OPEL GT-R 1973 Service Manual

3D- 341973 OPEL SERVICE MANUALILOCK PLATE
7, @-, FLEXIBLE COUPLING NUTFLEXIBLE
COUPLING
-/BOLTPINION SHAFI
RUBBER BOOT
es+--RETAINER
ew O-RING
‘lNTERED METAL BUSHING 1y STEERING GEAR HOUSING @+ NEEDLE
BEARlNG
y-7RACK GUIDE BUSHING
RACK
he---THRUST SPRINGiRUBBERADJUSTER SCREW
BUSHING
ILOCK NUT
BOLT
\Figure 3D-17 Steering Gear Assembly Exploded View30-17

OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY 3E.35
II
OPEL 1900 AND MANTA STEERING COLUMN
ASSEMBLY
CONTENTS
SubjectPage No.
DESCRIPTION AND OPERATION:
Description and Operation of Directional Signal
Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description
andOperationofHorn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description of Steering Column Assembly
. . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS: (Not
Applicable)
MAJOR REPAIR:
3E-353E-363E-36
Removal and Installation of Steering Column
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RemovalandInstallationofSteeringWheel. . . . . . . . . . . .Disassembly and Reassembly of Direction Signal
Switch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly and Reassembly of Steering and
Ignition Lock Cylinder, and Electrical Switch
from Mast Jacket Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:
Steering
ColumnSpecifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3E-363E-383E-393E-403E-41
DESCRIPTION AND OPERATIONDESCRIPTION AND OPERATION OF
DIRECTIONAL SIGNAL LEVERhigh to low beam or vice versa. On all
19M) Rallye
cars, when switching from low to high beam posi-
tion, with the fog lamp instrument panel switch ON
The direction signal switch lever is a multi- purpose
lever controlling direction signals, passing signal and
headlight high and low beams. See Figure
3E-2.The dire&M signal lever is provided with a two-
step mechanism for operation of headlight high and
low beams, and passing signal (not in N.J.). With
headlights off, moving the lever repeatedly towards
steering wheel flashes headlights as a passing signal.
With headlights on, moving the lever repeatedly to-
wards steering wheel up to first stop also flashes
passing signal regardless whether or not the direction
signals are switched on. When the lever is moved up
to the second stop, the headlights are changed from
SE.2Figure
3E-2 Directional Signal Lever Position for
Headlamp Operation

3E- 361973 OPEL SERVICE MANUAL
and ignition switch in RUN position, the fog lights
are automatically switched off. Direction signals
work in the normal manner; pushing the lever up for
right turn signal and pulling the lever down for left
turn signal.
DESCRIPTION AND OPERATION OF HORN
The horn button is located in the center part of the
steering wheel. The horn is actuated by pushing on
the ends of the spokes for the Opel 1900 - Manta and
by pushing on the center horn button on 57R, 57L,
and GT. The button is provided with a plug connec-
tion for each springloaded plunger. See Figure
3E-3.Figure
3E-3 Horn Button Connections (Opel 1900Manta)DESCRIPTION OF STEERING COLUMN
ASSEMBLYThe steering column mast jacket is provided with a
tube-frame section
.(See B of Figure 3E-4) with
bulges which compresses or folds itself, if a suffi-
ciently large energy is exerted to one or other end of
the steering mast jacket assembly. This tube-frame
section absorbs most of the energy. The steering col-
umn consists of two parts, the upper and lower mast
jacket assembly and’the steering shaft. The
upp,ersteering mast is firmly connected to the tube while
the lower steering mast is clearance-free attached to
the tube by means of injected plastic (See Figure
3E-4). Consequently, the steering mast withstands
all torsional stresses.
As soon as the primary energy becomes effective, the
plastic pins (c) shear off and the steering shaft com-
presses. Thereafter the steering mast jacket is partly
compressed.
A slide-off base is welded to the steering mast jacket.
It is provided with two (2) slots for the respective
attaching bolts. A metal piece (See Figure 3E-4) is
located in each slot which is attached to the slide-off
base with injected plastic. The open sides of the slots
face the driver so that the primary energy cannotpush the steering mast jacket assembly into the pas-
senger compartment. The secondary energy caused
by the driver can on the other hand effect a shearing
of the plastic pins and loosening of the slide-off base
so that it moves downwards. Thereby the steering
mast jacket assembly is compressed further and ab-
sorbs the impact energy to a large extent.
The energy absorbing steering is not more suscepti-
ble to damage than a standard steering. However, the
steering mast jacket assembly, especially if removed,
has in contrast with the standard steering to be given
a difierent treatment.
Figure
3E-4 Energy Absorbing Steering Column
The energy absorbing steering column must by no
means be subject to impacts or blows. A sharp blow
onto the exposed steering shaft ends, leaning onto
steering column or dropping may loosen or even
shear off the plastic attachments which bring about
rigidity of assembly. In spite of a steering column
damaged in this way the operating function of the
steering is retained due to the lateral flattenings on
steering shaft tube and lower steering shaft. How-
ever, after a short period of operation rattling noises
will be noticeable so that the steering column has to
be replaced. For pulling steering wheel off steering
column use appropriate special tool. Therefore, it is
of importance that the instructions for removal and
installation as well as disassembly and assembly are
Strictly adhered to.
MAJOR REPAIRREMOVAL AND INSTALLATION OF
STEERING COLUMN ASSEMBLY
The removal of this assembly is only necessary for

OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY3E- 37
Figure 3E-5 Steering Column Assembly With Gear
replacement of steering column or steering ignition
lock parts.
Removal (Opel 1900 . Manta)1. Disconnect battery.
2. From underside of car, remove clamp screw of
upper steering mast out of universal joint flange. See
Figure
3E-6.Figure
3E-6 Upper Steering Mast Clamp Screw
3. Remove hex nut from steering mast jacket attach-
ment at front of dash panel. See Figure
3E-7.Figure
3E-7 - Steering Mast Jacket Attachment
4. Pull off signal switch, as well as steering and igni-
tion lock wire sets.
5. Unscrew slide-off base from underside of instru-
ment panel and remove steering column assembly
from car. See Figure
3E-8. Carefully put down as-
sembly. Avoid impacts and blows to steering column
assembly.
Figure
3E-8 - Slide-Off Base Attaching Nuts
Installation (Opel 1900. Manta)
CAUTION:
Fasteners are important attaching parts in
that they could affect the performance of
vital com-

3E- 38 ,1973 OPEL SERVICE MANUAL
ponents and systems, and/or could result in major
repair expense. They must be replaced with one or
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.On installation, make sure steering wheel spokes
point downwards and steering gear is in high point.
1. Carefully insert steering mast into universal joint
flange.
2. Loosely attach slide-off base attaching nuts at un-
derside of instrument panel.
3. Attach steering mast jacket at front of dash, using
a notched hex nut.
4. Torque nuts at slide-off base to II
lb.ft.5. Tighten screw at steering mast clamp to 22
lb.ft.6. Reconnect wires to directional signal switch and
ignition switch.
7. Reconnect battery.
REMOVAL AND INSTALLATION OF
STEERING WHEELThis procedure may be performed with the steering
column assembly either removed or installed in the
car.
Removal
1. Disconnect battery.
2. Pry off horn cap and remove wires from cap. See
Figure
3E-3.3. Bend lockplate tabs down and take off steering
shaft nut and lockplate.
4. Install steering wheel remover J-21686 as shown
in Figure
3E-9 and pull off steering wheel.
Installation1. Before installing steering wheel, lubricate return
pin and sliding area on directional signal switch re-
turn cams and horn contact ring.
2. Make sure that clamp bolt in steering shaft flange
is on top.
3. Make sure notch on steering shaft face is in hori-
zontal position.Figure
3E-9 Removing Steering Wheel
4. With the steering wheel centered, place the steer-
ing wheel onto the steering shaft.
5. Install steering wheel lockplate and nut. Torque to
11
lb.ft.
CAUTION:
This steering wheeI to steering shaft fas-
tener is an important attaching part in that it could
affect the
performance of vital components and sys-
tems, and/or could result in major repair expense. It
must be repked
with one of the same part number
or with an equivalent part if replacement becomes
necessary. Do not use a replacement part of lesser
quality or substitute design. Torque
values must be
used as specified during reassembly to assure proper
retention of this part.6. Bend lockplate tabs up, connect horn cap wires
and replace cable and cap.
7. Reconnect battery.
REMOVAL AND REPLACEMENT OF HORN
CONTACT RING
1. Remove steering wheel.
2. Cut off defective contact ring at wire.
3. Strip wire approximately
l/8”.4. Install new part and solder connection with resin
core solder.
5. Lubricate contact ring with lubriplate, or equiva-
lent.
6. Reinstall steering wheel.

OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY3E- 39~~~A~SEMBLY AND ~EASBEMBL~ 0~
DIRECTIONAL SIGNAL SWITCHThis procedure may be performed with the steering
column assembly removed or installed in the car.
Disassembly (Opel 1900. Manta)
1. Remove steering wheel (see paragraph above).
2. Pull off signal switch and steering and ignition
lock wire set.
3. Pull directional signal lever out of seat. Lever is
held in place by a lock ball.
4. Unscrew lower half of signal switch housing cover.
See Figure
3E-10.Figure
3E-1 1 Removing Upper Part of Signal Switch
Housing Cover
Figure 3E-10 Lower Half of Signal Switch Housing
COVSr5. Remove hex nut from steering mast jacket attach-
ment at front of dash panel. See Figure
3E-7.6. Unscrew slide-off base from underside of instru-
ment panel and remove upper part of signal switch
housing cover. See Figure 3E-
11,7. Place a thick piece of wood onto front seat and let
down steering mast jacket assembly. When doing
this, the front seat must be in its front position.
8. Centerpunch tear-off bolt for steering and ignition
lock bracket attachment. Drill a. 12 in. (3mm) diam-
eter hole, using an angular-type drill and with a bolt
remover with left-hand twist screw out bolt. See Fig-
ure
3E-12.Figure
3E-12 Removing Tear-Off Bolt
9. Remove steering and ignition lock, as well as sig-
nal switch from steering mast jacket and
foosefyattach slide-off base below instrument panel.
Reassembly (Opel 1900 - Manta)
1 When replacing a new directional signal switch,
install new bearing and snap ring in switch assembly.
2. Install signal switch, as well as steering and igni-
tion lock, to steering mast jacket. To do this, screw

3E- 40 1973 OPEL SERVICE MANUAL
on steering and ignition lock bracket using a new
tear-off bolt (hexagon head tears
ofD.
3. Disconnect slide-off base, install upper half of sig-
nal switch housing cover, and loosely reattach
slide-
off base.
4. Attach steering mast jacket at front of dash panel.
See Figure
3E-7.
5. Torque slide-off base attaching nuts to 11 lb.ft.
6. Install lower half of signal switch housing cover
and connect signal switch, as well as steering ignition
lock wire set.
7. Install steering wheel and torque nut to 11
Ib.ft.
Always use new lock plate.
DISASSEMBLY AND REASSEMBLY OF STEERING
AND IGNITION LOCK CYLINDER AND ELECTRICAL SWITCH FROM MAST JACKET
ASSEMBLY
Disassembly. GT
Disconnect the battery before proceeding.
1. Remove steering wheel.
2. Turn ignition switch to ON position.
3. Insert a suitable rod into stop pin hole on side of
steering and ignition lock (See Figure
3E-13) and
take out steering and ignition lock cylinder. 4. Remove two screws securing electrical switch to
steering and ignition lock housing and take out
switch.
Disassembly (Opel 1900 . Manta)
1. Rezmove steering wheel.
2. Unscrew split signal switch housing cover and
remove lower half. See Figure
3E-10.
3. Remove lock cylinder by pushing in lock spring of
the cylinder using a piece of wire. Cylinder must be
in the
” 1” position. See Figure 3E-14.
Figure 3E-14 Removing Lock Cylinder
Reassembly
1. On the GT reassemble electrical switch into steer-
ing and ignition
lock housing and rotate switch until:
(1) cam in lock housing recess fits into slotted hole
in rear of electrical switch, and (2) projection on
electrical switch fits into recess on lock housing.
2. On the Opel 1900
- Manta, insert lock cylinder in
the
P l* position into housing. Install lower half of
signal switch housing.
3. Reinstall steering wheel.
Figure 3E-13 Removing Ignition Lock Cylinder

OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY3E- 41
SPECIFICATIONS
Steering Column Tightening Specifications
PartLocationToraue
1b.k.Nut
Steering Wheel Retaining (1900
- Manta) .._......._...,,....BoltSteering Column Flexible Coupling (1900 - Manta) ._.,
NutSlide Off Base Attaching (1 900 - Manta) ._..,,,,,,...._,,,,,..
NutMass Jacket (1 900
- Manta) .,............,,,............,,,,,.......,,,,,
screw
Steering Mast Clamp (1900
- Manta) .,.........,.._...............1122
10::

3E- 421973 OPEL SERVICE MANUAL
GT STEERING COLUMN ASSEMBLY
CONTENTS
Subject
DESCRIPTION AND OPERATION:
DescriptionofSteeringColumn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS: (Not
Applicable)
MAJOR REPAIR:
RemovalandInstallationofSteeringWheel. . . . . . . . . . . .Removal and Installation of Ignition Lock
Cylinder
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation of Steering Column
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation of Center Steering Shaft
Removal and Installation of Ignition Switch
and/or Steering Lock
.,~ ,........ ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal and Installation of Upper Steering
Bearing and/or Directional Signal Switch
. . . . . . . . . . . .Removal and Installation of Steering Column
Lower Bearing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPECIFICATIONS:
Steering Column Torques
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page No.
3E-42
3E-44
3E-45
3E-45
3E-46
3E-46
3E-48
3E-49
3E-50
DESCRIPTION AND OPERATION
DESCRIPTION OF STEERING COLUMNThe Energy Abosrbing, Locking Steering .Column
assembly is used on the GT. This cohnnn is designed
to compress under impact. When an automobile is
being driven, the forward movement of the automo-
bile and the forward movement of the driver both
constitute a form of energy or force. When an au-
tomobile is involved in a frontal collision, the pri-
mary force (forward movement of the car) is
suddenly halted, while the secondary force (the
driver) continues its forward direction. A severe col-
lision generally involves these two forces
- the pri-
mary and the secondary forces. The secondaryjmpact occurs when the driver is thrust forward onto
the steering wheel and column.
The Energy Absorbing Column is designed to absorb
these primary and secondary forces to the extent thatthe severity of the secondary impact is reduced. Dur-
ing a collision, the steering column compresses and
thereby reduces its tendency to move rearward into
the driver’s compartment. A split second later when
the driver is thrown forward (the secondary impact)
his energy is also partially abosrbed by the compres-
sion characteristics of the column.
The Energy Absorbing, Locking Column assembly
may be easily disassembled and reassembled. The
serviceman should be aware that it is important that
only the specified screws, bolts and nuts be used as
designated during reassembly, and that they are
tightened to their specified torque. This precaution
will insure the energy absorbing action of the assem-
bly. Particular care should be exercised to avoid us-
ing overlength bolts as they may prevent a portion of
the assembly from compressing under impact.
Equally as important is correct torquing of all bolts
and nuts.
When the Energy Absorbing, Locking Column is

GT STEERING COLUMN ASSEMBLY3E- 43
UPPER STEERING
COLUMN ASSEMBLY-\-AUPPER UNIVERSAL JOINT-
STEERING
-CENTER STEERING SHAFT
LOWER UNIVERSAL JOINT
Figure
3E-15 GT Steering Column Assembly
_--7FORCE
PRIMARY FORC
/FORCES
BEFORE
COLLISIONI ST STAGE
(PRIMARY COLLISION)2ND STAGE
(SECONDARY COLLISION)3E-16
Figure
3E-16 Reaction of Forces in a Collision