height OPEL FRONTERA 1998 Owner's Manual

8G–4SEATS
Disassembly
1. Remove the head rest.
2. Remove the reclining knob.
3. Remove the dial(1) (W/height adjuster).
Remove the side cover fixing screws and the dial
lock spring(2).
750RW025
4. Remove the side cover.
5. Remove the armrest assembly.
Open the armrest fastener and remove the armrest
fixing bolt.
750RS004
6. Remove the trim cover.
7. Remove the pad and frame assembly.
8. Remove the hinge cover.
9. Remove the back board assembly(3).
Pull out the back board while prying the clip (4) of
the back board free from the seat back assembly.
750RW032
10. Remove the reclining device.
Turn up the seat back trim cover in order to remove
the reclining device fixing bolts.
750RS006

SEATS8G–5
11. Remove the seat back assembly.
Remove the clips (2) from the seat heater harness
(1), and separate the seat heater connector (3)
(models with the seat heater).
750RW029
Remove the seat back assembly fixing nut on the
opposite side of the reclining device.
750RS007
12. Remove the guide holder.
Pull the guide holder out by holding the bottom end
of it from the seat back assembly.
13. Remove the trim cover.
Remove the trim cover hog rings from the back side
of the seat back.
With close attention paid to the hog rings and the
wire which connect the trim cover and the pad and
frame assembly, remove the trim cover while
turning it up.14. Remove the pad and frame assembly.
15. Remove the seat heater assembly.
16. Remove the seat adjuster.
Disconnect the release wire(4) and remove the
fixing bolts.
750RW006
Remove the seat belt buckle assembly.
17. Remove the height adjuster.
18. Remove the spacer (W/O height adjuster).
19. Remove the seat cushion assembly.
20. Remove the trim cover.
Remove the trim cover hog rings from the back side
of the seat cushion assembly.
With close attention paid to the hog rings and the
wire which connect the trim cover and the pad and
frame assembly, remove the trim cover while
turning it up.
21. Remove the frame assembly.
22. Remove the pad assembly.
23. Remove the seat heater assembly.
Reassembly
To reassembly, follow the disassembly steps in the
reverse order, noting the following point.
1. Tighten the armrest assembly fixing bolts to the
specified torque.
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)
2. Tighten the reclining device fixing bolts to the
specified torque.
Torque: 47 Nꞏm (4.8kgꞏm/35 lb ft)

SUPPLEMENTAL RESTRAINT SYSTEM9J–11
Handling / Installation / Diagnosis
1. Air bag assembly should not be subjected to
temperatures above 93
C (200F).
2. Air bag assembly, and SDM should not be used if they
have been dropped from a height of 100 centimeters
(3.28 feet) or more.
3. When a SDM is replaced, it must be oriented with the
arrow on the sensor pointing toward the front of the
vehicle. It is very important for the SDM to be located
flat on the mounting surface, parallel to the vehicle
datum line. It is important that the SDM mounting
surface is free of any dirt or other foreign material.
4. Do not apply power to the SRS unless all components
are connected or a diagnostic chart requests it, as this
will set a diagnostic trouble code.
5. The “SRS Diagnostic System Check” must be the
starting point of any SRS diagnostics. The “SRS
Diagnostic System Check” will verify proper “AIR
BAG” warning lamp operation and will lead you to the
correct chart to diagnose any SRS malfunctions.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacement.
Air Bag Assembly Handling /
Shipping / Scrapping
Live (Undeployed) Air Bag Assembly
Special care is necessary when handling and storing a
live (undeployed) air bag assembly. The rapid gas
generation produced during deployment of the air bag
could cause the air bag assembly, or an object in front of
the air bag assembly, to be thrown through the air in the
unlikely event of an accidental deployment.
827RV004
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG OPENING IS
POINTED AWAY FROM YOU. IN CASE OF AN
ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN
DEPLOY WITH MINIMAL CHANCE OF INJURY.
NEVER CARRY THE AIR BAG ASSEMBLY BY THEWIRES OR CONNECTOR ON THE UNDERSIDE OF
THE MODULE.
Pretensioner Seat Belt Handling /
Shipping / Scrapping.
Live (undeployed) pretensioner seat belt.
Special care is necessary when handling and storing a
live (undeployed) pretensioner seat belt.
The rapid gas generation produced during deployment of
the pretensioner seat belt (could cause the pretensioner
seat belt), or an object around of pretensioner seat belt, to
be thrown through the air in the unlikely event of an
accidental deployment.
WARNING: WHEN CARRYING A LIVE
PRETENSIONER SEAT BELT, MAKE SURE THE
PRETENSIONER SEAT BELT CYLINDER IS POINTED
AWAY FROM YOU. IN CASE OF AN ACCIDENTAL
DEPLOYMENT, THE PRETENSIONER SEAT BELT
WILL THEN DEPLOY WITH MINIMAL CHANCE OF
INJURY. NEVER CARRY THE PRETENSIONER SEAT
BELT BY THE CYLINDER OR WIRES ON THE
UNDERSIDE OF THE MODULE.
827RS044
Air Bag Assembly and/or Pretensioner
Seat Belt Shipping Procedure For
Live(Undeployed) Them.
Service personnel should refer to the Service Bulletins for
proper SRS composition parts shipping procedures.

SUPPLEMENTAL RESTRAINT SYSTEM 9J–30
Service Precautions for SRS
Component Service
CAUTION: When fasteners are removed, always
reinstall them at the same location from which they
were removed. If a fastener needs to be replaced, use
the correct part number fastener for that application.
If the correct part number fastener is not available, a
fastener of equal size and strength (or stronger) may
be used. fasteners that are not reused, and those
requiring thread locking compound will be called
out. The correct torque value must be used when
installing fasteners that require it. If the above
conditions are not followed, parts or system damage
could result.
WARNING: WHEN PERFORMING SERVICE ON OR
AROUND SRS COMPONENTS OR SRS WIRING,
FOLLOW THE PROCEDURES LISTED BELOW TO
TEMPORARILY DISABLE THE SRS. FAILURE TO
FOLLOW PROCEDURES COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY OR OTHERWISE UNNEEDED SRS REPAIRS.
The SDM in Driver–Passenger SRS can maintain
sufficient voltage to cause a deployment for up to 15
seconds after the ignition switch is turned “OFF,” the
battery is disconnected, or the fuse powering the SDM is
removed.
Many of the service procedures require removal of the
“C–21” fuse, and disconnection of the air bag assembly
from the deployment loop to avoid an accidental
deployment. If the air bag assembly is disconnected from
the deployment loop as noted in the “Disabling the SRS”
procedure that follows, service can begin immediately
without waiting for the 15 second time period to expire.
Disabling The SRS
Removal
Turn the ignition switch to “OFF” and turn the steering
wheel so that the vehicle’s wheels are pointing straight
ahead.
1. Remove SRS fuse “C–21” from left dash side lower
fuse block or disconnect battery.
2. Disconnect yellow 2–pin connector at the base of
steering column.
3 . R e m o v e g l o v e b o x a s s e m b l y ; R e f e r t o “ P a s s e n g e r a i r
bag assembly replacement” in this section.
4. Disconnect passenger air bag assembly yellow 2–pin
connector behind the glove box assembly.
CAUTION: W i t h t h e “ C – 2 1 ” f u s e r e m o v e d a n d
ignition switch “ON,” the “AIR BAG” warning lamp
will be “ON.” This is normal operation and does not
indicate an SRS malfunction.
Enabling The SRS
Installation
Turn ignition switch to “LOCK” and remove key.
1. Connect yellow 2–pin connector passenger air bag
assembly.2. Install glove box assembly. Refer to “Passenger Air
Bag Assembly Replacement” in this section.
3. Connect yellow 2–pin connector at the base of the
steering column.
4. Install “AIR BAG” fuse “C–21” to left dash side lower
fuse block or connect battery.
Turn ignition switch to “ON” and verify that the “AIR BAG”
warning lamp turn on 3.5 seconds and then turns “OFF.” If
it does not operate as described, perform the “SRS
Diagnostic System Check” in this section.
Handling / Installation / Diagnosis
1. Air bag assembly should not be subjected to
temperatures above 93
C (200F).
2. Air bag assembly, and SDM should not be used if they
have been dropped from a height of 100 centimeters
(3.28 feet) or more.
3. When a SDM is replaced, it must be oriented with the
arrow on the SDM pointing toward the front of the
vehicle. It is very important for the SDM to be located
flat on the mounting surface, parallel to the vehicle
datum line. It is important that the SDM mounting
surface is free of any dirt or other foreign material.
4. Do not apply power to the SRS unless all components
are connected or a diagnostic chart requests it, as
this will set a diagnostic trouble code.
5. The “SRS Diagnostic System Check” must be the
starting point of any SRS diagnostics. The “SRS
Diagnostic System Check” will verify proper “AIR
BAG” warning lamp operation and will lead you to the
correct chart to diagnose any SRS malfunctions.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacements.
Inspections Required After An Accident
CAUTION: C e r t a i n S R S c o m p o n e n t s m u s t b e
replaced after a frontal crash involving air bag
deployment.
In all types of accidents regardless of “Air Bag”
deployment, visually inspect all of the following
components and replace as required:
— Driver air bag assembly
— Passenger air bag assembly
— Driver pretensioner assembly
— Passenger pretensioner assembly
— Steering wheel
— SRS coil assembly
— Steering column
— Knee bolster and instrument panel mounting
attachments
— Driver seat and belt
— Passenger seat and belt
—SDM
SDM always should be checked according to “SDM
Replacement Guidelines.”

4D1–36
TRANSFER CASE (STANDARD TYPE)
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Standard : 23.4 mm (0.921 in)
Limit : 22.8 mm (0.898 in)
Interlock pin
Standard : 1.59 mm (0.063 in)
Limit : 1.53 mm (0.060 in)
220RW035
Detent Spring Tension
1. Use a spring tester to measure the detent spring
tension.
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Compressed height : 18.7 mm (0.736 in)
Standard : 68.6–88.2 N (7.0–9.0kg/15.4–19.8 lb)
Interlock pin
Compressed height : 11.5 mm (0.453 in)
Standard : 9.8 N (1.0kg/2.2 lb)
220RS013
Shift Arm
1. Inspect the shift arms for wear, distortion or scoring.
Replace if these conditions are present.
Shift Arm Thickness
1. Use a micrometer to measure the shift arm thickness.
2. If the measured value is less than the specified limit,
the shift arm must be replaced.
Shift arm thickness
Standard : 9.60–9.85 mm (0.378–0.388 in)
Limit : 9.0 mm (0.354 in)
230RS006

6A–27
ENGINE MECHANICAL
Exhaust Manifold RH
Removal
1. Disconnect battery ground cable.
2. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
3. Remove exhaust front pipe three stud nuts and two
nuts then disconnect exhaust front pipe.
150RW061
Legend
(1) Exhaust Front Pipe RH
(2) O
2 Sensor (for IGM)
4. Remove heat protector two fixing bolts then the heat
protector.
5. Remove exhaust gas recirculation (EGR) pipe fixing
bolt and nut from exhaust manifold, remove a nut
from EGR valve and a bolt from rear side of cylinder
head for bracket of EGR pipe then remove the EGR
pipe.
056RW001
Legend
(1) Exhaust Gas Recirculation (EGR) Valve
(2) EGR Pipe
6. Remove exhaust manifold eight fixing nuts then the
exhaust manifold.
Installation
1. Install exhaust manifold and tighten bolts to the
specified torque.
Torque : 57 Nꞏm (5.8 Kgꞏm/42 lb ft)
2. Install the EGR pipe, tighten bolt and nut on exhaust
manifold to specified torque.
Torque : 28 Nꞏm (2.9 Kgꞏm/21 lb ft)
Tighten nut to EGR valve to the specified torque.
Torque : 44 Nꞏm (4.5 Kgꞏm/33 lb ft)
Tighten the bolt for EGR pipe bracket to specified
torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
3. Install heat protector
4. Install exhaust front pipe and tighten three stud nuts
and two nuts to the specified torque.
To r q u e :
Stud nuts: 67 Nꞏm (6.8 Kgꞏm/49 lb ft)
Nuts: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
5. Install the torsion bar and readjust the vehicle height.
Refer to installation and vehicle height adjustment
procedure for Front Suspension.

6A–53
ENGINE MECHANICAL
2. Remove camshaft bracket fixing bolt (5), camshaft
bracket (6), then camshaft exhaust (7), and intake
side (8).
3. Remove tappet with shim (11).
4. Use the 5–8840–2446–0 valve spring compressor
and 5–8840–2547–0 valve spring compressor
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).
014RW042
5. Remove spark plug (1).
CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.
Inspection and Repair
1. Cylinder head gasket and mating surfaces for leaks,
corrosion and blow–by. If the gasket has failed,
determine the cause.
– Insufficient torque on head bolts.
– Improper installation
– Loose or warped cylinder head
– Missing dowel pins
– Warped case surface
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.3. Cylinder head deck for corrosion, sand particles in
head and porosity.
CAUTION:
Do not attempt to weld the cylinder head. Replace
it.
Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and exhaust
manifold mating surfaces for flatness. These
surfaces may be reconditioned by milling. If the
surfaces are “out of flat” by more than specification,
the surface should be ground to within specifications.
Replace the head if it requires machining beyond the
repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362 in)
011RW019
5. Water jacket sealing plugs seating surfaces.
Reassembly
1. Install Spark plug and tighten all the spark plugs to
specified torque.
Torque: 18 Nꞏm (1.8 Kgꞏm/13 lb ft)
2. Tighten sub gear setting bolt.
1. Use 5–8840–2443–0 gear spring lever to turn sub
gear to right direction until the M5 bolt aligns with
the hole between camshaft driven gear and sub
gear.

6A–57
ENGINE MECHANICAL
5. Use 5–8840–2446–0 valve spring compressor and
5–8840–2547–0 valve spring compressor adapter to
remove split collar.
014RW042
6. Remove valve spring.
7. Remove valve.
8. Remove oil controller and spring lower seat.
9. Remove the valve guide using the 5–8840–2442–0
valve guide replacer.
Inspection and Repair
Valve Spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is evident.
1. Measure the free height of the springs. The springs
must be replaced if the free height is below the
specified limit.
Standard : 44.6 mm (1.7559 in)
Limit : 43.6 mm (1.7165 in)
014RS004
2. Measure the valve spring squareness with a steel
square and replace the valve springs if the measured
value exceeds the specified limit.
Limit : 2 mm (0.0787 in)
014RS005
3. Using a spring tester to compress the springs to the
installed height, measure the compressed spring
tension, and replace the springs if the measured
tension is below the specified limit.
At installed height: 35.0 mm (1.38 in)
Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)
014RS006
Valve Guide
CAUTION: Take care not to damage the valve seat
contact surface, when removing carbon adhering to
the valve head. Carefully inspect the valve stem for
scratchs or abnormal wear. If these conditions are
present, the valve and the valve guide must be
replaced as a set.

6A–58
ENGINE MECHANICAL
1. Measure the valve stem diameter with a micrometer.
If the valve stem diameter is less than the specified
limit, the valve and the valve guide must be replaced
as a set.
Diameter of Valve Stem
Intake
Standard : 5.977 mm–5.959 mm
(0.2353 in–0.2346 in)
Limit : 5.90 mm (0.2323 in)
Exhaust
Standard : 5.952 mm–5.970 mm
(0.2343 in–0.2350 in)
Limit : 5.90 mm (0.2323 in)
014RS007
2. Measure the inside diameter of the valve guide with a
micrometer. Subtract the measured outer diameter of
the valve stem from the measured inner diameter of
the valve guide. If the value exceeds the specified
limit, the valve and the valve guide must be replaced
as a set.
Inside Diameter of the Vale Guide
Inlet clearance
Standard : 0.023 mm–0.056 mm
(0.0009 in–0.0002 in)
Limit : 0.20 mm (0.00787 in)
Exhaust clearance
Standard : 0.030 mm–0.063 mm
(0.0012 in–0.0025 in)
Limit : 0.20 mm (0.00787 in)
Valve Guide Replacement
1. Using Valve guide replacer: 5–8840–2442–0, drive
out the valve guide from the combustion chamber
side.
014RS008
2. Apply engine oil to the outside of the valve guide.
Using valve guide replacer 5–8840–2442–0, drive in
a new valve guide from the camshaft side, and check
the valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)
014RW046
3. Check the clearance. If the clearance is less than the
specified value, ream the inside diameter of valve
guide. Using a sharp 6 mm reamer, ream the valve
guide to obtain the specified clearance.
Va l v e S e a t
1. Measure the protrusion of the valve stem when a new
valve is installed in the cylinder head. If the protrusion
of the valve stem exceeds the limit, replace the valve
seat insert or the cylinder head assembly.
Protrusion of valve stem
Intake
Standard: 39.32 mm (1.5480 in)

6A–64
ENGINE MECHANICAL
014RW060
2. Remove twenty fixing bolts from inlet and exhaust
camshaft bracket on one side bank, then camshaft
brackets (2).
014RW027
3. Remove camshaft assembly (3), (4).
4. Remove three fixing bolts (7) from camshaft drive
gear retainer (8), then camshaft drive gear assembly.
Inspection and Repair
1. Use a micrometer to measure the cam lobe height
and uneven wear. Replace the camshaft if either the
lobe height or the uneven wear exceeds the specified
limit.
Lobe height : 44.709 mm (1.7602 in)
Uneven wear : 0.05 mm (0.0020 in)
014RW043
2. Use a micrometer to measure the diameter and the
uneven wear of the camshaft journals.
Replace the camshaft if the diameter or the uneven
wear exceeds the specified limit.
Journal Diameter
Standard : 25.972 mm–25.993 mm
(1.0225 in–1.0233 in)
Limit : 25.8 mm (1.0157 in)
Uneven wear : 0.05 mm (0.0020 in)
014RS023
3. Place the camshaft on V–blocks.
Slowly rotate the camshaft and measure the runout
with a dial indicator.
Replace the camshaft if the runout exceeds the
specified limit.