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Opel 1900 Service Manual
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Opel 1900 Service Manual

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I
SUSPENSION
AND
STEERING
GROUP 3
Section
3A
Front Suspension . . . . . . . . . .
3B
Steering Linkages
3 C
Front End Alignment
3 D
Steering Gear .._........
I
Steering Column
3E
1900 - Manta ,._________...
GT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Suspension . . . . . . . . .
3G
Wheels and Tires . . . . . . . . . .
Title
Page No

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Summary of Contents for Opel 1900

  • Page 1 Steering Column 1900 - Manta ,._________... GT ........
  • Page 2 1973 OPEL SERVICE MANUAL FRONT SUSPENSION CONTENTS Subject Page No. DESCRIPTION AND OPERATION: Suspension Description ........... .
  • Page 3 GT Front Suspension (Disc Brakes) the upper and lower control arm are not in parallel (anti- dive). The lower control arm is connected to the steering knuckle with a ball joint. Figure 3A-3 Cross Member Marking Figure Front Suspension - Opel 1900 Manta...
  • Page 4 Removal GT 1. Prior to raising front end of car, apply parking Removal Opel 1900 - Manta brake and block rear wheels. 1. Prior to raising front end of car, apply parking 2. Raise front end of car with a jack. It is recom- brake and block rear wheels.
  • Page 5 FRONT SUSPENSION Figure 3A-6 GT Steering Mast Joint Figure 3A-9 Removing Guard Plate 2. Install Hooks J-23697 before jacking up car to assure proper loading of suspension bushings and 7. Suspend engine with a suitable engine lifter, simi- mounts. See Figure 3A-7. lar to the one shown in Figure 3A-9.
  • Page 6 9. Inr;tall mast guide sleeve stop bolt. Always install new lock plate. See Figure 3A-7. 10. Remove front support stands and lower vehicle. Installation Opel 1900 - Manta 1. With jack, lift up front suspension assembly so that the individual attaching points coincide. At the same time, insert lower steering mast into pinion flange.
  • Page 7 The lower ball joints are checked for wear by using Checking Gauge J-23402 for the GT, and using CAUTION: Fasteners are important attachingparts in Checking Gauge J-23745 for the Opel 1900 - Manta. that they could afEct the pertkmance of vital com- See Figure 3A-15.
  • Page 8 1973 OPEL SERVICE MANUAL HOUSING Figure 3A-16 Spring Compressa Figure 3A-14 Lower Ball Joint attachment bolt and swing shock absorber out of the 6. Remove castle nut from ball joint stud. Prior to the removal of the lower ball joint from the control arm, note the position of the locating notch, shown in Figure 3A-17, in the rim of the ball joint housing.
  • Page 9 2. Install dust cap on lower ball joint and fill with 8. Press ball stud out of lower control arm. chassis lubricant. Attach dust cap retainer. Removal Opel 1900 - Manta 3. Press ball joint into steering knuckle. Use J- 9519-3 as installer...
  • Page 10 Do not use a re- placement part or lesser quality or substitute design. Torque values must be used as specified during reas- Figure 3A-18 Lower Ball Joint Notch Opel 1900 - sembly to assure proper retention of these parts. M a n t a...
  • Page 11 FRONT SUSPENSION UPPER CONTROL ARM SHAFT INNER SLEEVE OUTER SLEEVE RUBBER DAMPENIN GUIDE SLEEVE ABSORBER SUPPOR SHOCK ABSORBER SUPPORT ON FRONT SUSPENSION CROSS MEMBER TOOTHED WASHER UPPER CONTROL ARM RUBBER BUSHINGS PLATE WASHER Figure 3A-19 Upper Control Arm Shaft and Bushings placement part of lesser quality or substitute design.
  • Page 12 Release spring compressor and remove control front cross member and remove lower control arm. Installation GT Removal Opel 1900. Manta CAUTION: Fasteners are important attaching parts in that they could affect the performance of vital com- 1. Prior to raising car, install upper control arm ponents and systems, and/or could result in major hooks J-23697.
  • Page 13 30 lb.ft. from steering knuckle. 9. Install nuts on upper shock absorber attaching Removal Opel 1900. Manta studs. Tighten nuts until a distance from top of nut to stud is approximately l/2 inch. 1. Raise car and support with stands.
  • Page 14 7. Install caliper on steering knuckle and torque bolts to 72 lb.ft. See Figure 3A-21. 8. Install wheel and torque wheel nuts to 65 lb.ft. Installation Opel 1900 - Manta Fasteners are important attachingparts in CAUTION: that they could affit the performance of vital com- ponents and systems, and/or could result in ma&...
  • Page 15 SHOCK ABSORBER REMOVAL AND mets when replacing a shock absorber. INSTALLATION 2. Install the lower grommet retainer and grommets Removal Opel 1900. Manta on shock absorber. Compress shock absorber and place in position. 1. Raise car and support with stands.
  • Page 16 9. Slowly lower hoist to release spring tension. Removal (Opel 1900 - Manta) 10. Swing lower control arm downwards and remove front spring. 1. Prior to raising car, install upper control arm hooks J-23697.
  • Page 17 For proper location of the marking lugs, see Figure 5. Attach stabilizer bar to cross member to body support. Installation (Opel 1900. Manta) 6. Install shock absorber and torque lower attaching nut and bolt to 30 lb.ft. CAUTION: Fasteners are important attachingparts in that they co&d affect the performance of vital com-...
  • Page 18 (1 900 Manta) ..............Upper Control Arm Ball Joint to Upper Control Arm Shock Absorber to Lower Control Arm ......Steering Arm to Steering Knuckle (1900 - Manta) ..Brake Backing Plate or Brake Disc Shield and Steering Arm to Steering Knuckle (GTJ Hex Head Bolt M 10 ..
  • Page 19 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...
  • Page 20 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.
  • Page 21 4. Attach rubber bellows to axial joint using hose OUTER TIE ROD CLAMP 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 RETAINER RING rod ball stud from tie rod.
  • Page 22 FRONT END ALIGNMENT CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Front Wheel Alignment ......“......DIAGNOSIS: (Not Applicable) MAINTENANCE AND ADJUSTMENTS: Inspection Before Checking Front Wheel Alignment Adjusting Caster .
  • Page 23 To decrease caster ADJUSTING CASTER (OPEL 1900. MANTA) place one thick washer at the front of the control arm shaft and one thin washer at the rear.
  • Page 24 Figure 3C-3 Upper Control Arm Shaft and Bushings FRONT OF CAR 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.
  • Page 25 The bellows must not be twisted and wire Torque to 29 ft. lbs. on GT and 44 ft.lbs. on Opel ends must show towards steering gear adjusting screw opening.
  • Page 26 With camber known to be within specitied limits, theoretical king pin inclination should check to 8.5 degrees for Opel 1900 - Manta, and 6 degrees for GT. If camber is incorrect beyond limits of adjustment and theoretical king pin inclination is correct, or nearly so, a bent steering knuckle is indicated.
  • Page 27 It is laterally guided by the sintered bronze shell in the adjusting screw opening, and in the short The Opel 1900 - Manta and GT steering gear is the gear housing neck by the rack guide bushing. See rack and pinion type. The steering gear pinion shaft, Figure 3D-3.
  • Page 28 1973 OPEL SERVICE MANUAL FLEXIBLE COUPLING S H A F T . NEEDLE BEARING BUSHING O-RING SEAL Figure 3D-2 Steering Gear Assembly - End View RACK GUIDE Figure 3D-3 Steering Gear Assembly Front View until a resistance is felt. By threading in adjusting...
  • Page 29 Figure 3D-6 Steering Gear Assembly Attaching Bolts Removal (Opel 1900. Manta) Figure 3D-4 Stop Bolt 1. Remove splash shield from lower deflector pa: and both side members. See Figure 3D-7.
  • Page 30 1973 OPEL SERVICE MANUAL 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. CAUTION: Fasteners are important attachingparts in...
  • Page 31 6. From steering gear housing remove “0” rings from retainer and pinion bushing. Also take out thrust washer. See Figure 3D-17. Disassembly (Opel 1900. Manta) Figure 3D-1 1 - Removing Axial Joint 1. Carefully clamp steering gear assembly in soft jaw vise.
  • Page 32 Check that bellows is not twisted and will compress and expand properly. IN FLEXIBLE COUPLING PARALLEL OR Reassembly (Opel 1900 - Manta) 1. Clamp steering gear housing in a soft jaw vise and Figure 3D-14 Installing Pinion Shaft reassemble new “0” rings onto retainer and pinion shaft bushing.
  • Page 33 Tie R o d Ball - Connects to Rack (GT) . Ball Stud - Axial Joint to R a c k ( 1 9 0 0 - M a n t a ) Tie R o d Lock Nut (1900 - Manta) . Bolt Steering Gear Housing to Front Suspension Crossmember (GT) ,,.._.._..........
  • Page 34 1973 OPEL SERVICE MANUAL LOCK PLATE 7, FLEXIBLE COUPLING -/ PINION SHAFI BOLT RUBBER BOOT RETAINER RACK GUIDE BUSHING RACK ADJUSTER SCREW RUBBER BUSHING LOCK NUT BOLT \ Figure 3D-17 Steering Gear Assembly Exploded View...

  • Page 35: Table Of Contents

    OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY 3E.35 OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Description and Operation of Directional Signal Lever ................. .

  • Page 36: Description And Operation Of Horn

    The horn is actuated by pushing on steering mast jacket assembly, especially if removed, the ends of the spokes for the Opel 1900 - Manta and has in contrast with the standard steering to be given by pushing on the center horn button on 57R, 57L, a difierent treatment.
  • Page 37 OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY Figure 3E-7 - Steering Mast Jacket Attachment Figure 3E-5 Steering Column Assembly With Gear replacement of steering column or steering ignition 4. Pull off signal switch, as well as steering and igni- lock parts.

  • Page 38: Removal And Installation Of Steering Wheel

    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.
  • Page 39 OPEL 1900 AND MANTA STEERING COLUMN ASSEMBLY DIRECTIONAL SIGNAL SWITCH This 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.
  • Page 40 (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.
  • Page 41 Steering Column Tightening Specifications Location Part Steering Wheel Retaining (1900 - Manta) .._.._...,,..Steering Column Flexible Coupling (1900 - Manta) ._., N u t Slide Off Base Attaching (1 900 - Manta) ._..,,,,,,.._,,,,,.. N u t Mass Jacket (1 900 - Manta) .,....,,,....,,,,,..,,,,, screw Steering Mast Clamp (1900 - Manta) .,..,.._....
  • Page 42 1973 OPEL SERVICE MANUAL GT STEERING COLUMN ASSEMBLY CONTENTS Page No. Subject DESCRIPTION AND OPERATION: Description of Steering Column ........
  • Page 43 GT STEERING COLUMN ASSEMBLY UPPER STEERING C O L U M N A S S E M B L Y - \ U P P E R U N I V E R S A L J O I N T - STEERING - C E N T E R S T E E R I N G...
  • Page 44 1973 OPEL SERVICE’MANUAL Figure 3E-17 Steering Column Bracket installed in a car it is no more susceptible to damage joints to allow ~for the offset between the steering column and the gear assembly. through usage than an ordinary column; however, when the column is removed, special care must be taken in handling this assembly.
  • Page 45 GT STEERING COLUMN ASSEMBLY loose must never be done. The only recommendation for freeing frozen steering wheels is to use a penetrat- ing lubricant. Installation 1. Before installing steering wheel, lubricate return pin and slide area on direction signal switch return cams and horn ring contact.
  • Page 46 1973 OPEL SERVICE MANUAL Attachments Figure 3E-19 Steering Column 3. Install new tear bolts and tighten until hex head of bolt is tom off. Fasteners are important attaching parts CAUTION: in that they could affect the performance of vital 4. Reconnect ignition and direction signal wire sets.
  • Page 47 GT STEERING COLUMN ASSEMBLY tion signal switch lever into oblong opening in cover 2. Disconnect ignition (white) wire set plug. and push steering lock into housing and remove cover. See Figure 3E-37. 3. Remove steering lock retaining screw. See Figure Figure 3E-22 Figure 3E-20 Steering Lock Retaining Screw 4.

  • Page 48: Switch

    1973 OPEL SERVICE MANUAL 6. Install direction signal switch lever. 7. Install ignition lock cylinder. See previous para- graph in this section. REMOVAL AND INSTALLATION OF UPPER STEERING BEARING AND/OR DIRECTION SIGNAL SWITCH 1. Remove ignition switch and steering lock, see previous paragraph in this section.
  • Page 49 GT STEERING COLUMN ASSEMBLY 4. Install ignition switch and steering lock REMOVAL AND INSTALLATION OF STEERING COLUMN LOWER BEARING The following is with steering column assembly removed. 1. Remove steering wheel. 2. Remove screws securing lower bearing housing to mast jacket. 3.
  • Page 50 L O C A T I O N TORQUE P A R T Steering Wheel Upper Universal Joint - Lower Clamp Upper Universal Joint - Hex Head Bolt Lower Universal Joint Bolt...
  • Page 51 2. Extend shock absorber and position in car. Attach and also to the underbody through rubber bushings at lower end first, torque nut to 15 lb.ft. on the GT, in the central joint support bracket. and torque to 47 lb.ft. on the Opel 1900 - Manta.
  • Page 52 4. Attach shock absorbers and tighten retaining nuts 2. Properly install upper damper rings on springs. to 15 Ib.ft. For the GT and 47 lb.ft. for the Opel 1900 Fasteners are important attaching parts in CAUTION: that they could affect the performance...
  • Page 53 GT, place a load of approximately 150 Ibs. on dri- side member. ver’s seat. Torque control arm attaching nut and bolts to 18 lb.ft on GT’s and 23 Ib.ft. on the 1900 - Manta. Installation 2. Connect parking brake cable to support bracket on control ranI.
  • Page 54 1973 OPEL SERVICE MANUAL DAMPER RING TRACK ROD COIL SPRING SHOCK ABSORBER LOWER RUBBER ’ DAMPER RING REAR AX;E ASSEMBLY COIL SPRING SEAT STABILIZER ROD LOWER CONTROLA R M Figure 3F.5 Exploded View Rear Suspension...
  • Page 55 WHEELS AND TIRES WHEELS AND TIRES CONTENTS Subject Page No. DESCRIPTION AND OPERATION: (Not Applicable) DIAGNOSIS: Car Roughness and Vibration ........Abnormal Tire Wear .
  • Page 56 1973 OPEL SERVICE MANUAL tires that cause vibration as follows: parking brake cable. Spin the other wheel using the same procedure. By spinning the wheels, the offending tire will cause Unbalance vibration that may be felt by touching the bumper or fender.
  • Page 57 Tire grinding is .very effective in eliminating tire complaints due to excessive tire runout. Grinding can be accomplished on or off the car. Grinding is ASSEMBLY CAUSING REPOSITION TIRE/WHEEL approved by Opel, if done as recommended by the VIBRATIONS MOUNTING BY 1 80° equipment manufacturer...
  • Page 58 1873 OPEL SERVICE MANUAL should be deflated and the tire repositioned (indexed) Tire Wear Irregularities 180 degrees from original location. An additional cause of vibrations may sometimes be 5. After repositioning, rebalance tire/wheel assembly tire wear irregularities. These can also produce noise (static and dynamic preferred).
  • Page 59 WHEELS AND TIRES TREAD CONTAil WITH ROAD TREAD CON& I UNDERINFLAlIONI T R E A D C O N T A C T WITH ROAD P R O P E R I N F L A T I O N U N D E R I N F L A T I O N O V E R I N F L A T I O N CENTER OF TREAD WOI...
  • Page 60 1973 OPEL SERVICE MANUAL severe or careless driver. Rapid acceleration and de- Canter or Overinflation Tread Wear celeration, severe application of brakes, taking turns Excessive wheel camber, either positive or negative, at excessive speed, high-speed driving, and striking causes the tire to run at such an angle to the road...
  • Page 61 WHEELS AND TIRES Cornering Tread Wear car driven mostly at highway speeds without recom- mended tire rotation. Factors which promote cup- The modern independently-sprung automobile al- ping include underinflation, incorrect toe-in setting lows the driver to negotiate turns at a high rate of or camber setting, and steady highway speeds on speed with a greater feeling of safety.
  • Page 62 Leak test wheel and tire assembly and if satisfactory, reduce to recommended pressure. SPECIFICATIONS General Specifications Wheels Opel 1900 - Manta and GT ,._..,,,._....,...,,......~,,,....Tires 165-13 GT ..__.._....,...,,..,,,...,,..,..,..,,...,,..,....,,,..... 165-13 Tire Size and Pressures (Pounds Per Square Inch...
  • Page 63 WHEELS AND TIRES would require inflation pressures above the maximum allowable, speed must be limited to 75 miles per hour. Cool tire inflation pressure: After vehicle has been inoperative for 3 hours or more, or driven less than one mile. Hot tire inflation pressure: After vehicle has been driven 10 miles or more at 60-70 MPH.