1973 OPEL GT-R steering

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

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-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.