ECU OPEL GT-R 1973 Owner's Manual

2H-381973 OPEL SERVICE MANUAL
BUMPERS
CONTENTS
Subject
DESCRIPTION AND OPERATION: Protective Moldings
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . *. . . . . . . . . . . . . . . . .
DIAGNOSIS: (Not Applicable)
MAINTENANCE AND ADJUSTMENTS: (Not
Applicable) MAJOR REPAIR: Removal and Installation
1900
- Manta. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GT. . . . . . . . . . . . . . . . . . . . . . . . . . . * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . . . . . . . . . . .
Trailer Hitch Installation, . , . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . . . . .
SPECIFICATIONS: (Not Applicable) Page No.
2H-38
2H-38
2H-39
2H-41
DESCRIPTION ‘AND OPERATION
PROTECTIVE MOLDINGS
All 1973 Opel bumpers are equipped with rubber
protective moldings as standard equipment. The
moldings are easily removed by removing the attach-
ing nuts located on the inboard side of the bumper.
MAJOR REPAIR
REMOVAL AND INSTALLATION OF FRONT
BUMPER AND BUMPER GUARDS
(OPEL 1900 -
MANTA)
Removal
1. Remove bumper attaching screws on inside
- left
and right
- and from left and right brackets. See
Figure
2H-2.
2. From the front, unscrew bumper guard attaching
screws. See Figure‘
2H-2.
Remove bumper and bumper guards.
Installation
1. Attach bumper guards to bumper.
Figure ZH-2 Bumper Attaching Screws
2. From the front, secure bumper guards with attach-
ing screws. See Figure
2H-2.
3. Install attaching bolts on left and right brackets,
and on left and right inside. See Figure
2H-2.
REMOVAL AND INSTALLATION OF FRONT
BUMPER BRACKETS (OPEL 1900
- MANTA)
The front bumper brackets are attached with three
screws. Removal of the three screws will allow re- moval and installation of the front bumper brackets.
See Figure
2H-3.
REMOVAL AND INSTALLATION OF REAR
BUMPER AND GUARDS (OPEL 1900
- MANTA)
1. Remove license plate lamp.
2. Remove bumper attaching screws and bumper
brackets. See Figure
2H-4.

BUMPERS21-1-39--..,2H-3 i
Figure ZH-3 Bumper Bracket Screws
Figure ZH-4 Bumper Attaching ScrewsREMOVAL AND INSTALLATION OF FRONT REMOVAL AND INSTALLATION OF FRONT
BUMPER ASSEMBLY
(GT)BUMPER ASSEMBLY (GT)1. Remove grille. 1. Remove grille.
2. Disconnect bumper at points shown in Figure2H-5 and remove bumper. 2. Disconnect bumper at points shown in Figure2H-5 and remove bumper.
Installation
Installation1. Install bumper and secure at points shown in Fig-
ure 2H-5. 1. Install bumper and secure at points shown in Fig-
ure 2H-5.
RemovalFigure ZH-6 Removing Tail Lamp Assembly
Figure 2H-5 Front Bumper Attaching Points
Figure 2H-7 Rear Bumper Attaching Points

z-l-401973 OPEL SERVICE MANUAL
2. Install grille.
REMOVAL AND INSTALLATION OF REAR
BUMPER ASSEMBLY (GT)
Removal1. Remove tail lamp assembly. See Figure 2H-6.2. Remove bumper attaching nuts accessible through
lamp opening. See Figure 2H-7.Installation1. Install bumper and secure with attaching nuts
accessible through lamp opening. See Figure 2H-7.
2. Install tail lamp assembly. See Figure 2H-6.

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 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.

3D- 321973 OPEL SERVICE MANUAL
Figure 3D-13 Steering Gear Housing With Rack
Check to insure that three air channels of sintered
metal bushing (See Figure 3D-17) are not obstructed
by lubricant. If air channels are blocked, a vacuum
condition in the bellows may result during operation
of the gear assembly. Under such circumstances, the
bellows will be drawn inward and jam into the rack
teeth.
3. Reassemble pinion shaft into gear assembly so that
spline in pinion shaft meshes with twelfth tooth of
the rack. Use pinion mounting sleeve J-21712 during
installation of pinion shaft to avoid damage to “0”
ring in pinion bushing. When reassembling pinion
shaft into gear housing, be sure that pinion is so
positioned that bolt hole in pinion shaft flexible cou-
pling is on top and parallel to the rack. See Figure3D- 14..~.. ~. ..~.IN FLEXIBLE
COUPLING PARALLEL ORRIZONTAL WITH R
._..-_ - -._..-
Figure 3D-14 Installing Pinion Shaft
4. Reassemble special washer, flat washer, and new
pinion nut onto pinion shaft. Torque pinion nut to 11
Ib.ft. Do not exceed torque due to possibility ofjam-
ming gear.
5. Place sintered bronze shell into steering gear hous-
ing and fill adjusting hole with Calcium Soap No. 2.
6. Reassemble thrust spring, adjuster screw and lock-
nut on gear assembly.
Final adjustment of adjuster screw is performed after
gear assembly and tie rods are installed in car. See
Maintenance and Adjustments in this section for ad-
justment of steering gear.
7. Place rubber bellows, clamps, and new lock plates
on ball stud portion of tie rods; and screw ball studs
into rack while holding bent tab of lock plate against
flat
ton rack. Torque ball studs 43 lb.ft. See Figure
3D-9. It is important that rack be held secure with
open end wrench to prevent damage to rack teeth.
8. Bend round edges of lock plate over flat on ball
stud to lock ball stud in position. See Figure
3D-15.Figure 3D-15 Bending Lock Plate Over Ball Stud
9. Properly position rubber bellows and clamps over
tie rod and gear housing and adjust clamps so that
ends are pointing same direction as adjusting screw.
Check that bellows is not twisted and will compress
and expand properly.
Reassembly (Opel 1900 - Manta)1. Clamp steering gear housing in a soft jaw vise and
reassemble new “0” rings onto retainer and pinion
shaft bushing. Also, install thrust washer onto pinion
bushing.
Coat all moving parts during reassembly with suita-

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

GT STEERING COLUMN ASSEMBLY3E- 47
2. Disconnect ignition (white) wire set plug.
3. Remove steering lock retaining screw. See Figure3E-20.Figure 3E-20 Steering Lock Retaining Screw
4. Remove direction signal switch lever.
5. Remove three screws securing signal switch cover
to housing.
6. To remove housing cover, (a) pull cover toward
direction signal switch and move it slightly to the
right. See Figure
3E-21. (b) Turn cover toward the
left and move it further to the right so that the left
retaining screw ear is positioned under the left signal
switch return cam. See Figure
3E-22. (c) Insert direc-
Figure 3E-2 1tion signal switch lever into oblong opening in cover
and push steering lock into housing and remove
cover. See Figure
3E-37.Figure
3E-22Figure 3E.23
7. Remove ignition switch electrical unit. See Figure3B24.
8. Remove wires from connector plug making certain
to note location of each.
9. Tape wire ends together and remove electrical unit
and wire harness.
Installation1. Position electrical unit wire harness through col-
umn and reconnect to connector plug.