transmission OPEL FRONTERA 1998 Workshop Manual

MANUAL TRANSMISSION7B–73
Special Tools (Cont’d)
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–0015–0
(J–22912–01)
Bearing separator

CLUTCH7C–1
TRANSMISSION
CLUTCH
CONTENTS
Service Precaution 7C–1. . . . . . . . . . . . . . . . . . . . . .
General Description 7C–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 7C–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Assembly 7C–9. . . . . . . . . . . . . . . . . . . . . . . .
Clutch Assembly and Associated Parts 7C–9. . .
Removal 7C–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 7C–10. . . . . . . . . . . . . . . . . .
Installation 7C–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Control 7C–17. . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Control Parts 7C–17. . . . . . . . . . . . . . . . . . .
Removal 7C–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 7C–18. . . . . . . . . . . . . . . . . .
Installation 7C–19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 7C–19. . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder 7C–22. . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7C–22. . . . . . . . . . . . . . . . . . . .
Disassembly 7C–23. . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 7C–23. . . . . . . . . . . . . . . . . .
Reassembly 7C–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Slave Cylinder 7C–24. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7C–24. . . . . . . . . . . . . . . . . . . .
Disassembly 7C–24. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 7C–24. . . . . . . . . . . . . . . . . .
Reassembly 7C–25. . . . . . . . . . . . . . . . . . . . . . . . . .
Damper Cylinder 7C–26. . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7C–26. . . . . . . . . . . . . . . . . . . .
Disassembly 7C–26. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 7C–26. . . . . . . . . . . . . . . . . .
Reassembly 7C–26. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 7C–27. . . . . . . . . . . . .
General Specifications 7C–27. . . . . . . . . . . . . . . . .
Torque Specifications 7C–27. . . . . . . . . . . . . . . . . .
Special Tools 7C–30. . . . . . . . . . . . . . . . . . . . . . . . . . .
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 PERFOMING 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 fastner in the
proper location. When you reolace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that requir a
replacement after removal. ISUZU will also call out
the fasteners that requir thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fastners or fastner
joint interfaces. Generally,such coatings adversely
affect the fastner torque and the joint clamping force,
and may damage the fastner. When you install
fasteners, use the correct tightening sequence and
specifications. Following these instructions can
help you avoid damage to parts and systems.

CLUTCH7C–9
Clutch Assembly
Clutch Assembly and Associated Parts
201RW029
Legend
(1) Flywheel Assembly and Crankshaft Bearing
(2) Driven Plate Assembly (6VE1)
(3) Driven Plate Assembly (4JX1)
(4) Pressure Plate Assembly (5) Transmission Assembly
(6) Front Cover
(7) Shift Fork
(8) Release Bearing
Removal
1. Remove transmission assembly, refer to ”MANUAL
TRANSMISSION” of Section 7B for ”Removal AND
INSTALLATION” procedure.
2. Mark the flywheel, clutch cover and pressure plate lug
for alignment when installing.
3. Remove pressure plate assembly (3).
4. Remove driven plate assembly (1) or (2). Use the pilot
aligner 5-85253-001-0 (J-24547) to prevent the
driven plate assembly from falling free.
201RW031

7C–10CLUTCH
5. Mark the flywheel, clutch cover and pressure plate lug
for alignment when installing.
6. Remove the release bearing (3) from the
transmission case .
7. Remove the shift fork snap pin.
8. Remove the shift fork pin and shift fork (4) from the
front cover.
9. Remove the front cover bolts.
10. Remove the front cover (5) from the transmission
case.
220RW088
11. Remove flywheel assembly and crankshaft bearing.
Do not remove except for replacement.
12. Use the remover 5–8840–2000–0 (J–5822) and
sliding hammer 5–8840–0019–0 (J–23907) to
remove the crankshaft bearing
015RW053
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, or any other abnormal condition are found
through inspection.
Pressure Plate Assembly
201RS002
1. Visually check the pressure plate friction surface for
excessive wear and heat cracks.
2. If excessive wear or deep heat cracks are present,
the pressure plate must be replaced.
Pressure Plate Warpage
201RS003

7C–12CLUTCH
Driven Plate Assembly
201RW033
Legend
(1) Driven Plate Assembly (6VE1)
(2) Driven Plate Assembly (4JX1)
1. Visually check the torsion spring for looseness,
breakage, and weakening.
2. If any of these conditions are discovered, the driven
plate assembly must be replaced.
3. Visually check the facing surfaces for cracking and
excessive scorching.
4. Visually inspect the facing surfaces for the presence
of oil or grease.
5. If any of these conditions are discovered, the facing
must be cleaned or replaced.
6. Check that the driven plate moves smoothly on the
transmission top gear shaft spline.
7. Minor ridges on the top gear shaft spline may be
removed with an oil stone.
Driven Plate Warpage
201RW034
Legend
(1) Driven Plate Assembly (6VE1)
(2) Driven Plate Assembly (4JX1)
1. Insert the clutch pilot aligner into the driven plate
splined hub.
2. The clutch pilot aligner J-24547 must be held
perfectly horizontal.
3. Set a dial indicator to the driven plate outside
circumference.
4. Slowly turn the driven plate.
5. Read the dial indicator as you turn the driven plate.
6. If the measured value exceeds the specified limit, the
driven plate assembly must be replaced.
Driven Plate Warpage
Standard: 0.7 mm (0.028 in)
Limit: 1.0 mm (0.039 in)

CLUTCH7C–13
Driven Plate Splined Hub Spline Wear
201RW032
Legend
(1) Driven Plate Assembly (6VE1)
(2) Driven Plate Assembly (4JX1)
1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear
shaft spline.
3. Set a surface gauge to the driven plate outside
circumference.
4. Slowly turn the driven plate counterclockwise.
5. Measure the spline rotation play as you turn the
driven plate.
6. If the measured value exceeds the specified limit, the
driven plate assembly must be replaced.
Driven Plate Splined Hub Spline Wear
Standard: 0.5 mm (0.020 in)
Limit: 1.0 mm (0.039 in)
Rivet Head Depression
201RS010
1. Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression 1 from the facing
surface 2.
2. Be sure to measure the rivet head depression on both
sides of the driven plate.
3. If the measured value is less than the specified limit,
the driven plate assembly must be replaced.
Rivet Head Depression
Standard:
Flywheel sidePressure plate side
6VE11.95mm (0.077 in)1.95mm (0.077 in)
4JX11.60mm (0.063 in)1.60mm (0.063 in)
Limit: 0.2 mm (0.008 in)

CLUTCH7C–15
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Install flywheel assembly and crankshaft bearing.
Use the installer 5-8840-0125-0 (J-26516-A) and
driver handle 5-8840-0007-0 (J-8092) to install the
crankshaft bearing then clean and lubricate with
grease.
015RW054
2. Install new flywheel fixing bolts in the order illustrated
and tighten them to the specified torque.
Torque:
6VE1: 54 Nꞏm (5.5 kgꞏm/40 lb ft)
4JX1: 60 Nꞏm (6.1 kgꞏm/44 lb ft)+60
NOTE: Do not reuse the bolt and do not apply oil or thread
lock to the bolt.
015RS047
3. Install the front cover (5) to the transmission case.
4. Tighten eight front cover bolts to the specified torque.
Torque: 17 Nꞏm (1.7 kgꞏm/12 lb ft)
220RW088
5. Apply molybednum disulfide type grease to the pin
hole inner circumferences and thrust surfaces.
6. Attach the shift fork to the front cover and insert the
pin from below of the front cover.
7. Install the washer and snap pin.
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7C–16CLUTCH
8. Apply molybdenum disulfide type grease to the areas
shown in illustration.
201RW012
9. Install the release bearing in the proper direction.
NOTE: Ensure release bearing is properly positioned
during installation, as shown in illustration.
201RW020
10. Install driven plate assembly. Use the pilot aligner
5-85253-001-0 (J-24547) to install the driven plate
assembly.
201RW027
11. Install pressure plate assembly and tighten the bolts
holding the pressure plate assembly in the order
shown in illustration.
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)
201RS017
12. Remove the aligner.
NOTE: Do not strike the aligner with a hammer to remove
it.
13. Install transmission assembly.

The chassis electrical system is a 12–volt system with a
negative ground polarity.
Wire size are appropriate to respective circuits, and
classified by color. (The classification of harnesses by
color is shown on the circuit diagram for ease of harness
identification.)
The wire size is determined by load capacity and the
length of wire required.
The vehicle harnesses are: body harness, chassis
harness, engine room harness, instrument harness,
transmission harness, engine ECGI harness, dome light
harness, door harness, rear body harness, tailgate
harness, SRS harness and battery cables.
The harnesses are protected either by tape or corrugated
tube, depending on harness location.
The circuit for each system consists of the power source,
wire, fuse, relay, switch, load parts and ground, all of
which are shown on the circuit diagram.
In this section, each electrical device is classified by
system.
For major parts shown on the circuit based on the circuit
diagram for each system, a summary, diagnosis of
troubles and inspection procedures are detailed.
Notes for Working on Electrical
Items
Disconnecting the Battery Cable
1. All switches should be in the “OFF” position.
2. Disconnect the battery ground cable (2).
3. Disconnect the battery positive cable (1).
CAUTION: It is important that the battery ground
cable be disconnected first. Disconnecting the
battery positive cable first can result in a short circuit.
Connecting the Battery Cable
Follow the disconnecting procedure in the reverse order.CAUTION: Clean the battery terminal and apply a
light coat of grease to prevent terminal corrosion.
Disconnecting the Connector
Some connectors have a tang lock to hold the connectors
together during vehicle operation.
Some tang locks are released by pulling them towards
you (1).
Other tang locks are released by pressing them forward
(2).
Determine which type of tang lock is on the connector
being handled.
Firmly grasp both sides (male and female) of the
connector (3).
Release the tang lock and carefully pull the two halves of
the connector apart.
Never pull on the wires to separate the connectors (4).
2
1
General Description
1
2
3
4

P C M
C-1 A16
C-3
C-2 F14
C2
C-3
M-7M-7
M-7
M-7 E14
C-2D9
C-3M-6M-6C-2 F7
D2
C-3E3
C-3
M-6
M-6
M-6C-3 E4
E1
C-3
M-15
M-15E2
13
H-53
14
H-53
16
H-53
15
231 4
9 17 15
10
8
11
12
5
3412 21
6
7
5
13 7
1 H-53
COMMON CHAMBER
SPEED
SENSOR
(TRANSMISSION)
ADAPTER CASE
(TRANSMISSION) MAIN CASE
(TRANSMISSION)
1.0
B/R 1.25
B/P 1.25
V/W 1.25
V/R 0.5
BR/L 0.5
R/B
0.5
GR 0.85
GR
0.5
W 0.5
R 1.25
V/W 1.25
V/R 0.75
BR/L 0.75
G 1.25
BR/W 0.5
BR/B 0.5
BR/R 0.5
BR/Y
1.25
BR/W 0.75
BR/B 0.75
BR/R 1.25
BR/Y0.5
G/R0.5
W 0.5
R
JOINT
CONNEC-
TOR
E-29H-5
JOINT
CONNECTORC-88
C-88
(+) (–) (+) (–)H-53
H-53 H-53 H-53 H-53 H-53H-53 H-53
OIL TEMP.
SENSOR
TCC
SOLENOID2-3
SOLENOID 1-2,3-4
SOLENOID BAND APPLY
FORCE
MOTOR
PCM:POWERTRAIN CONTROL MODULE
D08RW597