lock OPEL GT-R 1973 Manual PDF

3A- 101973 OPEL SERVICE MANUAL
Figure 3A-18 Lower Ball Joint Notch Opel 1900 -
MantaUPPER CONTROL ARM REMOVAL AND
INSTALLATION
Removal GT1. Raise car and support at rear of front frame rails.
2. Remove front wheel.
3. Install spring compressor and compress spring
until there is 3-l/8” between compressor and lower
spring leaf.
4. Remove cotter pin and castle nut from upper ball
joint stud. Discard cotter pin.
5. Use tie rod remover J-21687 remove ball jointfrom.steering knuckle. 6. Support brake drum to
relieve tension on brake hose.
7. Remove hex nut from upper control arm shaft.
Remove shaft and washers from shock absorber sup
port. Do not damage threads on control arm shaft.
8. Remove control arm from car. Do not lose inner
toothed washers. Note size and location of toothed
washers.Removal
Opel 1900 . Manta
1, Raise car and support at rear of front frame rails.
2. Remove front wheel
3. Unscrew upper control arm to cross member
self-locking attaching nut.4. Unscrew ball joint from upper control arm. Do not
turn upper control arm ball joint flange, as this
would result in a change of camber.
5. Support front wheel hub so that brake hose is not
stressed.6. Pull out upper control shaft to cross member at-
taching bolt and remove control arm. Shims have to
be reinstalled in their original location to maintain
the proper caster setting.
Installation GT
CAUTION:
Fasteners are important attaching parts in
that they could affect the the
perfonmmce of vital
components and systems, and/or could result in ma-
jor 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 quality or substitute design.
Torque values must be used as specified during reas-
sembly to
assure proper retention of these parts.If rubber bushings on control arms are worn, arms
must be replaced.
1. Slide rubber rings over bushings. Slide rings over
inner sleeves of bushings. Place control arm in posi-
tion on shock absorber support, installing toothed
washers in their original positions. See Figure 3A-
19.2. From front to rear, install control arm shaft. If
necessary, align washers and control arm bushings
with a small drift prior to installing control arm
shaft. See Figure
3A-19.3. Tighten hex nut on control arm shaft finger tight.
4. Increase tension on spring compressor in order to
relieve tension on control arm shaft. Then torque hex
nut on control arm shaft to 33
Ib.ft.5. Press ball joint stud into steering knuckle and
torque castle nut to 29 lb.ft. Install new cotter pin.
6. Remove spring compressor and lower car.
7. Check front end alignment.
Installation Opel 1900. Manta
CAUTION:
Fasteners are important attaching parts in
that they could at?&
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 equivalent parts, if
replacement becomes necessary. Do not use a
re-

FRONT SUSPENSION3A- 11UPPER CONTROL ARM SHAFT
INNER SLEEVE
OUTER SLEEVE
RUBBER DAMPENIN
GUIDE SLEEVE
ABSORBER SUPPOR
SHOCK ABSORBER SUPPORT
ON FRONT SUSPENSION
CROSS MEMBER
-TOOTHED WASHER
l-UPPER CONTROL ARM
RUBBER BUSHINGS
PLATE WASHER
Figure
3A-19 Upper Control Arm Shaft and Bushings
placement part of lesser quality or substitute design.
Torque
valves must be used as specified during reas-
semb/y to assure proper retention of these parts.1. On installation of the upper control arm, make
sure that damper bushing with the rubber shoulder
on both sides is always located in the rear.
2. Attach upper control arm to cross member and
torque to
40 lb.ft. Always use new self-locking hex
nut. The upper control arm must be tightened in
horizontal position only. This applies also to all other
attaching joints in connection with rubber damper
bushings in the control arms of the front suspension
so that the rubber parts under load are in an almost
twist-free condition. This position exists, if the hooks
J-23697 are used.
3. Attach ball joint to upper control arm and torque
to 29
lb.ft.4. Install wheel and torque nuts to 65
lb.ft. Lowercar.LOWER CONTROL ARM REMOVAL AND
INSTALLATION
Removal GT
1. Raise car and support at rear of front frame rails.
2. Remove front wheel.
3. Remove cotter pin from castle nut on ball joint
stud and back off castle nut two (2) turns. Hit ball
stud a sharp blow to break it loose. DO NOT
REMOVE NUT.
4. Install spring compressor (J-21689) and compress
spring until a distance of
3-l/8 inches is achieved
between spring compressor and lower spring leaf.
5. Disconnect and compress shock absorber.
6. Support rail of spring compressor with a jack.
Remove lower control arm from frame cross mem-
ber. Nuts may have to be removed with a punch. See
Figure 3A-20. Discard the lock nuts.
7. Remove lower ball joint stud nut. Slightly lower

3A- 121973 OPEL SERVICE MANUAL
Figure 3A-20 Lower Control Arln Attachment
jack so that spring and lower control arm assembly
is removed from the front cross member and steering
knuckle.
8. Lower jack, spring compressor, and front spring
with control arm assembly. Remove lower control
arm to spring nuts.
9. Release spring compressor and remove controlarm attaching bolts and control aRn.
Removal Opel 1900. Manta1. Prior to raising car, install upper control arm
hooks J-23697.
2. Raise car and support 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. In lower control arm, remove self-locking hex
head bolt from stabilizer support and remove
washer.6. Using a pry bar, pry stabilizer bar out of lower
control arm support.
7. Remove shock absorber.
8. At lower control arm ball joint, remove castle nut
cotter pin and remove nut.
9. With suitable drift, detach lower control arm ball
joint from steering knuckle.10. Loosen nut that retains lower control to front
cross member.
11. Slowly lower hoist to release spring tension.
12. Swing lower control arm downwards and remove
front spring.13. Remove nut that retains lower control arm to
front cross member and remove lower control arm.
Installation GT
CAUTION:
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 expeme. 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 parts1. Attach lower control arm to front spring eye.
Torque bolts to 18
1b.R.2. Install spring compressor and with a jack raise
spring compressor with spring and control arm as-
sembly into position for pressing ball joint into steer-
ing knuckle.
3. Press ball joint into steering knuckle. Use
J-;lYN;: as installer and J-21690 as a supporting
4. Install castle nut on ball joint stud and torque to
54
lb.ft. Install new cotter pin.
5. Attach lower control arm to frame cross member
using new lock nuts.

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

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-24 1973 OPEL SERVICE MANUAL
NOTE:
FRONT OF CAR
4Figure
3C-3 Upper Control Arm Shaft and Bushingsx.3
Figure
3C-4 Supporting Vehicle at Both Lower
Control Arms(B) (rear) between upper control arm and shock ab-
sorber support. See Figure
3C-5.5. One
.24” thick washer each is installed in produc-
tion on each car side. Consequently, only two adjust-
ments are possible by adding washers of different
thickness.
6. One
.12” in front and one .36” in the rear (caster
increase of 1 degree) or one
.36” in front and one. 12”
in the rear (caster decrease of 1 degree). Never addFRONT OF CAR
3G5
Figure
3C-5 Caster Adjustment Washer Location -Opel 1900 - Manta
several washers in one place. The washers B installed
in production have a larger outer diameter than the
washer A. For service, the Parts and Accessories
Department supplies only larger washers with an
outer diameter of 1.57”.
7. Insert control arm shaft from front towards the
rear into upper control arm and shock absorber
SUP-port. Observe that the crown of both plate washers
shows inwards. See Figure
3C-5.8. Torque hex nut of control arm shaft to 40 ft.lbs.
Always use new self-locking nut.
9. Torque wheel nuts to 75
ft.lbs.10. Recheck caster setting.