parking brake OPEL GT-R 1973 Owner's Manual

Figure 5C-53 Rear Brake Assembly
10. Check all backing plate attaching bolts to make
sure they are tight. Using line emery cloth, clean all
rust and dirt from shoe contact surfaces on plate. See
Figure Z-53.
Relining Brake ShoesIf old brake shoes are to be relined, inspect shoes for
distortion and for looseness between the rim and
web; these are causes for discarding any shoe. If
shoes are serviceable, be governed by the following
points in installing new linings:
1. Remove old rivets by drilling them out. Punching
out rivets will cause distortion of shoe rim. Care5C- 301973 OPEL SERVICE MANUAL
must also be taken to support shoes properly while
drilling.
2. Thoroughly clean brake shoes and remove all
burrs around rivet holes.
3. Use Opel brake lining or equivalent. Install in
place and rivet in sequence shown in Figure
Z-54.Keep hands clean while handling brake lining. Do
not permit oil or grease to come in contact with
lining.
Installation and Adjustment
1. If any hydraulic conne&tions were disturbed, bleed
hydraulic system. If new parts were installed in
brake system, flushing of hydraulic system is recom-
mended.
2. Adjust rear wheel brakes.
3. Adjust parking brake.
4. Check fluid level in master cyliner and add fluid
if necessary.
5. Check brake pedal for proper feel and for proper
return.
6. Remove jacks and road test car for proper brake
action. Brakes must not be severely applied immedi-
ately after installation of new brake shoes or linings.
Severe application may perinanently injure new lin-
ings and may score brake drums. When linings are
new, they must be given moderate use for several
days until burnished.
INSPECTING AND RECONDITIONING
BRAKE DRUMSWhenever brake drums are removed, they should
bethoroughly cleaned and inspected for cracks, scores,
deep groves, and out-of-round. Any of these condi-
tions must be corrected since they can impair the
efficiency of brake operation and also can cause
premature failure of other parts.
Cracked, Scored or Grooved DrumA cracked drum is unsafe for further service and
must be replaced. Welding a cracked drum is not
recommended.
Smooth up any slight scores by polishing with tine
emery cloth. Heavy or extensive scoring will cause
excessive brake lining wear and it will be necessary
to rebore in order to true up the braking surface.
Figure 5C.54 Brake Lining Riveting
SequenceIf the brake linings are slightly worn and drum is
grooved, the drum should be rebored just enough to

5C- 321973 OPEL SERVICE MANUAL
Never use copper tubing because copper is subject to
fatigue cracking which would result in brake failure.2. Cut tubing to length. The correct length may be
determined by measuring the old pipe using a cord
and adding l/8” for each double lap flare.
To make up a brake pipe assembly, proceed as fol-
lows:3. Double lap flare tubing ends, using a suitable flar-
ing tool such as J-8051. Follow the instructions in-
cluded in the tool set. Make sure fittings are installed
1. Procure the recommended tubing and fittings of
the correct size. (Outside diameter of tubing is used
to specify size.)before starting second flare.
4. Bend pipe assembly to match old pipe.
SPECIFICATIONS
BRAKE SPECIFICATIONS
Torque Specifications
Use a reliable torque wrench to tighten the parts listed to insure proper
tightness without straining or distorting parts. These specifications are for
clean and lightly-lubricated threads only; dry or dirty threads produce in-
creased friction which prevents
accurage measurement of tightness.
PartName
TorqueNut
BoltBrakeHose to Front WheelBrake Cylinder
Brake Backing Plate to Steering Knuckle(Uccer
Bolts)Lb&.
22
22...BoltBrake Backing’Plate to Steering Knuckle and
SteeringArm(Lower
Bolts)............................................
BoltBackingPlatetoRearAxleHousing................................
NutMaster Cylinder Actuator Rod to BrakePedal
..............
BoltWheelBrake Cylinder to Brake Backing Plate
..............
General Specifications47
43
5
5OperatingMechanism,ServiceBrakes
....................................................................Hydraulic
Parking Brakes
..........................................................................................Lever and Cables
Operation of Service Brakes Independent of
ParkingBrakes
..................................................................................................................Yes
WheelBrakes,Service
......................................................................................FrontandRear
Parking.
..................................................................................................................Rear Only
BrakePedalHeightAdjustment......................................................................................None
Static Pressure in Hydraulic System When Brakes
are Released
- Drum Brakes................................................................................4 psi Min.
Static Pressure in Hydraulic System to Rear
BrakesOnly
-DiscBrakes..................................................................................
4psiMin.
Brake Master Cylinder (for Drum Brakes) Bore
............................................................13/16
Wheel Cylinder Size
- Rear - All.......................................................................................: 5/8
Approved Hydraulic Brake ,Fluid
..........................................GM or Delco Supreme No. 11
Fluid Level in Reservoir
..........................................................................Fill to “Max.” Level
BrakeDrumRebore,Max&urnAllowable Inside
Diameter........................................
9.090Max. Allowable Out-of-Round
...........................................................................................CKl4Rear Brake Drum Size. New
............................................................................................
9.060

7A- 41973 dPEL SERVICE MANUALConditionPossible CauseCorrectionHeat-blued driven plate
and pressure plate
assembly.
1. Improper pedal1. Replace only driven plate, and
adjustment.adjust clutch pedal and cable.
Grab and chatter with
oil present on clutch
assembly.1. Oil leak.1. Correct oil leakage, clean
pressure plate in solvent, replace
driven plate and adjust pedal lash.
MAINTENANCE AND ADJUSTMENTS
CLUTCH LASH ADJUSTMENT
GTPedal lash, free pedal travel must be adjusted occa-
sionally to compensate for normal wear of the clutch
facings. As the driven plate wears thinner, pedal lash
decreases. Adjust clutch pedal free travel only with
ball stud located on right side of clutch housing if
cable length is not to be changed. To adjust pedal
lash proceed as follows:
1. Loosen lock nut on ball stud end located to the
right of the transmission on the clutch housing. Posi-
tion ball stud so that the outer end protrudes 3/4
inches out of housing and finger tighten lock nut. See
Figures
7A-1 and 7A-6.
2. Adjust ball stud, pivoting clutch release fork, to
obtain 3/4 to
l-1/4 inches pedal lash, free pedal. See
Figure 7A-6.
Opel 1900 and MantaThe clutch actuation works without clutch pedal free
travel. A readjustment of the clutch is only required
if the indicator lamp at the instrument panel lights
up.In synchronism with the gradual wear of the clutch
linings the clutch pedal travels from its basic adjust-
ment position upwards,
ie., towards driver. If the
clutch lining wear has reached such an extent that
the clutch pedal rests against switch, the indicator
lamp at the instrument panel lights up.
This is an indication that the clutch pedal position
has to be corrected to ensure proper clutch operat-
ion.
To
&~sure proper clutch operation, observe the fol-
lowing adjustment instructions.. For all adjustment
dimensions, refer to Figure 7A-7.
1. If the parking brake is provided with an indicator
lamp, the parking brake has to be disengaged, other-wise the same indicator lamp as for the clutch lights
UP.2. Carry out adjustment only with ball stud on clutch
housing whereby the distance (Item 20, Figure 7A-7)
between clutch housing contacting surface and
clutch release lever has to be adjusted in the rear to
4
l/4 inches.
Clutch Control Cable Adjustment(Only on
Installation of a New Clutch Disc or
Bowden
Control Wire)
GT1. Adjust ball stud so that outer end protrudes ap-
proximately 3/4 inches out of clutch housing.
2. Adjust distance between release lever and clutch
housing face at eye for control cable to approxi-
mately 4
l/4 inches. See Figure 7A-6. Hold cable in
this position and place E-ring two grooves ahead of
washer on rubber grommet. Clutch pedal free travel
is now between 3/4 and 1
l/4 inches and clutch
release bearing has proper clearance from pressure
plate.
Opel 1900 and Manta1. Adjust ball stud on clutch housing to basic dimen-
sion of approximately 3/4 inch. With lower end ofbowden control wire unhooked, push clutch release
lever towards the front so that the clutch release
bearing rests against clutch spring. Now, adjust ball
stud so that the dimension (Item 20, Figure
7A-7)between clutch housing contacting surface and
clutch release lever amounts in the rear to 4
l/4
inches.2. Pull reattached bowden control wire out of dash
panel so that clutch pedal rests against switch (in-
dicator lamp lights up).
3. In this position, install lockwasher at upper con-
trol wire attachment three grooves towards the front,
thereby completing control wire adjustment.

78.221973 OPEL SERVICE MANUAL
3. Install new bellows. Adhere to distance A
- 8.07”.
See Figure 7B-I 1.
4. Heat up new gearshift lever knob in boiling water
to 176 degrees F. and push it onto gearshift lever
tube. Adhere to distance A .3”, see Figure
7B-15.The gearshift lever tube end is provided with trans-
verse grooves for which reason the old button cannot
be reused. Install gearshift lever.
REPLACING RUBBER DAMPENING PARTS IN
GEARSHIFT LEVER1. Remove gearshift lever.
2. Knock off gearshift lever button and loosen
threaded pin for Bowden control wire attachment.
3. Remove lower snap ring from gearshift lever tube
and pull tube off shift finger.
4. Take off and replace rubber dampening parts.
5. After installation of tube, tighten Bowden control
wire with threaded pin. Prior to tightening, pull ring
must rest on gearshift lever tube and clamping block
on pull ring. See Figure
7B-15.6. Heat up new gearshift lever knob in boiling water
to 176 degrees F. and push it onto gearshift lever
tube. Adhere to distance A
- .3”, see Figure 7B-15.The gearshift lever tube end is provided with trans-
verse grooves for which reason the old button cannot
be reused.
7. Install gearshift lever.
MAJOR REPAIR
TRANSMISSION REMOVAL1. Remove air cleaner. Remove throttle rod from
carburetor and rear support and disconnect battery.
2. Remove screws from fan shroud.
3. Remove gearshift lever (refer to paragraph on ser-
vicing gearshift lever).
4. Support car with frame or wheel stands in the
front or frame stands in the rear.
5. Loosen front exhaust pipe to manifold flange.
6. Remove clutch cable from fork by pushing fork to
disengage the clutch and unsnap cable from slot.
7. Disconnect both wires from backup lamp switch.8. Disconnect speedometer cable from transmission
case extension housing.
9. Unhook parking brake cable return spring and
remove cable adjusting nut, equalizer, and spacer.
See Figure
7B-16.PARKING BRAKE CABLE
PARKING BRAKE
Figure 78-16 Parking Brake Equalizer and Return
Spring
9. Disconnect drive shaft at central joint and remove
as follows: See Figure
7B-16.a. Disconnect parking brake cable equalizer from
rod.b. Mark the mating parts of U-Joint and the drive
pinion extension shaft flange.
c. Loosen bolt locks and remove bolts or nuts.
d. Work propeller shaft slightly forward, lower rear
end of shaft and slide assembly rearward. Remove
thrust spring.
e. Install a plug in the rear of the transmission to
prevent loss of lubricant.
10. Remove rear engine mount bolts and lower trans-
mission as far as possible.
11. Remove transmission case to clutch housing at-
taching bolts and remove transmission.
INSTALLATION OF TRANSMISSION WITH
ENGINE IN CAR1. Make certain main drive gear splines are clean and
dry. Also, make certain the transmission is in Neu-
tral so that the main drive gear splines may be in-
dexed when making the installation.
2. Install transmission and support weight while in-
stalling transmission case to clutch housing bolts.
3. Install rear engine mount.
4. Install propeller shaft, align, and tighten U-Joint
to pinion flange U-Bolt nuts and torque to 11 lb. ft.

SubjectPage Number
Subject Page Number
A
Air Conditioning Refrigerant Components .................
98.17
Opel 1900
& Manta-In Car Components .....9B-90
GT.ln Car Components..................98-97
Alignment Opel 1900
& Manta .....................3C-22
GT-Opel ..............................
3C-22
Alternator Description ...........................
lD-28
Specifications. .........................1 D-35
Overhaul K-l..........................lD-30
Removal & Installation ..................lD-30
Testing...............................lD-29
Wiring Diagrams
Manta .............................
1 J-105
Opel 1900
..........................lJ-103
GT ................................
lJ-107
AM
Radio-GT............................9C-105
AM Radio-Opel 1900 &Manta ...............
9C-109
Antenna, Installation .......................
9C-111
Antenna Trimmer .........................
9C-110
Assembly of Transmission from Major Units Manual ...............................
78-23
3 Speed Automatic .....................
7C-103
Axle,
R&r, Disassembly ....................48~11
Bolt Torque Specifications
Engine ...............................
6A-27
Transmission. Manual ....................
78-33
3 Speed Automatic .....................
7C-136
Clutch ...............................
7A-7
Body ................................
2A-4
Brakes
Brake Drum, Shoes & Linings .............5C-28
Hydraulic Wheel Cylinder ................
5C-30
Hydraulic Master Cylinder ................
5A-2
Parking Brake Cables .....................
5C-33
Standard Brakes ........................
X-22
Disc Brakes...........................5B-10
Brake Booster and Vacuum
Coritrol Valve ....5A-5
Bumpers, Front and Rear ...................
ZH-33
C
B
Balance,,Wheel and Tire....................3G-62
Ball
J&tUpper .........................3A-7
Lower ...............................
3A-7
Battery
Specifications ..........................
lA-9
Testing...............................lA-6
Charging ..............................lA-9
Trouble Diagnosis ......................lA-4
Battery Test 421.........................l A-6
Belt Tensions ............................
68.33
Blower and Air Inlet Assembly, Removal and Installation
Owl 1900&Manta.....................9A-15
GT
.: ................................9A-5
Body Name Plate ............................
OA-1
Style’Numbers ......................... OA-2
Windows and Weatherstrips ...............
ZC-9
Doors ................................
ZD-13
Interior Trim and Headlining ..............
26-33
Seatsi................................26-33
Roof&d Sunroof-Opel 1900
& Manta ......2F.24 Camshaft,
1.9L
Engine .....................6A-25
Car Model Identification .......
.,............OA-1
Carburetor..............................6E-44
Trouble Diagnosis ......................
6E-49
Description ...........................
6E-44
Overhaul .............................
6E-53
Adjust ...............................
6E-50
Removal
& Installation ......,............6E-52
Specifications ..........................
6E-58
Charging
System
Description ..............
:............ 1 D-28
Specifications. ............
.,............lD-35
Testing..................:............lD-29
Wiring Diagrams
Manta .............................
lJ-105
Opel 1900 ..........................
lJ.103
GT ................................
lJ-107
Chart Lubrication ........................ OC-5
Chassis Springs, Front. ........
!............3A-15
Clutch, Second-Automatic Transmission .......
7C-103
Clutch Adjustment .........................
7A-4
Control Arm Front Upper ...................
:............3A-10
Lower ...............................
3A-11
Converter Checking Procedure ................
7C-125
Coolant Flow ............................
68-32
4 Speed Manual Transmission ...
!,...........7B-12
Cranking System. See Starting
SyStem
Crankshaft..............................6A-16
Cylinder Head ...............
:............6A-12
D
Description
3.Speed Automatic.....................7C-37

SubjectPage Number
Subject Page Number
o,,e, 1900 & Manta .....................1H-59
GT..................................lH-63
intake Manifold, 1.9L Engine
..........:.....6A-12
R
Radiator
JRadiator All Models .,.
Radio
66-32
Joint,
Ball
adder.; ...............................3A-7
dower...............................3A-7
K
Antenna Trimmer Adjustment GT
Antenna Trimmer Adjustment
Opel 1900
& Manta
Removal and Installation Opel 1900
& Manta
Removal and Installation GT
Trouble Diagnosis GT
.,.
Trouble Diagnosis -Opel 1900 &Manta
Reverse Clutch
Rings, Piston,
1.9L Engine
Rocker Arm Assembly.
1.9L Engine..
9C-1 06
9C-1 10
Keys and Locks ..........................OA-1
L
Low Servo Cover .........................7c-100
Lubrication
Engine Oil Change Interval ................OC-7
Oil Viscosity Chart. .....................
OC-7
Fluid Capacities........................OC-5
Lubrication System, Engine .................6A-4
9C-1 11
9c-107
9c-105
9c-109
7c-103
6A-19
6A-12
s
M
Mainshaft Assembly 4.Speed
Manual Transmission ....................
78-26
Manifold
Intake ...............................
6A-12
Exhaust ..............................
6A-12
Master
Cdlinder, Brake.....................5A-2
Model
D&ignation (Body Style)
.............. OA-2
Mountings. Engine, GT ....................
28-6
Opel 1900 & Manta
.......................28-6
0
Oil Chan& Interval ........................OC-7
Oil Filter: Engine
.........................OC-7
Oil Flow Circuits, Automatic Transmission .....7C-64
Oil
Pan. Engine ..........................6A-10
Oil Pump Engine.........................
6A-26
Oil Pump Transmission ....................
7C-103
Oil Recommendations Engine. ..............
OC-7
Oil Strainer-Transmission..................7C-99
Oil Viscosity Chart ........................
OC-7
Opel Emission Control System
(OECS)
Specifications..........................6F-64
Service Procedures......................6F-63
Trouble Diagnosis ......................
6F-62
P
Parking Brake............................5C-33
Piston, Pin Rings ..........................
6A~lS
Planetary Gear Set ........................
7C-118
Power Unit Brake ........................
5A-5
Propeller Shaft ...........................
4A-2
Pump, Oil Engine........................
6A-26 Sequence for Transmission Diagnosis
..........
7C-81
Service ProceduresClutch..................7A~5
Shift Linkage Adjustments
4.Speed Manual ........................78-19
3.Speed Automatic .....................7C~93
Shock Absorber, Rear
All Series .............................
3F-51
Spark Plug Specifications ...........................
66-68
Clean &Adjust. ........................
lC-22
Installation............................lC-22
Wires................................lC~21
Specifications
Engine ................................
6A-27
Front Wheel Alignment ....................
3C~22
Speedometer Installation
Opel1900&Manta.....................1 l-68
GT..................................11-70
Spring
Rear SuspensionAll Series ..............
:............3F-52
Front Suspension
Opel 1900
& Manta ...................3A~l6
GTO Opel ..........................
3A15
Starting Motor
Description ............................
1 E-1 0
Specifications .............:............1 B-1 7
Repairs
..................:............18-13
Removal..............................1 B-l 3
Steering Columns
Service Procedures -Opel 1900 &Manta ....
3E-36
Service Procedures
- GT ...._............3E-44
Steering Gear Adjustment. .....
:............3D-27
Steering Gear Disassembly and
Redssembly.....3D-30
Steering Gear Removal and Install&ion ........
30-28
Steering Linkage ..........................
38-19
Suspension
Front................................3A-2
Rear .................................
3F-51
,