1973 OPEL GT-R Service Manual

MM Inches.Ol.ocQ4
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.06.0024
.07.0028
.08.0032
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.I3.0051
.14.0055
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.16.OM3
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.22.0087MM InchesMM InchesMM InchesMM InchesMM Inches
23.0091A4.0173.65.025637.03439.354324
.0095.45.0177.66II260233.034710.3937
.25Al098.46.0181.67.0264.89.0350
.26.0102.47.0185.68.0268.90.035411.4331
.27.0106.48.0186.69~3272-12.4724
.28.OllO.49.0193.70.0276.91.035813.5118
.29.0114.50.0197.92I136214.5512
.30.0118.71.0280.93.036615.5906-
[email protected]
.31.0122.52.0205.73.0287.95.037417.6693
.32.0126.53.cRo9.74.0291.96.037818.7087
.33.0130.54ml3*75*0295.97.038219.7480
.34.0134.55.0217.76SE’99.98.038620.7874
.35.0138.56.0221.77.0303.99a390
.36.0142.57.0224.78.03071.00.039421.8268
.37.0146.58.0228.79.031122.8661
.38.0150.59.023230.03151.039423.9055
.39.0154.60.02362.078724.9449
.40.0158.81.03203.118125.9&13
22.0323
4.1575261.0236
.61.024033.03275.1969271.0630
.41.0161.623244.&I.0331
6.2362281.1024
.42.0165.63.0246.85.03357.2756291.1417
.43.016954.0252.86.03398.3150301.1811
* (one MM = .0394”; one inch = 25.4 MM)4538
Figure 48-38 Conversion Table
- Millimeter to Inch Equivalent

IREAR AXLE48.27J-21691-6
J-22935
J-22936
J-22919J-22931J-8872J-2241-1 I J-7818
J-22938J-24093
J-22937
J-22588Figure
48.39 Differential Special Tools

BRAKES
GROUP 5
Section
5A
5B
5C
Title
Brake Booster and
Master Cylinder
Disc Brakes
.._.__.._____
Drum Brakes. . . . . . . . . . . . .
Page No.
5A- 2
5B-10
5C-22

CONTENTS
SubjectPage No.
DESCRIPTION AND OPERATION:
Power
BrakeBooster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Master
Cylinder
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DIAGNOSIS:
Power
Brake
,UnitTroubleDiagnosis. . . . . . . . . . . . . . . . . . . . . . . . . .MAINTENANCE AND ADJUSTMENTS:
Checking Brake Booster Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Booster Filter Service
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..Vacuum Control Valve Service
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MAJOR REPAIR:
5A-2
5A-2SA-4SA-5
5A-65A-6
Brake Booster Removal and Installation
. . . . . . . . . . . . . . . . . .Master Cylinder Overhaul
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * . . . . . . . . . . .SPECIFICATIONS:
General
Specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SA-6
5A-7
5A-95A. 21973 OPEL SERVICE MANUAL
POWER BRAKE BOOSTER AND MASTER CYLINDER
DESCRIPTION AND OPERATION
POWER BRAKE BOOSTERThe vacuum power cylinder contains the power pis-
ton assembly which houses the control valve and
reaction mechanism and the power piston return
spring. The control valve is composed of the air valveand the floating control valve assembly. The reaction
mechanism consists of a hydraulic piston, reaction
plate, and a series of springs. An air filter element is
assembled around the push rod and fills the cavity
inside the hub of the power piston. This keeps dirt
and dust from entering the vacuum booster. The
push rod, which operates the air valve, projects out
of the end of the power cylinder ‘housing through a
boot.MASTER CYLINDER
The master cylinder is composed pf a primary pistonand secondary piston; it is supplied with fluid from
two separate reservoirs. A check valve is mounted onthe primary circuit which supplies fluid to the rear
brakes. This keeps a slight static pressure in the rear
brake system. When the pedal is depressed, the pushrod moves the two pistons forward simultaneously
until the seals of the two pistons cover the compen-
sating ports in the cylinder. The pressure is increasedin the two chambers simultaneously, thus supplying
fluid to both front and rear brake systems.Figure
5A-1 Brake Booster Attachment (Opel 1900
and Manta)
In the GT, the brake fluid container is arranged at
right angles to the tandem brake master cylinder. SeeFigure
5A-3. It is pushed over the feed port of the
rear brake circuit onto the brake master cylinder and

POWER BRAKE BOOSTER AND MASTER CYLINDER5A- 3
Figure 5A-2 Exploded View Master Cylinder (Opel 1900 and Manta)
held in position by a retaining plate. The front brake
circuit is connected to the brake fluid container by a
hose and a connector. See Figure
5A-4.An offset brake actuating rod, consisting of pedal
rod, adjuster and connecting tube, is used between
the brake pedal, the tandem brake master cylinder
and brake booster respectively. The connecting tube
is pressed onto the pedal rod and adjuster. The speci-
fied brake pedal free travel of
l/4 inch is obtained by
adjusting the brake booster piston rod and lock nut
of the adjuster.
VACUUM CONTROL VALVEhose between the intake manifold and the brake
booster and serves to prevent air from flowing back
(vacuum release) when the engine is shut off. See
Figure 5A-5.
This valve cannot be disassembled andmust be replaced when defective. To do this, the
short hose should be used between the intake mani-
fold and the vacuum control valve and the long hose
between the vacuum control valve and the brake
booster. Arrows on the valve housing indicate its
correct position in the line. Should a vacuum control
valve be installed backward no air could be drawn
out of brake booster, thus rendering it inoperative.
Hose clamps should be installed to prevent the possi-
bility of vacuum leaks.
A vacuum control valve is installed into the vacuum

5A- 41973 OPEL SERVICE MANUAL
Figure
5A-4 Brake Pedal and Master Cylinder
Attachment
(GT)
v1I cy
1 THRUST SPRING
2 VALVE SEAT
3 HOUSING
Figure
5A-5 Vacuum Control Valve
DIAGNOSIS
POWER BRAKE UNIT TROUBLE DIAGNOSIS
ConditionPossible Cause
CorrectionHard Pedal
1. Broken or damagedhydraulic
brake lines.
1, Inspect and replace as necessary.
2. Vacuum failure.
2. Check for:a) Faulty vacuum check valve or
grommet
- replace.
b) Collapsed or damaged vacuum
hose
- replace.
c) Plugged or loose vacuum
fitting
- repair.
d) Faulty air valve seal
drsupport plate seal
- replace.
e) Damaged floating control valve.
3. Defective diaphragm.
4. Restricted air filter
element.3. Replace
4. Replace5. Defective apply piston5. Repair and replace master
seals.cylinder.
6. Cracked or broken powerpistons or retainer.6. Replace power unit.

POWER BRAKE BOOSTER AND MASTER CYLINDER5A- 5ConditionGrabby Brakes (Apparent
Off-and On Condition)
Possible Cause1. Broken or damaged
hydraulic brake lines.Correction1. Inspect and replace, as
“CXXSSary.2. Insufficient fluid in
master cylinder.
3. Defective master cylinder
seals.4. Cracked master cylinder
casting.2. Fill reservoirs with approved
brake fluid check for leaks.
3. Repair or replace, asnecessary.4. Replace
5. Leaks at front disc brake
calipers or rear wheel
cylinders
in pipes or connections.5. Inspect and repair, as
necessary.Brakes Fail to Release6. Air in hydraulic system.
1. Blocked passage in power
piston.
2. Air valve sticking shut.6. Bleed system.
1. Inspect and repair or replace,
as necessary.
2. Check for proper lubrication of
air valve “0” ring.
3. Broken piston return spring
3. Replace
master cylinder.
4. Tight pedal linkage.5. Repair or replace, as
necessary.
MAINTENANCE AND ADJUSTMENTS
CHECKING BRAKE BOOSTER OPERATIONThe operation of the brake booster can be checked by
simple means and without any special devices.
1. With engine off, first clear the booster of any
vacuum by depressing brake pedal several times.
2. Then depress brake pedal and start engine. If the
vacuum system is working correctly, the brake pedal,
kept under even foot pressure, moves farther down-
wards due to the additional pressure developed by
the booster. Should the brake pedal not move farther
downwards, the vacuum system is deficient. In this
case check the vacuum hose to booster, to vacuum
control valve and to engine intake manifold connec-
tions.3. If the vacuum system operates properly, the defect
is in the brake booster itself. A dirty filter impairs oreven prevents air from entering into the booster and
thereby the formation of a difference in pressure in
the vacuum cylinder.
Repairs cannot be carried out on the brake booster.
If no deficiency can be found in the vacuum system
or filter, the brake booster has to be replaced.
Under normal operating conditions the brake
booster requires no service. However, under adverse
conditions such as frequent driving on sandy or
dusty roads, the filter and sound deadener should be
replaced occasionally. To do so, the brake booster
must be removed but it isn’t necessary to detach the
master cylinder.
BRAKE BOOSTER FILTER SERVICEUnder normal operating conditions the filter need
not be exchanged for a new one.
Under adverse operating conditions
- frequent driv-