusting screw lock nut; remove adjusting
screw from steering gear housing, and take out thrust
spring and sintered bronze shell. See Figure
3D-11.4. Rotate gear assembly in vise so that pinion shaft
portion of assembly is held by vise, and remove pin-
ion nut, flat washer, and special washer.