1973 OPEL MANTA gear

1 E- 40 1973 OPEL SERVICE MANUALDisassemblyI
1. Remove two (2) motor housing attaching
screw$(Item No. 4) and two (2) angle brackets (Item No.
3). See Figure lE-9.
Figure 1 E-S Removing Motor Housing Attaching
SCFS”JSFigure
1 E-l 0 Transmission and Armature Removed
from Motor Housing2. Remoyz transmission housing together with arma-
ture from motor housing. See Figure lE-10. It may
be necessary to hold armature in transmission hous-
ing with a screw driver.
3.
Rem~ove armature from transmission housing.
4. Remove five (5) transmission housing cover
screws. See Figure lE-11.Figure 1 E-l 1 Remove Transmission Housing CoverSCEWS
5. Remove cover, gasket and driven gear from trans-
mission housing. See Figure IE-12. Remove pivot
ball from driven gear. See Figure lE-15.
Figure 1 E-l 2 Remove Driven Gear
6. If required, remove brushes.
a. To remove positive brushes, cut brush leads off at
brush holder. See Figure lE-13.
b. To remove negative brush, remove brush retaining
screw from commutator end frame. See Figure
lE-
14.

WINDSHIELD WIPERSlE-41
Figurk 1 E-l 3 Cut Off Positive Brush Leads
i
Figure iE-14 Remove Negative Brush Retaining
S.X?WI
Cleaning apd Inspection of PartsWith the ekception of electrical parts and bushings,
clean all components in a cleaning solvent.
1. Check irmatare windings for ground, or open
circuit. If
b ground or open circuit is evident, the
armature must be replaced. If the armature checks
out, the c 2. Check brush springs. Spring pressure of new
brushes should be 6.35 to 8.47 ounces. Spring pres-
sure of worn brushes should be at least 3.5 ounces.
In case of /ower spring pressure, replace springs.
3. Check blushes for wear and replace if necessary.
Minimum brush length should be
.24’inch.4. Check d$ven gear for wear and replace if neces-
sary.
Assembly l/8inch layer’ of grease meeting GM Specification
02383. I
2. Install
d&en gear into housing3. Apply a small amount of grease to ball cavity of
driven gear and insert ball. See Figure lE-15.
Figure lE-15 Insert Ball into Driven Gear
4. Install transmission housing cover. See Figure
lE-
16.2. DRIVEN GEAR
3. CONTACT SPRINGS
4. TRANSMISSION
HOUSING COVER
Figure 1 E-l 6 Install Transmission Housing
Cover5. Solder positive brush lead(s) to brush holder(s).
Hold brush lead with needle nose pliers to prevent
solder from running up wire strands. See Figure
lE-
17.6. Install negative brush
7. Apply a small amount of grease to end of armature
shaft. Lightly oil armature shaft.
8. Insert brush springs and brushes into brush hold-
ers. Slide armature into housing, taking care not to
damage brushes.

1 E- 421973 OPEL SERVICE MANUAL
Figure 1 E-l 7 Solder Positive Brush Lead to Brush
Holder
9. Install motor housing over armature so that large
drain hole on housing is facing downward when
mb-tor assembly is installed in car.
InSert angle brackets
into motor housing and tighten attaching screws. Be
sure to reseal angle brackets to motor housing after
retaining screws are tightened.
10. Connect assembled motor with an ammeter and
adjust end play of armature shaft grid drive gear. To
do so, turn in the respective adjusting screw until the
current consumption increases. Then back off adjust-
ing screw
l/2 turn. Secure driven gear adjusting
screw with lock nut and armature adjusting screw
with paint. See Figures lE-18 and lE-19.
Installation1. Connect wiper motor electrical connector to mo-
tor.
2. Place wiper motor in position on cowl and secure.
Torque attaching nuts 14 to 17 in.lbs.
3. Place crank arm on motor drive shaft and torque
nut as follows: Bosch and SWF, 70 to 87 imlbs. and
Siemans, 122 to 139 in.lbs.Figure 1 E-l
8 Adjusting Armature End Play
Figure
lE-19 Adjusting Driven Gear End Play
4. Check the position of the windshield wiper blades
for proper position after the crank arm is attached.
See Figure lE-3 for the proper distance the blades
should be from the windshield molding in the park
position.

1 E- 44 1973 OPEL SERVICE MANUAL)
‘30
1.2.
3.4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.ATTACHING SCREWS16. NEGATIVE BRUSH
TRANSMISSION COVER 17. ATTACHING SCREW
HEX. NUT
THREADED END ~18. RETAiNING PLATE
19. POSlilVE BRUSH
PLAY PIN20. WIRE’
GASKET21. THRUST SPRING
BALL22. RUBBFR MOUNTS
DRIVEN GEAR23. ARMATURE
WASHER24. ATTACHING SCREWS
THREADED END25. LOCKWASHER
PLAY PIN26. ANGLE BRACKE’TS
SLEEVE27. MOTOR HOUSING
MOUNTING PLATE28. MAGNET RING
GASKET29. MAGNET THREADED
TOOTHED WASHERSPi N
LOCATORSATTACHING SCREWS30. NORTH POLE PAINT
TRANSMISSIONMARKING ON
HOUSING
THISfSIDENOTE: MOTOR HOUSING
WITH MAGNET RING HAS
TO BE INSTALLED SO THAT
THE NORTH POLE MARKING
(PAINT DOT ON MAGNET
RING) FACES TOWARDS
‘IRANSMISSION.
301 E20Figure 1620 Wi$er Motor
- Exploded View

1F. 46 1973 OPEL SERVICE MANUAL
’
/
Headlight High-Low Beam Control and Passing:
SignalI
When the headlights have been switched on, high
and low beam selection is made by raising the direc-
tional signal lever toward steering wheel. Each
ti&the lever is raised, beam position, will change.
When the headlights are not on, a flashing headlight
signal may be given by raising and lotiering the di-
rectional signal lever. With the headlights on and
inlow beam position, raising and lowering the direc-
tional signal lever will also cause the headlights to
flash.
Fog Light SwitchAll Rallye models are equipped with two white f?g
lights mounted below the front bumper.
The fog light toggle switch is located on the
insty-ment cluster to the left of the temperature and
fuelgauge cluster.
/
The fog lights can be turned off at any time by the
toggle switch, but can only be tyrned on when: :
1. The ignition switch on or the
?gine running.!
2. The fog light toggle switch lower half is pushed
in.3. The parking lights and/or low beam headlights
are
OKThe fog lights are automatically turned off if the
ignition switch is on and the headlights are switched
to high beam position.
Courtesy LightThe courtesy light illuminates the interior of the Car
when any door is opened. The courtesy light can also
be turned on with all doors closed by tilting the l&s.
GT Headlamp MechanismThe concealed headlamps are moved mechanically.
Pushing actuating lever on left side of console opens
headlamps and pulling lever closes headlamps. Two
(2) meshing gear segments convert the movement, of
the lever to a rotation of 180 degrees. The pivots of
the headlamps lie below the centerline so that with
headlamps in closed position, the headlamp housing
is flush with front sheet metal. Refer to Group 110,
Section “F”, for service procedures on the GT head-
lamp mechanism.
A white indicator lamp in the instrument panel lights
if the headlamps are not completely opened lorclosed The switches of the headlamp electrical sys-
tem are located behind the left headlamp operating,
mechanism.
MAINTENANCE AND ADJUSTMENTSHEADLAMP AIMING
The headlamps must be properly aimed in order to
obtain maximum road illumination and safety that
has been built into the headlighting equipment. With
the Guide T-3 type sealed beam units, proper aiming
is even more important because the increased range
and power of this lamp make even slight variations
from recommended aiming hazardous to approach-
ing motorists. The headlamps must be checked for
proper aim whenever a sealed beam unit is replaced
and after an adjustment or repairs of the front end
sheet metal assembly.
Regardless of method used for checking headlamp
aim, car must be at normal weight, that is, with gas,
oil, water, and spare tire. Tires must be uniformly
inflated to specified pressure. If car will regularly
carry an unusual load in rear compartment, or a
trailer, these loads should be on car when headlamps
are checked. Some States have special requirements
for headlamp aiming adjustment, and these require-
ments should be known and observed.
Horizontal and vertical aiming of each seal beam
unit is provided by two adjusting screws which move
the mounting ring in the body against the tension of
the coil spring. There is no adjustment for focus,
since the sealed beam unit is set for proper focus
during manufacturing assembly.
MAJOR REPAIRHEADLIGHT SWITCH
- OPEL 1900. MANTA
Removal1. Remove instrument cluster cover panel. See Sec-
tion H.
2. Compress retaining springs and pull switch out.
See Figure 1 F-
1.3. Pull multiple socket off switch.
Installation
1: Plug multiple socket in switch and push switch in
panel until clips lock in place.
2. Replace instrument cover and secure with two (2)
screws.

I
GROUP 3
SUSPENSION
AND
STEERING I
SectionTitlePage No
3AFrontSuspension. . . . . . . . . .3A- 2
3BSteering Linkages38-l 9
3C Front End Alignment3C-22
3DSteering Gear.._........3D-27
Steering Column
3E1900 - Manta ,._________...3E-35
GT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3E-42
3FRear Suspension. . . . . . . . .3F-51
3GWheelsand Tires. . . . . . . . . .36-55

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.