engine OPEL FRONTERA 1998 Workshop Manual

7C–14CLUTCH
Release Bearing
201RS011
1. Visually check the release bearing for excessive play,
noise and breakage.
2. If any of these conditions are discovered, the release
bearing must be replaced.
3. When replacing the release bearing, replace both the
wedge collar and wire ring at the same time.
201RW010
Legend
(1) Wire Ring
(2) Pressure Plate Assembly
(3) Wedge Collar
(4) T/M Side
(5) Release Bearing
(6) Engine Side
Wedge Collar
201RS013
1. Visually check the surfaces of the wedge collar
making contact with the release bearing for excessive
wear and damage.
2. Replace any exhibiting excessive wear or damage.
Shift Fork
201RS014
1. Visually check the surfaces of the shift fork making
contact with the release bearing for excessive wear
and damage.
2. Remove any minor stepping or abrasion from shift
fork with an oil stone.
3. Replace any exhibiting excessive wear or damage.

7C–20CLUTCH
2. Adjust clutch padel adjusting bolt by backing it out
half a turn, and measure the clearance (
)
between the clutch pedal arm and the adjusting
bolt.
203RW010
Legend
(9) Bracket
(10) Clutch Pedal Adjusting Bolt
(11) Lock Nut
(12) Clutch Pedal Arm
3. Lock the lock nut.
Clutch Switch and Clutch Pedal Clearance (
)
0.5 mm – 1.5 mm (0.020 in – 0.059 in)
5. After adjusting the clutch pedal height, push the
clutch pedal by hand rightly to check the clutch pedal
free play (4) to within specification.
Pedal Free Play (4)
5 mm – 15 mm (0.20 in – 0.59 in)
203RW004
6. Clutch pedal engagement height inspection:
1. Operate the parking brake lever and block the
wheels.
2. Start the engine, fully step on the clutch pedal,
and move the shift lever to 1st position.
3. With the engine idling, release the clutch pedal
slowly and measure its stroke just prior to its
clutching position.
Clutch Pedal Engagement Height (14)
MIN. 30 mm (1.18 in)
7. If the measured value exceeds the specified limit,
check the following points. Repair if necessary:
Hydraulic circuit for fluid leakage or air in circuit.
Clutch disc warped.
Diaphragm spring weakened or tip of fingers worn.
Driven plate sticking on sprines.
Release bearing worn or damaged.
Master cylinder and slave cylinder worn.
203RW007
Legend
(3) Floor Panel
(14) Clutch Pedal Engagement Height

LIGHTING SYSTEM8A–29
Light NameRated PowerNumber of
BulbsLens ColorRemarks
Headlight60w/55w2WhiteHalogen
FrontTurn signal light21w2Whitecombination
lightClearance light5w2Amber
FRT fog light55w2WhiteHalogen
Taillight/Stoplight5w/21w2Red
RearBumperTurn signal light21w2Ambercombination
lightTaillight/Stoplight5w/21w2RedBodyTurn signal light21w2Amber
Backup light21w2White
RR fog light21w2Red
Side turn signal light5w2Amber
License plate lightBumper5w2White
Body5W1White
High mount stoplight——RedLED
Map light5w2White
Dome light10w1White
Luggage room light8w1White
Courtesy light3.8w2White
A/C SW60mA1
RR defogger SW0.84w1
Mirror defogger SW0.84w1
FRT fog light SW0.7w1
RR fog light SW0.7w1
Cruise (Set)1.4w1Meter
Cruise (Main)1.4w1Meter
Check trans3w1Meter
Anti-theft3w1Warning box
Turn signal1.4w2Meter
Golw1.4w1Meter
Water sedimenter1.4w1Meter
Indicator/High beam1.4w1MeterWa rnin g
lightABS1.4w1Meter
Check engine1.4w1Meter
Low fuel1.4w1Meter
4WD1.4w1Meter
Oil Pressure1.4w1Meter
Brake system1.4w1Meter
Charge1.4w1Meter
Seat belt2w1Meter
A/T shift position0.91w7Meter
A/T oil temp3w1Meter

8A–30LIGHTING SYSTEM
Power drive1.4w1Meter
Winter drive1.4w1Meter
Air bag2w1Meter
Engine warming SW0.84w1
FRT fog light SW0.84w1
RR fog light SW0.84w1
Glove box1.2w1
Ashtray1.4w1
Illumination controller0.7w1
Heater bezel150mA2
Hazard warning light SW0.84w1
Meter3.4w4Meter ASM
IlluminationCigar lighter1.4w1Light
Rear wiper & washer SW0.84w1
Rear defogger SW0.84w1
Mirror control SW45mA1
Mirror defogger SW0.7w1
Mirror folding SW0.7w1
A/T select lever1.2w1
Power & Winter SW50mA2
Cruise control main SW0.84w1
Headlight wiper SW0.84w1
Torque Specifications
ApplicationNꞏmkgꞏmLb FtLb In
Steering Shaft Nut343.525—

The chassis electrical system is a 12–volt system with a
negative ground polarity.
Wire size are appropriate to respective circuits, and
classified by color. (The classification of harnesses by
color is shown on the circuit diagram for ease of harness
identification.)
The wire size is determined by load capacity and the
length of wire required.
The vehicle harnesses are: body harness, chassis
harness, engine room harness, instrument harness,
transmission harness, engine ECGI harness, dome light
harness, door harness, rear body harness, tailgate
harness, SRS harness and battery cables.
The harnesses are protected either by tape or corrugated
tube, depending on harness location.
The circuit for each system consists of the power source,
wire, fuse, relay, switch, load parts and ground, all of
which are shown on the circuit diagram.
In this section, each electrical device is classified by
system.
For major parts shown on the circuit based on the circuit
diagram for each system, a summary, diagnosis of
troubles and inspection procedures are detailed.
Notes for Working on Electrical
Items
Disconnecting the Battery Cable
1. All switches should be in the “OFF” position.
2. Disconnect the battery ground cable (2).
3. Disconnect the battery positive cable (1).
CAUTION: It is important that the battery ground
cable be disconnected first. Disconnecting the
battery positive cable first can result in a short circuit.
Connecting the Battery Cable
Follow the disconnecting procedure in the reverse order.CAUTION: Clean the battery terminal and apply a
light coat of grease to prevent terminal corrosion.
Disconnecting the Connector
Some connectors have a tang lock to hold the connectors
together during vehicle operation.
Some tang locks are released by pulling them towards
you (1).
Other tang locks are released by pressing them forward
(2).
Determine which type of tang lock is on the connector
being handled.
Firmly grasp both sides (male and female) of the
connector (3).
Release the tang lock and carefully pull the two halves of
the connector apart.
Never pull on the wires to separate the connectors (4).
2
1
General Description
1
2
3
4

5. The wiring harness between engine and chassis
should be long enough (2). Tension of the wire (1) may
causes chafing or damage due to various vibrations.
Splicing Wire
1. If the harness is taped, remove the tape. To avoid wire
insulation damage, use a sewing “seam ripper”
(available from sewing supply stores) to cut open the
harness.
If the harness has a black plastic conduit, simply pull
out the desired wire.
2. Begin by cutting as little wire off the harness as
possible. You may need the extra length of wire later
if you decide to cut more wire off to change the location
of a splice. You may have to adjust splice locations to
make certain that each splice is at least 1–1/2”
(40 mm) away from other splices, harness branches,
or connectors.
3 . W h e n r e p l a c i n g a w i r e , u s e a w i r e o f t h e s a m e s i z e a s
the original wire.
Check the stripped wire for nicks or cut stands. If the
wire is damaged, repeat the procedure on a new
section of wire. The two stripped wire ends should be
equal in length.
4. Select the proper clip to secure the splice.
To determine the proper clip size for the wire being
spliced, follow the directions included with your clips.
Select the correct anvil on the crimper. (On most
crimpers your choice is limited to either a small or
large anvil.)
Overlap the two stripped wire ends and hold them
between your thumb and forefinger as shown in the
figure.
The center the spline clip (1) under the stripped wires
and hold it in place.
Open the crimping tool to its full width and rest one
handle on a firm flat surface.
Center the back of the splice clip on the proper anvil
and close the crimping tool to the point where the back
of the splice clip touches the wings of the clip.
Make sure that the clip and wires are still in the correct
position. Then, apply steady pressure until the
crimping tool closes as shown in the figure.
2
11

3
P-2
H-142
2
B-11
P-10P-7
PCM
(A4)
CONDENSER
FANEHCU STARTER
(B)
STARTER
RELAY
(3)
P-6
BODY ENGINE FRAME
BATTERY
STARTER
SWRELAY & FUSE BOX
CONDENSER
FAN
RELAY
FL-2 50A
KEY SWFL-3 30A
PCMFL-4 30A
CONDENSER
FANFL-6 40A
ABS FL-1 80A
MAIN 8.0
B/R
8.0
B30.0
B8.0
B30.0
B/R
3.0
W/B
3.0
W/B
3.0
W/B
3.0
B/Y3.0
W/G3.0
B/R3.0
L/B2.0
W1.25
L/O
1.25
L3.0
W/G
3.0
W/B5.0
W
5.0
W
3.0
W/B
B-11IG1 ST IG2 ACC B1
7B-11
3B-11
5B-11
1
B2
OFF 4
B-11
P-5
P-1�＋
�−
X-191
X-19
D08RWC56.

3.0
B/Y3.0
B/Y
3.0
B/Y3.0
B/Y3.0
W/G3.0
B/R
3.0
B/R 3.0
B/Y
0.5
R/B
HAZARD
WARNING
SW
(8)PCM
MAIN
RELAY
(1)IGNITION
COILMETER STARTER
RELAY
(6)SEAT
HEATERWINDSHIELD
WIPER
MOTORRR
WIPER
MOTORHEADLIGHT
WIPER
MOTOR
AC GENERATOR
(IG) ALARM & RELAY
CONTROL UNIT C-3 10A
TURN
BACK
0.5
L/WC-4 10A
ELEC.
IGN.
0.5
L/YC-10 10A
METER
GAUGE
0.5
W/RC-1 10A
STARTER
RELAY
0.85
W/LC-5 15A
FRT WIPER
& WASHERC-6 10A
RR WIPER
& WASHERC-7 10A
H/LAMP
WIPER
FUSE BOX
1.25
B/OC-9 15A
IG COIL C-8 15A
ENGINE
0.5
L/B
0.85
B/Y
0.85
B/Y
0.5
R
0.75
B/R
SDM
(12)C-21 10A
SRS
1.25
G/RC-2 15A
SEAT
HEATER
H-631
3
H-63

D08RWB15

P-2
H-142
2
B-11
P-10P-7
STARTER
RELAY
(4)
P-6
BODY ENGINE FRAME
BATTERY
STARTER
SWFUSE & RELAY BOX
FL-2 50A
KEY SW FL-1 80A
MAIN 8.0
B/R
8.0
B30.0
B8.0
B
3.0
W/B
3.0
W/B
3.0
W/B
3.0
B/Y3.0
W/G3.0
B/R3.0
L/B 3.0
W/B 3.0
W/B 30.0
B/R
B-11IG1 ST IG2 ACC B1
7
E
F
G
A
B-11
3
B
B-11
5
C
B-11
1
D
B2
OFF 4
B-11
STARTER
(B)
P-5
P-1＋
−
X-112
4
X-11
ECM
(J3-1)
ECM
RELAY-1
FL-4 50A
ECM
3.0
R 3.0
W/B
X-102
4
X-10
ECM
(J3-2)
ECM
RELAY-2
3.0
R/W3.0
W/B
D08RWB17

P-2
H-142
2
B-11
P-10P-7
STARTER
RELAY
(4)
P-6
BODY ENGINE FRAME
BATTERY
STARTER
SWFUSE & RELAY BOX
FL-2 50A
KEY SW FL-1 80A
MAIN 8.0
B/R
8.0
B30.0
B8.0
B
3.0
W/B
3.0
W/B
3.0
W/B
3.0
B/Y3.0
W/G3.0
B/R3.0
L/B 3.0
W/B 3.0
W/B 30.0
B/R
B-11IG1 ST IG2 ACC B1
7
E
F
G
A
B-11
3
B
B-11
5
C
B-11
1
D
B2
OFF 4
B-11
STARTER
(B)
P-5
P-1�＋
�−
X-191
3
X-19
CONDENSER
FAN
CONDENSER
FAN
RELAY
FL-4 30A
CONDENSER
FAN
1.25
L 1.25
L/O
D08RWC54