OPEL FRONTERA 1998 Workshop Manual

7C–22CLUTCH
Master Cylinder
Disassembled View
208RW016
Legend
(1) Master Cylinder Assembly
(2) Gasket(3) Damper Cylinder Assembly
(4) Nut
(5) Push Rod Damper

CLUTCH7C–23
Disassembly
(4JX1)
1. Remove damper cylinder assembly and gasket.
2. Remove push rod damper.
NOTE: The master cylinder assembly cannot be
disassembled because of point–staked rod stopper.
Inspection and Repair
Clean and inspect the removed parts.
Make necessary parts replacement if any abnormalities
such as wear, oil leaks or other damage are found through
inspection.
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
1.Push rod set length
RHD: 117.5 mm (4.626 in)
LHD: 119 mm (4.685 in)
2.Push rod nut torque
17 Nꞏm (1.7 kgꞏm/12 Ib ft)
3.Damper cylinder torque
47 Nꞏm (4.8 kgꞏm/35 Ib ft)

7C–24CLUTCH
Slave Cylinder
Disassembled View
206RW004
Legend
(1) Cylinder Body
(2) Spring(3) Piston and Piston Cup
(4) Boot
(5) Push Rod
Disassembly
1. Remove boot.
2. Remove push rod.
3. Remove piston and piston cup.
4. Remove spring.
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
Cylinder Body
206RS003
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it
if necessary.

CLUTCH7C–25
Piston and Piston Cup
1. Visually inspect the disassembled piston and piston
cup for excessive wear and damage.
2. Replace the inner parts with new parts shown in the
illustration.
206RS004
3. Measure the clearance between slave cylinder wall
and piston.
4. If the measured value exceeds the specified limit, the
slave cylinder assembly must be replaced.
Standard: 0.07 mm (0.0028 in)
Limit: 0.15 mm (0.0059 in)
206RS005
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
1. Before installing the parts, apply a thin coat of rubber
grease.
2. Install cup in groove in piston with the lip turned to the
front of cylinder. Use care so as not to scratch the
cylinder.
206RS006

7C–26CLUTCH
Damper Cylinder
Disassembled View
205RW005
Legend
(1) Cylinder Body
(2) Spring
(3) Piston Assembly(4) Spacer
(5) Damper Rubber
(6) Cover and Gasket
Disassembly
1. Remove cover and gasket.
2. Remove damper rubber.
3. Remove spacer.
4. Remove piston assembly.
5. Remove spring.
Inspection and Repair
Check damper rubber and piston cup for cracks,
deformation or damage.
Replace the damper cylinder assembly if necessary.
Reassembly
To assemble, follow the disassembly steps in the reverse
order.

CLUTCH7C–27
Main Data and Specifications
General Specifications
Ty p eDry single plate type with diaphragm spring
Size275 mm (10.83 in)
Pressure plate Outside diameter332 mm (13.07 in)
Pressure plate Clamping force7208 N (1621 lb)
Pressure plate Spring finger height49.9–51.9mm(1.965–2.043in)
Driven plate Outside diameter x inside diameter275180 mm (10.836.69 in)
Thickness Clutch disengaged8.8 mm (0.346 in)
Thickness Clutch engaged8.3 mm (0.327 in)
Total friction area 3392cm(522in)
Clutch control type Hydraulic
Clutch pedal free play 5 – 15 mm (0.20 – 0.59 in)
Clutch pedal heightLHD: 217 – 227 mm (8.543 – 8.937 in)
RHD:
(6VE1) 238.5 mm – 248.5 mm (9.390 in – 9.783 in)
(4JX1) 231 mm – 241 mm (9.094 in – 9.488 in)
Clutch pedal stroke 152.5 – 162.5 mm (6.004 – 6.398 in)
4JX1, RHD: 145 – 155mm (5.709 – 6.102 in)
Torque Specifications
E07RW053

7C–28CLUTCH
Torque Specifications (Cont’d)
(6VE1 LHD)
E07RW054

CLUTCH7C–29
Torque Specifications (Cont’d)
(Except 6VE1 LHD)
E07RW055

7C–30CLUTCH
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5-85253-001-0
(J-24547)
Driven plate aligner
5-8840-2000-0 and
5-8840-0019-0
(J-5822 and J-23907)
Pilot bearing remover
and Sliding hammer
5-8840-0125-0
(J-26516-A)
Crankshaft pilot bearing
installer
5-8840-0007-0
(J-8092)
Driver handle

LIGHTING SYSTEM8A–1
BODY AND ACCESSORIES
CONTENTS
Lighting System 8A. . . . . . . . . . . . . . . . . . . . . . . . .
Wiper/Washer System 8B. . . . . . . . . . . . . . . . . . .
Entertainment 8C. . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring System 8D. . . . . . . . . . . . . . . . . . . . . . . . . .
Meter and Gauge 8E. . . . . . . . . . . . . . . . . . . . . . . Body Structure 8F. . . . . . . . . . . . . . . . . . . . . . . . . .
Seats 8G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Security and Locks 8H. . . . . . . . . . . . . . . . . . . . . .
Sun Roof/Convertible Top 8I. . . . . . . . . . . . . . . .
Exterior/Interior Trim 8J. . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM
CONTENTS
Service Precaution 8A–2. . . . . . . . . . . . . . . . . . . . . .
Headlight Bulb 8A–3. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight 8A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight and Associated Parts 8A–4. . . . . . . . .
Removal 8A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight Adjustment 8A–4. . . . . . . . . . . . . . . . . .
Fog Light Bulb 8A–5. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog Light Assembly 8A–6. . . . . . . . . . . . . . . . . . . . .
Removal 8A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog Light Adjustment 8A–6. . . . . . . . . . . . . . . . . .
Clarence Light Bulb 8A–6. . . . . . . . . . . . . . . . . . . . . .
Removal 8A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Fog Light Bulb (RHD) 8A–7. . . . . . . . . . . . . . .
Removal 8A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taillight Bulb (Body) 8A–7. . . . . . . . . . . . . . . . . . . . .
Removal 8A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taillight Bulb (Bumper) 8A–8. . . . . . . . . . . . . . . . . . .
Removal 8A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
License Plate Light Bulb (Body) 8A–8. . . . . . . . . . .
Removal 8A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
License Plate Light Bulb (Bumper) 8A–9. . . . . . . . .
Removal 8A–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stoplight Bulb 8A–9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation 8A–9. . . . . . . . . . . . . . . High Mount Stoplight 8A–10. . . . . . . . . . . . . . . . . . . .
Removal 8A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Turn Signal Light Bulb 8A–10. . . . . . . . . . . . . .
Removal 8A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Turn Signal Light Bulb 8A–11. . . . . . . . . . . . . . .
Removal 8A–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Turn Signal Light Bulb 8A–11. . . . . . . . . . . . . .
Removal 8A–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Backup Light Bulb 8A–12. . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–12
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Dome Light Bulb 8A–12. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Luggage Room Light Bulb 8A–13. . . . . . . . . . . . . . . .
Removal 8A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Courtesy Light Bulb 8A–13. . . . . . . . . . . . . . . . . . . . . .
Removal 8A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Map Light Switch/Bulb 8A–14. . . . . . . . . . . . . . . . . . .
Removal 8A–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cigarette Lighter Illumination Bulb 8A–14. . . . . . . . .
Removal 8A–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Ashtray Illumination Bulb 8A–15. . . . . . . . . . . . . . . . .
Removal 8A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glove Box Illumination Bulb 8A–15. . . . . . . . . . . . . . .
Removal 8A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .