brakes OPEL FRONTERA 1998 Owner's Manual

5B–1 ANTI–LOCK BRAKE SYSTEM
BRAKES
ANTI-LOCK BRAKE SYSTEM
CONTENTS
Service Precaution 5B–1. . . . . . . . . . . . . . . . . . . . . .
Electronic Hydraulic Control Unit 5B–2. . . . . . . . . .
Electronic Hydraulic Control Unit and
Associated Parts 5B–2. . . . . . . . . . . . . . . . . . . . . .
Removal 5B–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5B–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
G-Sensor 5B–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5B–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5B–3. . . . . . . . . . . . . . . . . .
Installation 5B–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Speed Sensor 5B–4. . . . . . . . . . . . . . . Front Wheel Speed Sensor and
Associated Parts 5B–4. . . . . . . . . . . . . . . . . . . . . .
Removal 5B–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5B–5. . . . . . . . . . . . . . . . . .
Installation 5B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Speed Sensor 5B–6. . . . . . . . . . . . . . .
Rear Wheel Speed Sensor and
Associated Parts 5B–6. . . . . . . . . . . . . . . . . . . . . .
Removal 5B–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5B–6. . . . . . . . . . . . . . . . . .
Installation 5B–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM(SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.CAUTION: Replace all components included in
repair kits used to service this system. Lubricate
rubber parts with clean, fresh brake fluid to ease
assembly. Do not use shop air with in–line
lubricators on brake parts, as damage to rubber
components may result. If any hydraulic component
is removed or brake line disconnected, it may be
necessary to bleed part or all of the brake system.
NOTE: The use of rubber hoses or parts other than those
furnished specifically for the Anti–lock Brake System may
lead to functional problems requiring major overhaul.

5B–2ANTI–LOCK BRAKE SYSTEM
Electronic Hydraulic Control Unit
Electronic Hydraulic Control Unit and Associated Parts
350RW013
Legend
(1) Connector
(2) Hydraulic Unit ASM(3) Bolts
(4) Nut
(5) Bolt
Removal
1. Remove battery ASM.
2. Remove harness connector.
3. Remove EHCU fixing nuts.
4. Remove brake pipes.
After disconnecting brake pipe, cap or tape the
openings of the brake pipe to prevent the entry of
foreign matter.
5. Remove hydraulic unit fixing nuts.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
To r q u e
Hydraulic unit fixing nuts : 22 Nꞏm (2.2kgꞏm/16
lb ft)
Ground cable : 14 Nꞏm (1.4kgꞏm/10 lb ft)
Brake pipe (joint bolts) : 16 Nꞏm (1.6kgꞏm/12
lb ft)
After installing the hydraulic unit, bleed brakes
completely. Refer to Servicing in Power Assisted
Brake System section.

7A1–42
TRANSMISSION CONTROL SYSTEM (4L30–E)
DTC P0719 TCC Brake Switch Circuit High (Stuck On)
D07RW032
Circuit Description
The TCC brake switch is used to indicate brake pedal
status. The normally opened brake switch signal voltage
circuit is opened.
Brake switch supplies a B+ signal on circuit GRN/YEL to
the PCM when the brakes are applied. The PCM uses
this signal to deenergize the TCC solenoid when the
brakes are applied.
This DTC detects a closed brake switch during
accelerations. This is a type “D” DTC.
Conditions For Setting The DTC
No OSS DTCs P0722 or P0723.
The PCM detects a closed brake switch/circuit (12
volts) for 2 seconds, and the following events occur
seven consecutive times: vehicle speed is less than 8
km/h (5 mph); then vehicle speed is between 8 and 32
km/h (5 and 20 mph) for 4 seconds; then vehicle
speed is greater than 32 km/h (20 mph) for 4 seconds.
Action Taken When The DTC Sets
If throttle opening is greater than 10% and vehicle
speed is greater than 45 km/h (28 mph), then
disregard brake switch contingency for TCC off
mode.
The PCM will not illuminate the CHECK TRANS
Lamp.
Conditions For Clearing The DTC
The DTC can be cleared from the PCM history by
using a scan tool.
The DTC will be cleared from history when the vehicle
has achieved 40 warmup cycles without a failure
reported.
The PCM will cancel the DTC default actions when
the fault no longer exists and the ignition is cycled “off”
long enough to power down the PCM.
Diagnostic Aids
Inspect the wiring for poor electrical connections at
the PCM and TCC brake switch. Look for possible
bent, backed out, deformed or damaged terminals.
Check for weak terminal tension as well. Also check
for a chafed wire that could short to bare metal or
other wiring. Inspect for a broken wire inside the
insulation.
When diagnosing for a possible intermittent short or
open condition, move the wiring harness while
observing test equipment for a change.
Check customer driving habits and/or unusual driving
conditions (i.e. stop and go, highway).
Check brake switch for proper mounting and
adjustment.
Test Description
The numbers below refer to the step numbers on the
diagnostic chart:
3. This test checks for voltage at the brake switch.
6. This test checks the brake switch.
9. This test checks circuit GRN/YEL at the PCM.

PAGE BACK PAGE NEXT
THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTRNTS
5A BRAKE CONTROL SYSTEM
5B ANTI-LOCK BRAKE SYSTEM
5C POWER ASSISTED BRAKE SYSTEM
5D PARKING BRAKES
HOME
5A
5B
5C
5D

DIFFERENTIAL (FRONT) 4A1–6
3. Remove the drain bolt to drain differential oil.
NOTE:
a. During the work, be sure that the diff case is
supported by the jack.
412RS003
b. Remove the brake caliper fixing bolt and hang the
caliper. Refer to Front Disc Brake Caliper Assembly
in Brake section.
c. Remove the antilock brake system speed sensor (if
equipped). Refer to Front Wheel Speed Sensor in
Brakes section.
4. Remove the hub assembly (Disc, back plate and
knuckle), refer to Front Hub and Disc in this section.
5. Disconnect the knuckle and the suspension arm.
Refer to Suspension section.
6. Remove steering link and arm assembly, refer to
Steering Linkage in Steering section.
7. Remove suspension crossmember.
8. Remove propeller shaft, refer to Front Propeller Shaft
in this section.
9. Remove protector (Shift on the fly model).
10. Remove the hose clip.
11. Disconnect breather hose from front drive axle tube.
(and disconnect housing : Shift on the fly model).
12. Disconnect vacuum hose from actuator (Shift on the
fly model).13. Disconnect shift switch connector (Shift on the fly
model).
412RS031
14. Remove VSV assembly (1) (Shift on the fly model).
NOTE: Be sure not to remove hose and connector from
VSV asm.
412RW002

4A2A–4
DIFFERENTIAL (REAR 220mm)
Axle Housing
Axle Housing and Associated Parts
420RW022
Legend
(1) Coil Spring and Insulator
(2) Axle Housing Assembly
(3) ABS Speed Sensor and Harness(if equipped)
(4) Nut
(5) Parking Brake Cable
(6) Bolt and Nut
(7) Antilock Brake System (ABS) Connector and
Bracket (if equipped)
(8) Bolt and Nut(9) Nut
(10) Differential Assembly
(11) Axle Shaft Assembly
(12) Brake Disc
(13) Brake Pipe
(14) Brake Caliper
(15) Nut
(16) Breather Hose
(17) Flare Nut
Removal
1. Raise the vehicle and support it with suitable safety
stands.
The hoist must remain under the rear axle housing.
2. Drain brake fluid. Refer to Hydraulic Brakes in Brake
section.
3. Remove rear wheels and tires. Refer to Wheel in
Suspension section.4. Remove propeller shaft. Refer to Rear Propeller
Shaft in this section.
5. Drain the rear axle oil into a proper container.
6. Remove parking brake cable, release the connection
between the cable fixing clip equalizer. Refer to
Parking Brakes in Brake section.
7. Move the clip aside and pull out the breather hose.

DIFFERENTIAL (REAR 220mm)
4A2A–5
8. Disconnect the ABS connectors (1) and remove the
brackets (2) attached to the frame and center link
(ABS model only).
350RS001
9. Loosen the brake tube flare nut, remove the clip and
take out the brake tube.
10. Remove the shock absorber fixing nut from the axle
housing.
11. Remove the stabilizer linkage mounting nut from the
axle housing.
12. Remove the lateral rod fixing nut from the axle
housing.
13. Remove the center link mounting bolt and nut from
the axle housing.
14. Remove the trailing link fixing bolt and nut from the
axle housing.
15. Jack down and remove the coil spring and insulator.
16. Axle housing assembly can be separated from the
vehicle on completion of steps 1 – 11.
17. Remove the brake caliper fixing bolt (3), loosen the
flare nut (1), release the clip (2) and take out the brake
caliper together with the flexible hose.
306RS001
18. Remove brake disc.
19. Remove antilock brake system speed sensor fixing
bolt and the clip and bracket on the axle housing
(ABS model only).
20. Remove the brake pipe clip and fixing bolt on the axle
housing and take out the brake pipe.
21. Remove the bearing holder fixing nut and take out the
axle shaft assembly, be sure not to damage the oil
seal by the spline of the shaft, Refer to Axle Shaft in
this section.
22. Remove differential assembly, refer to Differential
Assembly in this section.
Oil Seal Replacement
Remove the oil seal, carefully not to damage the housing,
and mount new oil seal using oil seal installer
5–8840–2294–0.
420RW028
Installation
1. Install differential assembly, refer to Differential
Assembly in this section.
2. Install axle shaft assembly then tighten the bearing
holder mounting nut to the specified torque. Be sure
not to damage the oil seal by the spline of the shaft.
Torque: 74Nꞏm (7.5kgꞏm/54lb ft)
3. Install brake pipe.
4. Connect antilock brake system (ABS) speed sensor
and harness, refer to 4–Wheel Anti–Lock Brake
System (ABS) in Brake section (ABS model only).
5. Install brake disc.
6. Install brake caliper. Refer to Disk Brakes in Brake
section.
7. Install axle housing assembly.
8. Install coil spring and insulator.
9. Install the trailing link fixing bolt and nut to the axle
housing. For the procedures in items 9–13, refer to
Suspension section.
10. Install the center link bolt and nut to the axle housing.

4A2A–6
DIFFERENTIAL (REAR 220mm)
11. Install the lateral rod fixing nut to the axle housing.
12. Install the stabilizer linkage mounting nut to the axle
housing.
13. Install the shock absorber fixing nut to the axle
housing.
14. Install brake tube flare nut, Refer to Disk Brakes in
Brake section.15. Install ABS connector and bracket (ABS model only).
16. Connect breather hose.
17. Install parking brake cable, Refer to Parking Brakes in
Brake section.
18. Bleed brakes. Refer to Hydraulic Brakes in Brake
section.
Axle Shaft
Axle Shaft and Associated Parts
420RY00005
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
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.
6. Remove Parking brake assembly. Refer to Parking
Brakes in Brake section.

DIFFERENTIAL (REAR 220mm)
4A2A–9
6. Install snap ring.
7. Install axle shaft assembly.
NOTE: Be sure not to damage the oil seal.
8. Tighten the bearing holder mounting nut to the
specified torque.
Torque: 74Nꞏm (54 Ib ft)
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.
12. Install brake disc.
13. Install brake caliper, refer to Disk Brakes in Brake
section.
Pinion Oil Seal
Pinion Oil Seal and Associated Parts
425RW054
Legend
(1) Flange Nut and Washer
(2) Flange(3) Oil Seal
(4) Outer Bearing
(5) Collapsible Spacer
Removal
1.Remove the rear propeller shaft. Refer to Rear
Propeller Shaft in this section.
2. Drain the rear axle oil.

DIFFERENTIAL (REAR 220mm)
4A2A–11
Differential Assembly
Differential Assembly and Associated Parts
425RW055
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(ABS model only).
Refer to 4–Wheel Anti–lock Brake System (ABS) in
Brake 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.