brakes OPEL FRONTERA 1998 User Guide

4A2B–8DIFFERENTIAL (REAR 244mm)
Differential Assembly
Differential Assembly and Associated Parts
425RW044
Legend
(1) Bolt and Nut
(2) Axle Shaft Assembly(3) Parking Brake Cable
(4) Differential Assembly
(5) Nut
Removal
1. Jack up and support the frame with stands.
2. Remove the wheel and tire. Refer to Wheel in
Steering section.
3. Drain the differential oil.
4. Remove the propeller shaft. Refer to Rear Propeller
Shaft in this section.
5. Remove the ABS speed sensor. Refer to Anti–lock
Brake System in Brakes section.6. Remove the parking brake cable fastening clip and
disconnect the equalizer section. Refer to Parking
Brakes in Brake section.
7. Remove the bearing holder fixing nuts.
8. Remove axle shaft assembly, be sure not to damage
the oil seal by axle shaft.
9. Remove differential carrier mounting bolts and nuts.
10. Remove differential assembly.

DIFFERENTIAL (REAR 244mm)
4A2B–9
Installation
1. Clean the contact surfaces of the axle and differential
carrier. As shown in the drawing, apply Three Bond
TB1215 or equivalent then install differential
assembly.
425RS006
2. Install bolt and nut. Tighten the differential carrier
mounting bolts and nuts to the specified torque.
Torque:Nuts 44Nꞏm (4.5kgꞏm/33 lb ft)
Bolts 64Nꞏm (6.5kgꞏm/47 lb ft)
3. Install axle shaft assembly. Be sure not to damage
the oil seal by axle shaft.
4. Install nut, refer to Axle Shaft in this section.
5. Install parking brake cable, refer to Parking Brakes in
Brake section.
NOTE: After completing the assembling work, fill the
prescribed gear oil to the filler hole.
Lubricant capacity: 3.0 liter (2.6 Imp qt/3.2
US qt)
6. Tighten the oil filler plug to the specified torque.
Torque: 78Nꞏm (8.0kgꞏm/58 lb ft)

4C–4
DRIVE SHAFT SYSTEM
Rear Axle Shaft
Rear Axle Shaft and Associated Parts
420RW014
Legend
(1) Brake Caliper
(2) Brake Disc
(3) Wheel Pin
(4) Axle Shaft Assembly
(5) Back Plate
(6) Parking Brake Assembly
(7) Bearing Holder(8) Bearing
(9) Retainer
(10) Snap Ring
(11) Bolt
(12) Nut
(13) Antilock Brake System (ABS) Speed Sensor (if
so equipped)
Removal
1. Raise the vehicle.
2. Remove tires and wheels. Refer to Wheel in Steering
section.3. Remove brake caliper. Use a wire to attach the brake
caliper to the frame. Refer to Disk Brakes in Brake
section.
4. Remove brake disc.
5. Remove ABS sensor (if so equipped).
6. Remove Parking brake assembly. Refer to Parking
Brakes in Brake section.

4C–7 DRIVE SHAFT SYSTEM
9. Fix the parking brake cable mounting bolt (Behind the
back plate).
10. Install parking brake assembly, refer to Parking
Brakes in Brake section.
11. Install antilock brake system sensor (if so equipped).
12. Install brake disc.
13. Install brake caliper, refer to Disk Brakes in Brake
section.

4C–9 DRIVE SHAFT SYSTEM
Front Hub and Disc (with Shift on the Fly)
Disassembled View
411RW001
Legend
(1) Bolt
(2) Cap
(3) Snap Ring and Shim
(4) Hub Flange
(5) Lock Washer and Lock Screw
(6) Hub Nut(7) Outer Bearing
(8) Bolt
(9) Hub and Disc Assembly
(10) Wheel Pin
(11) ABS Sensor Ring (If equipped)
(12) Inner Bearing
(13) Oil Seal
Disassembly
1. Before disassembly, select the 2WD position.
2. Jack up the front of vehicle and support frame with
jack stands.3. Remove the disc brake caliper assembly and hang it
on the frame with wires. Refer to Front Disc Brake
Caliper Assembly in Brakes section.
4. Remove bolt.
5. Remove cap.
6. Remove snap ring and shim.
7. Remove hub flange.

4C–10
DRIVE SHAFT SYSTEM
8. Remove lock washer and lock screw.
9. Use wrench 5–8840–2117–0, remove hub nut.
411RW005
10. Remove hub and disc assembly.
11. Remove ABS sensor ring (If equipped).
12. Remove outer bearing.
13. Remove oil seal.
14. Remove inner bearing.
15. Remove bolt , if necessary, replace the wheel pin in
the following manner.
Apply a scribe mark(1) to disc to hub.
Clamp the hub and disc assembly in a vise, using
protective pads. Remove the 6 disc–to–hub
retaining bolts.
411RS003
Place hub on a suitable work surface and remove
the studs by using a hammer.
411RS004
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal conditions are
found through inspection.
Check the following parts:
Hub
Hub bearing oil seal
Knuckle spindle
Disc
Caliper
Shift on the fly system parts (Cap, Hub flange, Shim,
Snap ring)
ABS sensor ring (If equipped)
For inspection and servicing of disc caliper and related
parts, refer to Brakes section.

4C–14
DRIVE SHAFT SYSTEM
Front Hub and Disc with Manual Locking Hub
Disassembled View
411RW009
Legend
(1) Bolt
(2) Cover Assembly
(3) Gasket
(4) Knob
(5) X–ring
(6) Detent Ball and Spring
(7) Snap Ring
(8) Clutch Assembly
(9) Compression Spring
(10) Follower
(11) Retaining Spring
(12) Snap Ring and Shim(13) Body Assembly
(14) Inner Assembly
(15) Spacer
(16) Ring
(17) Snap Ring
(18) Snap Ring
(19) Lock Washer and Lock Screw
(20) Hub Nut
(21) Hub and Disc Assembly
(22) Outer Bearing Outer Race
(23) ABS Sensor Ring (if so equipped)
(24) Inner Bearing Outer Race
(25) Oil Seal
Disassembly
1. Before disassembly, jack up the front of vehicle and
support frame with jack stands.2. Remove the disc brake caliper assembly and hang it
on the frame with wires. Refer to Front Disk Brake
Caliper Assembly in Brakes section.

4C–16
DRIVE SHAFT SYSTEM
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts.
Hub
Hub bearing, oil seal
Knuckle spindle
Disc
Caliper
Free wheeling hub parts (Clutch, knob, follower,
inner, ring and spring)
ABS sensor ring (if so equipped)
For inspection and servicing of disc caliper, and relative
parts, refer to Brakes section.
Reassembly
1. Install spacer.
Apply about 1 g wheel bearing grease to both face of
spacer.
2. Install ring.
Apply about 3 g wheel bearing grease to inside face
of ring.
3. Install snap ring
Assembly with grease surplus being left unwiped up
as illustrated.
411RW013
Legend
(1) Inner Assembly
(2) Apply Grease
(3) Body
4. Install inner assembly.
Apply grease to splined portion of body.
5. Install snap ring.6. Install X–ring.
Apply wheel bearing grease to hub lock ring and fit it
in knob paying attention to mounting direction.
NOTE: After fitting, make sure that the hub lock ring is not
twisted.
7. Apply wheel bearing grease to ball and spring and fit
them in knob.
8. Install knob.
1. Apply grease to outer circumference of knob and
inner circumference of cover.
2. Align detent ball (1) to a groove cut in the cover.
411RW014
9. Install snap ring.
Turn the smoother face to knob side.
10. Align the end of retaining spring (1) with clutch spring
groove (2) and fit in the spring.
411RW015

5A–1 BRAKE CONTROL SYSTEM
BRAKES
CONTENTS
Brake Control System 5A. . . . . . . . . . . . . . . . . . . .
Anti–lock Brake System 5B. . . . . . . . . . . . . . . . . . Power–Assisted Brake System 5C. . . . . . . . . . . .
Parking Brakes 5D. . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE CONTROL SYSTEM
CONTENTS
Service Precaution 5A–2. . . . . . . . . . . . . . . . . . . . . .
General Description 5A–3. . . . . . . . . . . . . . . . . . . . .
System Components 5A–3. . . . . . . . . . . . . . . . . . .
Electronic Hydraulic Control Unit (EHCU) 5A–3.
ABS Warning Light 5A–4. . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor 5A–4. . . . . . . . . . . . . . . . . .
G-Sensor 5A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal and Anti-lock Braking 5A–4. . . . . . . . . . .
Brake Pedal Travel 5A–4. . . . . . . . . . . . . . . . . . . .
Acronyms and Abbreviations 5A–4. . . . . . . . . . . .
General Diagnosis 5A–5. . . . . . . . . . . . . . . . . . . . . . .
General Information 5A–5. . . . . . . . . . . . . . . . . . . .
ABS Service Precautions 5A–5. . . . . . . . . . . . . . .
Computer System Service Precautions 5A–5. . .
General Service Precautions 5A–5. . . . . . . . . . . .
Note on Intermittents 5A–5. . . . . . . . . . . . . . . . . . .
Test Driving ABS Complaint Vehicles 5A–6. . . . .
“ABS” Warning Light 5A–6. . . . . . . . . . . . . . . . . . .
Normal Operation 5A–6. . . . . . . . . . . . . . . . . . . . .
Basic Diagnostic Flow Chart 5A–6. . . . . . . . . . . .
Basic Inspection Procedure 5A–7. . . . . . . . . . . . .
Tech 2 Scan Tool 5A–8. . . . . . . . . . . . . . . . . . . . . .
Getting Started 5A–9. . . . . . . . . . . . . . . . . . . . . . . .
Operating Procedure 5A–10. . . . . . . . . . . . . . . . . . .
Data List 5A–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EHCU Connector Pin-out Checks 5A–12. . . . . . . .
Circuit Diagram (LHD model / 6VD1 and
4JG2) 5A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram (LHD model / 4JG2) 5A–14. . . . .
Circuit Diagram (LHD model / 4JG2) 5A–15. . . . .
Circuit Diagram (LHD model / 6VD1) 5A–16. . . . .
Circuit Diagram (LHD model / 6VD1) 5A–17. . . . .
Connector List (LHD model) 5A–18. . . . . . . . . . . .
Part Location (LHD model) 5A–20. . . . . . . . . . . . . .
Circuit Diagram (RHD model / 6VD1 and
4JG2) 5A–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram (RHD model / 4JG2) 5A–22. . . . .
Circuit Diagram (RHD model / 4JG2) 5A–23. . . . .
Circuit Diagram (RHD model / 6VD1) 5A–24. . . . .
Circuit Diagram (RHD model / 6VD1) 5A–25. . . . .
Circuit Diagram (RHD model / 6VE1 and
4JX1) 5A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Diagram (RHD model / 4JX1) 5A–27. . . . .
Circuit Diagram (RHD model / 4JX1) 5A–28. . . . .
Circuit Diagram (RHD model / 6VE1) 5A–29. . . . .
Circuit Diagram (RHD model / 6VE1) 5A–30. . . . .
Connector List (RHD model) 5A–31. . . . . . . . . . . .
Part Location (RHD model) 5A–34. . . . . . . . . . . . .
Symptom Diagnosis 5A–35. . . . . . . . . . . . . . . . . . . . .
Chart A–1 ABS Works Frequently But
Vehicle Does Not Decelerate 5A–35. . . . . . . . . . .
Chart TA-1 ABS Works Frequently But
Vehicle Does Not Decelerate (Use
TECH 2) 5A–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart A-2 Uneven Braking Occurs While
ABS Works 5A–36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart A-3, TA-3 The Wheels Are Locked 5A–36.
Chart A-4 Brake Pedal Feed Is Abnormal 5A–37.
Chart A-5, TA-5 Braking Sound (From
EHCU) Is Heard While Not Braking 5A–38. . . . . .
Diagnostic Trouble Codes 5A–39. . . . . . . . . . . . . . . .
Diagnosis By “ABS” Warning Light
Illumination Pattern 5A–40. . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes (DTCs) 5A–40. . . . . . .
Chart B-1 With the key in the ON position
(Before starting the engine). Warning light
(W/L) is not activated. 5A–43. . . . . . . . . . . . . . . . .
Chart B-2 EHCU Abnormality (DTC 14) 5A–43. . .
Chart B-3 Power Voltage Drop (DTC 15) 5A–44. .
Chart B-4 CLASS-2 Communication Line
Abnormality (DTC 16) 5A–44. . . . . . . . . . . . . . . . .
Chart B-5 G-Sensor Circuit (DTC 21) 5A–45. . . . .
Chart B-6 Abnormal Transmission Input
(DTC 23) 5A–46. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-7 Transfer Monitor (DTC 24) 5A–47. . . . .
Chart B-8 EHCU Pump Motor And Motor
Relay Circuit (DTC 32) 5A–47. . . . . . . . . . . . . . . . .
Chart B-9 EHCU Pump Valve And Valve
Relay Circuit (DTC 35) 5A–47. . . . . . . . . . . . . . . . .
Chart B-10 FL Isolation Solenoid Valve
Abnormality (DTC 41) 5A–48. . . . . . . . . . . . . . . . .
Chart B-11 FL Dump Solenoid Valve
Abnormality (DTC 42) 5A–48. . . . . . . . . . . . . . . . .
Chart B-12 FR Isolation Solenoid Valve
Abnormality (DTC 43) 5A–48. . . . . . . . . . . . . . . . .
Chart B-13 FR Dump Solenoid Valve
Abnormality (DTC 44) 5A–49. . . . . . . . . . . . . . . . .
Chart B-14 Rear Isolation Solenoid Valve
Abnormality (DTC 45) 5A–49. . . . . . . . . . . . . . . . .
Chart B-15 Rear Dump Solenoid Valve
Abnormality (DTC 46) 5A–49. . . . . . . . . . . . . . . . .

5A–4
BRAKE CONTROL SYSTEM
normal braking when a malfunction has occurred in the
ABS.
The EHCU has a self-diagnosing function which can
indicate faulty circuits during diagnosis.
The EHCU is mounted on the engine compartment front
right side. It consists of a Motor, Plunger Pump, Solenoid
Valves and Check Valve.
On the outside, the relay box containing a motor relay and
a valve relay is installed.
Solenoid Valves: Reduces or holds the caliper fluid
pressure for each front disc brake or both rear disc brakes
according to the signal sent from the EHCU.
Reservoir: Temporarily holds the brake fluid that returns
from the front and rear disc brake caliper so that pressure
of front disc brake caliper can be reduced smoothly.
Plunger Pump: Feeds the brake fluid held in the reservoir
to the master cylinder.
Motor: Drives the pump according to the signal from
EHCU.
Check Valve: Controls the brake fluid flow.
ABS Warning Light
821RW033Vehicles equipped with the Anti-lock Brake System have
an amber “ABS” warning light in the instrument panel.
The “ABS” warning light will illuminate if a malfunction in
the Anti-lock Brake System is detected by the Electronic
Hydraulic Control Unit (EHCU). In case of an electronic
malfunction, the EHCU will turn “ON” the “ABS” warning
light and disable the Anti-lock braking function.
The “ABS” light will turn “ON” for approximately three
seconds after the ignition switch is to the “ON” position.
If the “ABS” light stays “ON” after the ignition switch is the
“ON” position, or comes “ON” and stays “ON” while
driving, the Anti-lock Brake System should be inspected
for a malfunction according to the diagnosis procedure.
Wheel Speed Sensor
It consists of a sensor and a rotor. The sensor is attached
to the knuckle on the front wheels and to the axle shaft
bearing holder on the rear wheels.
The rotor is press-fit in the axle shaft.The flux generated from electrodes magnetized by a
magnet in the sensor varies due to rotation of the rotor,
and the electromagnetic induction generates alternating
voltage in the coil. This voltage draws a “sine curve” with
the frequency proportional to rotor speed and it allows
detection of wheel speed.
G-Sensor
The G-sensor installed inside the center console detects
the vehicle deceleration speed and sends a signal to the
EHCU. In 4WD operation, all four wheels may be
decelerated in almost the same phase, since all wheels
are connected mechanically.
This tendency is noticeable particularly on roads with low
friction coefficient, and the ABS control is adversely
affected.
The G-sensor judges whether the friction coefficient of
road surface is low or high, and changes the EHCU’s
operating system to ensure ABS control.
Normal and Anti-lock Braking
Under normal driving conditions, the Anti-lock Brake
System functions the same as a standard power assisted
brake system. However, with the detection of wheel
lock-up, a slight bump or kick-back will be felt in the brake
pedal. This pedal “bump” will be followed by a series of
short pedal pulsations which occurs in rapid succession.
The brake pedal pulsation will continue until there is no
longer a need for the anti-lock function or until the vehicle
is stopped. A slight ticking or popping noise may be heard
during brake applications when the Anti-lock features is
being used.
When the Anti-lock feature is being used, the brake pedal
may rise even as the brakes are being applied. This is
also normal. Maintaining a constant force on the pedal
will provide the shortest stopping distance.
Brake Pedal Travel
Vehicles equipped with the Anti-lock Brake System may
be stopped by applying normal force to the brake pedal.
Although there is no need to push the pedal beyond the
point where it stops or holds the vehicle, by applying more
force the pedal will continue to travel toward the floor.
This extra brake pedal travel is normal.
Acronyms and Abbreviations
Several acronyms and abbreviations are commonly used
throughout this section:
ABS
Anti-lock Brake System
CKT
Circuit
DLC
Data Link Connector
EHCU
Electronic Hydraulic Control Unit
FL
Front Left