heating OPEL FRONTERA 1998 Owner's Manual

SUPPLEMENTAL RESTRAINT SYSTEM 9J–12
Deployed Air Bag Assembly (Driver Side)
“You should wear gloves and glasses. After the air bag
assembly has been deployed, the surface of the air bag
may contain solid particulate. This solid particulate
c o n s i s t s p r i m a r i l y o f b y p r oducts of the chemical reaction,
Potassium Chloride and copper metal dust. Compounds
of Potassium Borate, Strontium Chloride, Copper
Chloride, and Ammonium Chloride may be found in
amounts of about 1% (each) of the total particulate.”
Deployed Pretensioner Seat Belt.
You should wear gloves and safety glasses. After the
pretensioner seat belt has been deployed, the surface of
the pretensioner seat belt cylinder may heating up.
Air Bag Assembly and/or Pretensioner
Seat Belt Scrapping Procedure.
During the cause of vehicle’s useful life, certain situations
may arise which will necessitate the disposal of a live air
bag and/or pretensioner seat belt. (This information
covers proper procedures for disposing of a live air bag
assembly and/or pretensioner seat belt.)
Before a live air bag assembly can be dispose off, it must
be deployed.
A live air bag assembly and/or pretensioner seat belt
must not be disposed of though normal refuse channels.
WARNING: FAILURE TO FOLLOW PROPER
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR
BAG ASSEMBLY DISPOSAL PROCEDURES CAN
RESULT IN AIR BAG DEPLOYMENT WHICH MAY
CAUSE PERSONAL INJURY. AN UNDPLOYED AIR
BAG ASSEMBLY MUST NOT BE DISPOSED OF
THROUGH NORMAL REFUSE CHANNELS. THE
UNDEPLOYED AIR BAG ASSEMBLY CONTAINS
SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS
OR PERSONAL INJURY IF THE SEALED CONTAINER
IS DAMAGED DURING DISPOSAL. DISPOSAL IN
ANY MANNER INCONSISTENT WITH PROPER
PROCEDURES MAY BE A VIOLATION OF LOCAL
LAW.
In situations which require deployment of a live air bag
assembly, deployment may be accomplished inside or
outside the vehicle. The method employed depends
upon the final disposition of the particular vehicle, as
noted in “Deployment Outside Vehicle” and “Deployment
Inside Vehicle” in this section.
Cautions About Air Bag Deployment And
Disposal
Failure to follow proper procedures could result in
erroneous air bag deployment which may cause personal
injury be sure to follow proper procedures.
1. Turn off (Lock) the ignition switch and disconnect the
minus terminal of the battery, then start the work 15 or
more sec later. (Air bag is designed to work by the
back-up power source even if the battery power
source is cut off at vehicle collision).
2. Be sure not to disassemble the air bag.
3. Do not give an impact to the air bag and bring the air
bag close to magnet. (The air bag could deploy
unexpectedly).4. Place the air bag with its trim cover up.
5. Do not let the air bag deploy directly on the floor. (The
air bag may be blown off 2
3 m (6.5 or 10 feet)).
6. Be sure to install the air bag firmly to a deployment
tool (fixing tool).
7. Set a battery 10 m (33 feet) or more away from the air
bag.
8. Before disconnecting air bag harness, ground the
worker by touching the vehicle outer panel with bare
hand.
9. When connecting or disconnecting the harness, do
not work just in front of the air bag.
10. As deployment gives rise to big sound, warn the
people around against it. Further, try to reduce the
sound by covering the steering wheel or tires, and
shut the vehicle windows in case of deployment
inside the vehicle.
11. As deployment generates smoke, select a well
ventilated place. (In case of deployment indoors,
avoid deployment just under a fire alarm, smoke
sensor, and fluorescent lamps).
12. Be careful not to inhale the smoke after deployment.
13. If part of the vehicle glass is damaged, cover the
vehicle with a car cover to prevent the glass from
braking at the time of deployment.
14. Do not touch the air bag immediately after
deployment, since it remains hot for 30 minutes.
15. Do not water the air bag immediately after
deployment.
16. Wear safety glasses and gloves throughout the work
and wash the glasses and gloves after the work.
17. Do not reuse the removed air bag for another vehicle.
(Deployment characteristic is different with vehicle
types).
Deployment Outside Vehicle (Driver Air
Bag Assembly)
Deployment outside the vehicle is proper when the
vehicle is to be returned to service. This includes, for
example, situations in which the vehicle will be returned to
useful service after a functionally or cosmetically deficient
air bag assembly is replaced. Deployment and disposal
of a malfunctioning air bag assembly is, of course, subject
to any required retention period.
For deployment of a live (undeployed) air bag assembly
outside the vehicle, the deployment procedure must be
followed exactly. Always wear safety glasses during this
deployment procedure until a deployed air bag assembly
is scrapped or until an undeployed air bag assembly is
shipped. Before performing the procedures you should
be familiar with servicing the SRS and with proper
handling of the air bag assembly. Procedures should be
read fully before they are performed.
The following procedure requires use of 5–8840–2468–0
SRS deployment harness with appropriate pigtail
adapter. Do not attempt procedure without
5–8840–2468–0 adapter.
WARNING: FAILURE TO FOLLOW PROCEDURES IN
THE ORDER LISTED MAY RESULT IN PERSONAL
INJURY. NEVER CONNECT DEPLOYMENT

PAGE BACK PAGE NEXT
THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTRNTS
1A HEATING AND VENTILATION
1B AIR CONDITIONING
1D COMPRESSOR OVERHAUL
HOME
1A
1B
1D

Occurrence of a trouble
Refer to the check list for
the inspection.Locate the failed location.
Check the failed part.
Correction
Correction
Correction
Troubleshooting by the
self-diagnosis function.Reference the "Check
Procedure by Failed
Location" for the inspection.
Reference the "Check
Procedure by Failed
Location" for the inspection.Correction
Check the cooling / heating
cycles.
End OK OK OK OKNG
NG
NG
NG
NG OK
Check if the automatic
heater / air conditioner
control unit indicator LED
is turned on.Check the power supply and
circuit on the automatic
heater / air conditioner control
unit.
Troubleshooting not relying
on the self-diagnosis
function(troubleshooting
by failure type).
F01RX009

6A–11
ENGINE MECHANICAL
Condition CorrectionPossible cause
Engine overheatingLevel of Engine Coolant too lowReplenish
Fan clutch defectiveReplace
Incorrect fan installedReplace
Thermostat defectiveReplace
Engine Coolant pump defectiveCorrect or replace
Radiator cloggedClean or replace
Radiator filler cap defectiveReplace
Level of oil in engine crankcase too
low or wrong engine oilChange or replenish
Resistance in exhaust system
increasedClean exhaust system or replace
defective parts
Throttle Position Sensor adjustment
incorrectReplace with Throttle Valve ASM
Throttle Position Sensor circuit open
or shortedCorrect or replace
Cylinder head gasket damagedReplace
Engine overcoolingThermostat defectiveReplace (Use a thermostat set to
open at 82
C (180F))
Engine lacks compression————Refer to Hard Start
OthersTire inflation pressure abnormalAdjust to recommended pressures
Brake dragAdjust
Clutch slippingAdjust or replace
Level of oil in engine crankcase too
highCorrect level of engine oil
Exhaust Gas Recirculation Valve
defectiveReplace
Engine Noisy
Abnormal engine noise often consists of various noises
originating in rotating parts, sliding parts and othermoving parts of the engine. It is, therefore, advisable to
locate the source of noise systematically.
Condition
Possible causeCorrection
Noise from crank journals or from
crank bearings
(Faulty crank journals and crankOil clearance increased due to worn
crank journals or crank bearingsReplace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing
yj
bearings usually make dull noise that
becomes more evident when
accelerating)Crankshaft out of roundReplace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing
Crank bearing seizedCrank bearing seized. Replace crank
bearings and crankshaft or regrind
crankshaft and install the undersize
bearing
Troubleshooting Procedure
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with defectivebearing by listening for abnormal noise that stops when
spark plug is shorted out.

6A–13
ENGINE MECHANICAL
Condition CorrectionPossible cause
Engine knockingPreignition due to use of spark plugs
of inadequate heat rangeInstall Spark Plugs of adequate heat
range
Carbon deposits in combustion
chambersClean
Fuel too low in octane ratingReplace fuel
Wide Open Throttle enrichment
system failureRefer to Section 6E
Selection of transmission gear
incorrectCaution operator of incorrect gear
selection
Engine overheatingRefer to “Engine Lacks Power”
OthersWater pump defectiveReplace
Drive belt slippingReplace auto tentioner or drive belt
Abnormal Combustion
ConditionPossible causeCorrection
Trouble in fuel systemFuel pressure control valve defectiveReplace
Fuel filter cloggedReplace
Fuel pump cloggedClean or replace
Fuel tank or fuel pipe cloggedClean or replace
Fuel injector cloggedClean or replace
Fuel pump relay defectiveReplace
Power supply cable for fuel pump
broken or poor connectionsReconnect, correct or replace
Mass Airflow (MAF) sensor circuit
open or defectiveCorrect or replace
MAF Sensor defectiveReplace
Manifold Absolute Pressure Sensor
circuit open or shortedCorrect or replace
Manifold Absolute Pressure Sensor
defectiveReplace
Engine Coolant Temperature (ECT)
Sensor circuit open or shortedCorrect or replace
ECT Sensor defectiveReplace
Throttle Position Sensor adjustment
incorrectReadjust
Throttle Position Sensor defectiveReplace
Throttle Position Sensor connector
poor connectionsReconnect
Vehicle Speed Sensor cable poor
connections or defectiveCorrect or replace
Vehicle Speed Sensor loosely fixedFix tightly
Vehicle Speed Sensor in wrong
contact or defectiveReplace
Powertrain Control Module cable
poor connections or defectiveCorrect or replace

6A–78
ENGINE MECHANICAL
015RS031
Remove any ridge or carbon build up from the top
end of the cylinder.
9. Remove the piston rings (8) with a piston ring
expander. Arrange the removed piston rings in the
cylinder number order.
015RS022
10. Remove the piston pin (9) using 5–8840–0551–0
piston pin service set and piston support with a press.
NOTE: Keep the parts removed from each cylinder
separate. All parts must be reinstalled in their original
positions. Heating the connecting rod will permit easy
removal of the piston pin.
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
11. Piston (10)
12. Connecting rod (11)
Inspection and Repair
Pistons (10)
Carefully clean away all the carbon adhering to the piston
head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston for
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must be
replaced.
Piston Diameter
1. Measure the piston outside diameter with micrometer
at the piston grading position and a right angle to the
piston pin.
Piston grading position (from piston head)
Piston grading position : 43.0 mm (1.6929 in)

ENGINE COOLING6B–5
Diagnosis
Engine Cooling Trouble
ConditionPossible causeCorrection
Engine overheatingLow Engine Coolant levelReplenish
Incorrect fan installedReplace
Thermo meter unit faultyReplace
Faulty thermostatReplace
Faulty Engine Coolant temperature
sensorRepair or replace
Clogged radiatorClean or replace
Faulty radiator capReplace
Low engine oil level or use of
improper engine oilReplenish or change oil
Clogged exhaust systemClean exhaust system or replace
faulty parts
Faulty Throttle Position sensorReplace throttle valve assembly
Open or shorted Throttle Position
sensor circuitRepair or replace
Damaged cylinder head gasketReplace
Engine overcoolingFaulty thermostatReplace
Engine slow to warm–upFaulty thermostatReplace
Thermo unit faultyReplace

6B–10
ENGINE COOLING
6. Disconnect the reserve tank hose(4) from radiator.
7. Remove bracket(5).
110RW004
8. Lift up and remove the radiator assembly with hose,
taking care not to damage the radiator core with a fan
blade.
9. Remove rubber cushions on both sides at the bottom.
Inspection
Radiator Cap
Measure the valve opening pressure of the pressurizing
valve with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside
the standard range.
Valve opening pressure kPa (psi) 88.3
117.7
(12.8
17.1)
Cap tester: 5–8840–0277–0
Adapter: 5–8840–2603–0
Check the condition of the vacuum valve in the center of
the valve seat side of the cap. If considerable rust or dirt is
found, or if the valve seat cannot be moved by hand, clean
or replace the cap.Valve opening vacuum kPa (psi) 1.96
4.91
(0.28
0.71)
110RS006
Radiator Core
1. A bent fin may result in reduced ventilation and
overheating may occur. All bent fins must be
straightened. Pay close attention to the base of the fin
when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator
Thoroughly wash the inside of the radiator and the engine
coolant passages with cold water and mild detergent.
Remove all signs of scale and rust.
Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator
through the filler neck at the specified pressure of 196 kPa
(28.5 psi) with a cap tester:
Leakage from the radiator
Leakage from the coolant pump
Leakage from the water hoses
Check the rubber hoses for swelling.

6E–38
ENGINE DRIVEABILITY AND EMISSIONS
General Service Information
OBD Serviceablity Issues
The list of non-vehicle faults that could affect the
performance of the OBD system has been compiled.
These non-vehicle faults vary from environmental
conditions to the quality of fuel used.
The illumination of the MIL (“Check Engine” lamp) due to
a non-vehicle fault could lead to misdiagnosis of the
vehicle, increased warranty expense and customer
dissatisfaction. The following list of non-vehicle faults
does not include every possible fault and may not apply
equally to all product lines.
Fuel Quality
Using fuel with the wrong octane rating for your vehicle
may cause driveability problems. Many of the major fuel
companies advertise that using “premium” gasoline will
improve the performance of your vehicle. Most premium
fuels use alcohol to increase the octane rating of the fuel.
Although alcohol-enhanced fuels may raise the octane
rating, the fuel’s ability to turn into vapor in cold
temperatures deteriorates. This may affect the starting
ability and cold driveability of the engine.
Low fuel levels can lead to fuel starvation, lean engine
operation, and eventually engine misfire.
Non-OEM Parts
All of the OBD diagnostics have been calibrated to run
with OEM parts. Something as simple as a
high-performance exhaust system that affects exhaust
system back pressure could potentially interfere with the
operation of the EGR valve and thereby turn on the MIL
(“Check Engine” lamp). Small leaks in the exhaust
system near the post catalyst oxygen sensor can also
cause the MIL (“Check Engine” lamp) to turn on.
Aftermarket electronics, such as cellular phones,
stereos, and anti-theft devices, may radiate EMI into the
control system if they are improperly installed. This may
cause a false sensor reading and turn on the MIL (“Check
Engine” lamp).
Environment
Temporary environmental conditions, such as localized
flooding, will have an effect on the vehicle ignition system.
If the ignition system is rain-soaked, it can temporarily
cause engine misfire and turn on the MIL (“Check Engine”
lamp).
Poor Vehicle Maintenance
The sensitivity of OBD diagnostics will cause the MIL
(“Check Engine” lamp) to turn on if the vehicle is not
maintained properly. Restricted air filters, fuel filters, and
crankcase deposits due to lack of oil changes or improper
oil viscosity can trigger actual vehicle faults that were not
previously monitored prior to OBD. Poor vehicle
maintenance can not be classified as a “non-vehicle
fault”, but with the sensitivity of OBD diagnostics, vehicle
maintenance schedules must be more closely followed.Related System Faults
Many of the OBD system diagnostics will not run if the
PCM detects a fault on a related system or component.
One example would be that if the PCM detected a Misfire
fault, the diagnostics on the catalytic converter would be
suspended until Misfire fault was repaired. If the Misfire
fault was severe enough, the catalytic converter could be
damaged due to overheating and would never set a
Catalyst DTC until the Misfire fault was repaired and the
Catalyst diagnostic was allowed to run to completion. If
this happens, the customer may have to make two trips to
the dealership in order to repair the vehicle.
Maintenance Schedule
Refer to the Maintenance Schedule.
Visual / Physical Engine Compartment
Inspection
Perform a careful visual and physical engine
compartment inspection when performing any diagnostic
procedure or diagnosing the cause of an emission test
failure. This can often lead to repairing a problem without
further steps. Use the following guidelines when
performing a visual/physical inspection:
Inspect all vacuum hoses for punches, cuts,
disconnects, and correct routing.
Inspect hoses that are difficult to see behind other
components.
Inspect all wires in the engine compartment for proper
connections, burned or chafed spots, pinched wires,
contact with sharp edges or contact with hot exhaust
manifolds or pipes.
Basic Knowledge of Tools Required
NOTE: Lack of basic knowledge of this powertrain when
performing diagnostic procedures could result in an
incorrect diagnosis or damage to powertrain
components. Do not attempt to diagnose a powertrain
problem without this basic knowledge.
A basic understanding of hand tools is necessary to effec-
tively use this section of the Service Manual.
Serial Data Communications
Class II Serial Data Communications
This vehicle utilizes the “Class II” communication system.
Each bit of information can have one of two lengths: long
or short. This allows vehicle wiring to be reduced by
transmitting and receiving multiple signals over a single
wire. The messages carried on Class II data streams are
also prioritized. If two messages attempt to establish
communications on the data line at the same time, only
the message with higher priority will continue. The device
with the lower priority message must wait. The most
significant result of this regulation is that it provides Tech 2
manufacturers with the capability to access data from any
make or model vehicle that is sold.

6E–270
ENGINE DRIVEABILITY AND EMISSIONS
Detonation/Spark Knock Symptom
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
A mild to severe ping, usually worse under acceleration.
The engine makes sharp metallic knocks that change
with throttle opening.
Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2
Go to OBD
System
Check
21. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?
—Verify repairGo to Step 3
3Was a visual/physical check performed?
—Go to Step 4
Go to
Visual/Physic
al Check
4If Tech 2 readings are normal (refer to Ty p i c a l S c a n
Va lu es
) and there are no engine mechanical faults, fill
the fuel tank with a known quality gasoline that has a
minimum octane rating of 87 and re-evaluate the
vehicle performance.
Is detonation present?
—Go to Step 5Verify repair
51. Check the transmission range switch circuit. Use
Tech 2 and be sure Tech 2 indicates that the vehicle
is in drive with the gear selector in drive or overdrive.
2. If a problem is found, diagnose and repair the
transmission range switch as necessary (refer to
4L30-E Automatic Transmission Diagnosis).
Was a problem found?
—Verify repairGo to Step 6
61. Check TCC operation. Refer to 4L30-E
Transmission Diagnosis
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 7
71. Check for obvious overheating problems:
Low engine coolant.
Restricted air flow to radiator, or restricted
water flow through radiator.
Correct coolant solution should be a 50/50 mix
of approved antifreeze/coolant and water.
Refer to
Engine Cooling.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 8
81. Check fuel pressure. Refer to Chart Fuel System
Pressure Test.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 9
91. Check items that can cause an engine to run lean
(long term fuel trim significantly in the positive
range). For a lean condition, refer to
Diagnostic
Aids
in DTC P0171 Diagnostic Support.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 10