steering OPEL FRONTERA 1998 Repair Manual

SUPPLEMENTAL RESTRAINT SYSTEM 9J–44
Installation
1. Set cancel cam and SRS coil in position and install the
SRS coil to combination switch by tightening the four
bolts to a specified tightening torque with four bolts.
Torque: 0.5 Nꞏm (0.05 kgꞏm/4 Ib ft)
825RX033
2. Insert the horn terminal into the connector NO.12 and
bind the combination switch harness and SRS coil
harness with a tape. (Refer to How to Connect the
Horn Terminal in this section.)
3. After installation steps above, same steps as SRS
Coil Assembly installation step 2 to step 13.
Steering Column
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL
AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT
OF THE DEPLOYMENT REACTION, THAT IS
IRRITATING TO THE SKIN AND EYES. MOST OF THE
POWER ON THE AIR BAG ASSEMBLY IS
HARMLESS. AS A PRECAUTION, WEAR GLOVES
AND SAFETY GLASSES WHEN HANDLING A
DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR
HANDS WITH MILD SOAP AND WATER
AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE
OF INJURY. WHEN PLACING ALIVE AIR BAG
ASSEMBLY ON A BENCH OR OTHER SURFACE,
ALWAYS FACE BAG AND RIM COVER UP, AWAY
FROM THE SURFACE. NEVER REST A STEERING
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD RESULT.NOTE: In the event deployment has occurred, inspect
coil assembly wire for any signs of scorching, melting or
any other damage due to excessive heat. If the coil has
been damaged, replace it.
Removal
1. Disable the SRS (Refer to “Disabling the SRS ” in this
section).
2. Loosen the air bag assembly fixing bolts from behind
the steering wheel assembly using a TORX
d r i v e r o r
equivalent until the air bag assembly can be released
from steering wheel.
827RT008

SUPPLEMENTAL RESTRAINT SYSTEM9J–45
3. Disconnect the yellow 2–pin connector located
behind the air bag assembly and remove air bag
assembly.Refer to “SRS Connectors” in this section
for removal and installation.
827RT009
4. Disconnect horn lead connector.
5. Remove the steering wheel attachment nut.
6. Apply a setting mark across the steering wheel and
shaft so parts can be reassembled in their original
position.
430RS004
7. Move the tires to the straight ahead position before
removing the steering wheel and removing wheel with
5–8521–0016–0.
430RT009
8. Feed wiring though the wheel and remove wheel.
9. Remove the steering lower cover and engine hood
opening lever.
10. Remove the driver knee bolster assembly.
740RT015
11. Remove the steering column cover.
12. Remove air conditioning lower duct.
13. Disconnect the wiring harness connectors located at
the base of steering column.
CAUTION: Never apply force to the steering wheel
in direction of the shaft by using a hammer or other
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
14. Remove the combination switch assembly with SRS
coil.

SUPPLEMENTAL RESTRAINT SYSTEM 9J–46
NOTE: SRS coil is a part of combination switch
assembly, which cannot be replaced separately.
Therefore, be sure not to remove the SRS coil from the
combination switch assembly.
15. Remove the snap ring.
16. Remove the cushion rubber.
17. Disconnect shift lock cable (A/T only).
18. Disconnect the starter switch harness connector
located base of steering column.
19. Remove steering lock cylinder assembly.
20. Apply a setting mark across the universal joint and
steering shaft to reassemble the parts in their original
position.
431RS013
21. Remove steering column assembly.
Installation
1. Install the steering column assembly and align the
setting marks on the universal joint and steering shaft
made during removal.
431RS013
2. Tighten the steering column fixing bolts (dash panel
side) to the specified torque.
Torque: 19 Nꞏm (1.9 Kgꞏm/14 Ib ft)
3. Tighten the steering column fixing bolts (Pedal
bracket) to the specified torque.
Torque: 17 Nꞏm (1.7 Kgꞏm/13 Ib ft)
4. Tighten the universal joint to the specified torque.
Torque: 25 Nꞏm (2.6 Kgꞏm/18 Ib ft)
5. Install steering lock cylinder assembly.
6. Connect shift lock cable (For A/T)
7. Install cushion rubber.
8. Install snap ring.
9. Install the combination switch assembly with SRS
coil.
10. Connect the wiring harness connector located on the
base of steering column.
11. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark (1).
CAUTION: W h e n t u r n i n g t h e S R S c o i l
counterclockwise to full, stop turning if resistance is
felt. Forced further turning may damage to the cable
in the SRS coil.
826RW014

SUPPLEMENTAL RESTRAINT SYSTEM9J–47
12. Install steering column cover.
CAUTION: When installing the steering column
cover, be sure to wire (through each harness) as
illustrated so that the harness starter switch,
combination switch and SRS coil may not catch
wiring.
825RS048
13. Install the steering wheel and align the setting marks.
430RS004
14. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 34 Nꞏm (3.5 Kgꞏm/25 Ib ft)15. Connect horn lead.
16. Connect air bag wiring harness connector.
NOTE: Pass the lead wire through the tabs on the plastic
cover (wire protector) of air bag to prevent lead wire from
being pinched.
827RT009
17. Install air bag into steering wheel and tighten bolts to
specified sequence as shown in figure.
Torque: 8 Nꞏm (0.8 Kgꞏm/69 Ib in)
CAUTION: Never use the air bag assembly from
another vehicle. Use only the air bag assembly
proper to the Trooper which is being repaired.
827RT008
18. Enable the SRS (Refer to “Enabling the SRS” in this
section).

SUPPLEMENTAL RESTRAINT SYSTEM 9J–48
Passenger Air Bag Assembly
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL
AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT
OF THE DEPLOYMENT REACTION, THAT IS
IRRITATING TO THE SKIN AND EYES. MOST OF THE
POWER ON THE AIR BAG ASSEMBLY IS
HARMLESS. AS A PRECAUTION, WEAR GLOVES
AND SAFETY GLASSES WHEN HANDLING A
DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR
HANDS WITH MILD SOAP AND WATER
AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE
OF INJURY. WHEN PLACING ALIVE AIR BAG
ASSEMBLY ON A BENCH OR OTHER SURFACE,
ALWAYS FACE BAG AND RIM COVER UP, AWAY
FROM THE SURFACE. NEVER REST A STEERING
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD RESULT.
NOTE: IN THE EVENT DEPLOYMENT HAS
OCCURRED, INSPECT COIL ASSEMBLY WIRE FOR
ANY SIGNS OF SCORCHING, MELTING OR ANY
OTHER DAMAGE DUE TO EXCESSIVE HEAT. IF THE
COIL HAS BEEN DAMAGED, REPLACE IT.
Removal
827RS001
1. Disable the SRS (Refer to “Disabling the SRS ” in this
section).
2. Remove gear control knob.
3. Remove front console assembly.
4. Remove rear console assembly and disconnect
harness connector.
5. Remove ECM and SDM cover.
6. Remove glove box assembly with lid.
7. Remove glove box cover.
8. Remove instrument panel assist side lower cover.
9. Disconnect engine hood opener lever.
10. Remove instrument panel door side lower cover.
11. Remove lower cluster with ashtray.
12. Remove meter cluster assembly and disconnect
harness connector.
13. Remove instrument panel lower center cover.
14. Disconnect passenger air bag assembly harness
connector.
15. Remove air bag assembly fixing bolts and nuts.
16. Remove passenger air bag assembly.
Installation
827RS001
1. Install passenger air bag assembly.
2. Install air bag assembly fixing bolts, nuts and tighten
to specified torque.
Torque: 6 Nꞏm (0.6 Kgꞏm/52 Ib in)
3. Connect air bag assembly harness connector.
4. Install instrument panel lower center cover.
5. Install meter cluster assembly and connect harness
connector.
6. Install lower cluster with ashtray.
7. Install instrument panel door side lower cover.
8. Connect engine hood opener lever.
9. Install instrument panel assist side lower cover.

SUPPLEMENTAL RESTRAINT SYSTEM 9J–50
Main Data and Specifications
Fastener Tightening Specification
ApplicationNꞏmKgꞏmLb FtLb In.
SDM101.0—87
Driver air bag fixing bolt8.80.9—78
Steering wheel fixing bolt343.525—
Steering column (dash panel side fixing bolts)191.914—
Steering column (Pedal bracket fixing bolt)171.713—
Steering column (Universal joint fixing bolt)252.618—
Passenger Air Bag fixing bolts and nuts60.6—52

9J1–9
RESTRAINT CONTROL SYSTEM
Chart B “AIR BAG” warning lamp comes “ON” Steady
StepActionYe sNo
11. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Ignition switch “OFF.”
3. Connect scan tool to data link connector, follow directions as
given in the scan tool instruction MANUAL.
4. Ignition switch “ON.”
5. Request SRS diagnostic trouble code display.
Dose scan tool indicate “No Data Received”?
Go to Step 2Go to Step 3
21. Ignition switch “OFF”.
2. Inspect SDM harness connector connection to SDM.
Is it securely connected to the SDM?
Ignition switch
“OFF”
Replace SDM
Go to Step 5
Connect SDM
securely to
de–activate
shorting clip in
SDM harness
connector
Go to Step 5
3Using scan tool, request SRS data list.
Is “ignition” less than 9 volts?
Go to Step 4
Ignition switch
“OFF”
Replace SDM
Go to Step 5
41. Ignition switch “OFF.”
2. Disconnect SRS coil and passenger air bag assemblies.
yellow 2–pin connector located at base of steering column and
behind the glove box assembly.
Disconnect SDM.
3. Disconnect the connector of “SRS Warning Lamp” of
instrument cluster.
4. Measure resistance from SDM harness connector terminal “7”
to ground “6”.
Does 5–8840–0285–0 display “OL” (Infinite)?
Go to Chart A
Replace SRS
harness
Go to Step 5
5Reconnect all SRS components, ensure all components are
properly mounted.
Was this step finished?Repeat the “SRS
Diagnostic
System Check”
Go to Step 5

9J1–11
RESTRAINT CONTROL SYSTEM
Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady
StepActionYe sNo
11. When measurements are requested in this chart,use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Ignition switch “OFF.”
3. Remove and inspect “C–10” fuse (meter) to the “AIR BAG”
warning lamp.
Is fuse good?
Go to Step 2Go to Step 7
21. Ignition switch “OFF.”
2. Disconnect SRS coil and passenger air bag assemblies.
Yellow 2–pin connector located at base of steering column and
behind the glove box assembly.
3. Disconnect SDM.
4. Ignition switch “ON.”
5. Measure voltage on SDM harness connector from terminal “7”
to terminal “6” (ground).
Is system voltage present on terminal “7”?
Go to Step 4Go to Step 3
31. Ignition switch “OFF.”
2. Remove instrument meter cluster.
3. Check for proper connection to instrument cluster at
IB04–WHT/RED terminal.
4. If ok, then remove and inspect “AIR BAG” bulb.
Is bulb good?
Go to Step 5
Replace bulb
Go to Step 6
41. Ignition switch “OFF.”
2. Disconnect instrument meter cluster harness connector.
3. Ignition switch “ON.”
4. Measure voltage on SDM harness connector from terminal “7”
to terminal “6” (GROUND).
Is voltage 1 volt or less?
Go to Chart A
Replace SRS
harness
Go to Step 6
51. Install bulb.
2. Measure resistance from instrument meter cluster harness
connector IB04–WHT/RED terminal to SDM harness
connector terminal “7”.
Is resistance 5.0 ohms or less?Service
instrument meter
cluster
Install instrument
meter cluster
Go to Step 6
Replace SRS
harness
Go to Step 6
6Reconnect all SRS components, ensure all components are
properly mounted.
Was this step finished?Repeat the “SRS
Diagnostic
System Check”
Go to Step 6
7Perform chart C.
Was this step finished?
Go to Step 8Go to Step 1
81. Replace “C–10” fuse.
2. Ignition switch “ON” wait 10 Seconds then ignition switch “Off.”
3. Remove and inspect “C–10” fuse.
Is fuse good?
Install “C–10”
fuse
Go to Step 10
Go to Step 9

RESTRAINT CONTROL SYSTEM 9J1–12
Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady (Cont’d)
StepNo Ye s Action
91. Disconnect SRS coil and passenger air bag assemblies.
Yellow 2–pin connectors located at base of steering column
and behind the glove box assembly.
2. Disconnect SDM.
3. Replace “C–10” fuse.
4. Ignition switch “ON” wait 10 seconds.
5. Ignition switch “OFF”.
6. Remove and inspection “C–10” fuse.
Is fuse good?
Install“C–10” fuse
Go to Chart A
Replace SRS
harness
Replace “C–10”
fuse
Go to Step 10
10Reconnect all SRS components, ensure all components are
properly mounted.
Was this step finished?Repeat the “SRS
Diagnostic
System Check”
Go to Step 10

RESTRAINT CONTROL SYSTEM 9J1–14
warning lamp is performing the bulb check, unless DTC
17 or DTC 26 is detected. When a scan tool “Clear
Codes” command is issued and the malfunction is stillpresent, the DTC will not reappear until the next ignition
cycle.
DTC 15 Passenger Deployment loop Resistance High
StepActionYe sNo
1Was the “SRS Diagnostic System Check” Performed?
Go to Step 2
Go to The “SRS
Diagnostic
System Check”
21. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
2. Use scan tool data list function, read and record the passenger
deployment loop resistance.
Is passenger resist. more than 2.9 ohms?
Go to Step 3Go to Chart A
31. Ignition switch “Off.”
2. Make sure the passenger air bag assembly yellow 2–pin
connector located behind the glove box assembly is seated
properly.
Is the yellow 2–pin connector connected properly?
Go to Step 4
Seat passenger
Air Bag assembly
yellow 2–pin
connector
properly
Go to Step 7
41. Disconnect and inspect the passenger air bag assembly
yellow 2–pin connector located behind the glove box
assembly.
2. If ok, reconnect the passenger air bag assembly 2–pin
connector.
3. Ignition switch “ON.”
Is DTC 15 current?
Go to Step 5Go to Step 7
51. Ignition switch “Off.”
2. Disconnect SRS coil and passenger air bag assembly, yellow
2–pin connector located at the base of the steering column and
behind the glove box assembly.
3. Connect 5–8840–2421–0 SRS driver / passenger load tool
and appropriate adapters to SRS coil and passenger air bag
assembly harness connectors.
4. Ignition switch “ON.”
Is DTC 15 Current?
Go to Step 6
Ignition switch
“Off”
Replace the
passenger air
bag assembly
Go to Step 7
61. Ignition switch “Off.”
2. There has been an increase in the total circuit resistance of t h e
passenger inflator deployment loop.
3. Use the high resolution ohmmeter mode of the DVM while
checking IB07–YEL/GRN and IB08–YEL/RED, and SDM
connector terminal “15” and “16” to locate the root cause.
Was a fault found?
Replace SRS
harness
Go to Step 7
Go to Chart A
71. Reconnect all components ensure all component are properly
mounted.
2. Clear diagnostic trouble codes.
Was This step finished?
Repeat the “SRS
Diagnostic
System Check”
Go to Step 7