engine oil OPEL FRONTERA 1998 Workshop Manual

SUPPLEMENTAL RESTRAINT SYSTEM9J–45
3. Disconnect the yellow 2–pin connector located
behind the air bag assembly and remove air bag
assembly.Refer to “SRS Connectors” in this section
for removal and installation.
827RT009
4. Disconnect horn lead connector.
5. Remove the steering wheel attachment nut.
6. Apply a setting mark across the steering wheel and
shaft so parts can be reassembled in their original
position.
430RS004
7. Move the tires to the straight ahead position before
removing the steering wheel and removing wheel with
5–8521–0016–0.
430RT009
8. Feed wiring though the wheel and remove wheel.
9. Remove the steering lower cover and engine hood
opening lever.
10. Remove the driver knee bolster assembly.
740RT015
11. Remove the steering column cover.
12. Remove air conditioning lower duct.
13. Disconnect the wiring harness connectors located at
the base of steering column.
CAUTION: Never apply force to the steering wheel
in direction of the shaft by using a hammer or other
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
14. Remove the combination switch assembly with SRS
coil.

SUPPLEMENTAL RESTRAINT SYSTEM 9J–48
Passenger Air Bag Assembly
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL
AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT
OF THE DEPLOYMENT REACTION, THAT IS
IRRITATING TO THE SKIN AND EYES. MOST OF THE
POWER ON THE AIR BAG ASSEMBLY IS
HARMLESS. AS A PRECAUTION, WEAR GLOVES
AND SAFETY GLASSES WHEN HANDLING A
DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR
HANDS WITH MILD SOAP AND WATER
AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE
OF INJURY. WHEN PLACING ALIVE AIR BAG
ASSEMBLY ON A BENCH OR OTHER SURFACE,
ALWAYS FACE BAG AND RIM COVER UP, AWAY
FROM THE SURFACE. NEVER REST A STEERING
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY COULD RESULT.
NOTE: IN THE EVENT DEPLOYMENT HAS
OCCURRED, INSPECT COIL ASSEMBLY WIRE FOR
ANY SIGNS OF SCORCHING, MELTING OR ANY
OTHER DAMAGE DUE TO EXCESSIVE HEAT. IF THE
COIL HAS BEEN DAMAGED, REPLACE IT.
Removal
827RS001
1. Disable the SRS (Refer to “Disabling the SRS ” in this
section).
2. Remove gear control knob.
3. Remove front console assembly.
4. Remove rear console assembly and disconnect
harness connector.
5. Remove ECM and SDM cover.
6. Remove glove box assembly with lid.
7. Remove glove box cover.
8. Remove instrument panel assist side lower cover.
9. Disconnect engine hood opener lever.
10. Remove instrument panel door side lower cover.
11. Remove lower cluster with ashtray.
12. Remove meter cluster assembly and disconnect
harness connector.
13. Remove instrument panel lower center cover.
14. Disconnect passenger air bag assembly harness
connector.
15. Remove air bag assembly fixing bolts and nuts.
16. Remove passenger air bag assembly.
Installation
827RS001
1. Install passenger air bag assembly.
2. Install air bag assembly fixing bolts, nuts and tighten
to specified torque.
Torque: 6 Nꞏm (0.6 Kgꞏm/52 Ib in)
3. Connect air bag assembly harness connector.
4. Install instrument panel lower center cover.
5. Install meter cluster assembly and connect harness
connector.
6. Install lower cluster with ashtray.
7. Install instrument panel door side lower cover.
8. Connect engine hood opener lever.
9. Install instrument panel assist side lower cover.

1. Perform oil return operation.
2. Discharge and recover the refrigerant and remove
the compressor.
3. Drain the compressor oil and measure the extracted
oil.
4. Check the compressor oil for contamination.
5. Adjust the oil level as required.
6. Evacuate, charge and perform the oil return
operation.
7. Check the system operation.
Contamination of Compressor Oil
Unlike engine oil, no cleaning agent is added to the
compressor oil. Even if the compressor runs for a long
period of time (approximately one season), the oil never
becomes contaminated as long as there is nothing
wrong with the compressor or its method of use.
Inspect the extracted oil for any of the following
conditions:
The capacity of the oil has increased.
The oil has changed to red.
Foreign substances, metal powder, etc., are present
in the oil.
If any of these conditions exists, the compressor
oil is contaminated. Whenever contaminated
compressor oil is discovered, the receiver/drier
must be replaced.
Oil Return Operation
There is close affinity between the oil and the
refrigerant. During normal operation, part of the oil
recirculates with the refrigerant in the system. When
checking the amount of oil in the system, or replacing
any component of the system, the compressor must be
run in advance for oil return operation. The procedure
is as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to "ON"
and set the fan control knob at its highest position.
3. Run the compressor for more than 20 minutes
between 800 and 1,000 rpm in order to operate the
system.
4. Stop the engine.
Replacement of Component Parts
When replacing the system component parts, supply
the following amount of oil to the component parts to be
installed.
Compressor Leak Testing (External and
Internal)
Bench-Check Procedure
1. Install test plate J-39893 on rear head of compressor.
2. Using Refrigerant Recovery System, attach center
hose of manifold gage set on charging station to a
refrigerant drum standing in an upright drum.
3. Connect charging station high and low pressure
lines to corresponding fittings on test plate J-39893.
Suction port (low-side) of compressor has large
internal opening. Discharge port (high-side) has
smaller internal opening into compressor and
deeper recess.
4. Open low pressure control, high pressure control
and refrigerant control on charging station to allow
refrigerant vapor to flow into compressor.
5. Using a leak detector, check for leaks at pressure
relief valve, rear head switch location, compressor
front and rear head seals, center cylinder seal,
through bolt head gaskets and compressor shaft
seal. After checking, shut off low pressure control
and high-pressure control on charging station.
6. If an external leak is present, perform the necessary
corrective measures and recheck for leaks to make
certain the leak has been connected.
7. Recover the refrigerant.
8. Disconnect both hoses from the test plate J-39893.
9. Add 90 ml (3 oz.) new PAG lubricant to the
compressor assembly. Rotate the complete
compressor assembly (not the crankshaft or drive
plate hub) slowly several turns to distribute oil to all
cylinder and piston areas.
10. Install a M9
1.25 threaded nut on the compressor
crankshaft if the drive plate and clutch assembly are
not installed.
11. Using a box-end wrench or socket and handle,
rotate the compressor crankshaft or clutch drive
plate on the crankshaft several turns to insure
piston assembly to cylinder wall lubrication.
12. Using Refrigerant Recovery System, connect the
charging station high-pressure line to the test plate
J-39893 high-side connector.
13. Using Refrigerant Recovery System, connect the
charging station low-pressure line to the low
pressure port of the test plate J-39893. Oil will drain
out of the compressor suction port if the compressor
is positioned with the suction port downward. (Component parts to be (Amount of Oil)
installed)
Evaporator 50 cc (1.7 fl. oz.)
Condenser 30 cc (1.0 fl. oz.)
Receiver/dryer 30 cc (1.0 fl. oz.)
Refrigerant line (one 10 cc (0.3 fl. oz.)
piece)
(Amount of oil drained (Charging amount of oil
from used compressor) to new compressor)
more than 90 cc same as drained amount
(3.0 fl.oz)
less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)

4B2–43 DRIVE LINE CONTROL SYSTEM (TOD)
Diagnostic Trouble Codes
CodeTe c h 2 c o d e
(P code)ItemDiagnosisCheck flow No.
12—Start codeNormal—
13P1735RefShorted GND6
14P1731Front speed sensorInput abnormality (open, sig or com)2
15P1736RefShorted VB6
16P1737Front speed sensorInput abnormality3
21P1716TPSShorted or disconnected wiring, abnormality in
input7
23—ECUCPU abnormality1
24P1733Rear speed sensorInput abnormality (open, sig or com)5
25—CHECK lampShorted14
26—EMC (+)Shorted GND10
27P1738Rear speed sensorInput abnormality4
28P1760ADC (+) & AXLE SWOutput abnormality11
31P1721EMC (+)Shorted or disconnected coil/wiring9
32P1761ADC (+)Shorted or disconnected coil/wiring12
33P1762ADC (+)Shorted GND13
34—D-G MAPInput abnormality8
35—CHECK lampShorted or disconnected wiring14
36—ECUCPU abnormality1
37P1712ECUCPU abnormality1
38P1714ECUCPU abnormality1
TPS : Throttle Position Sensor
EMC : Electromagnetic coil
ADC : Shift on the fly (Axle Dis Connect)
D-G MAP : Discrimination engine type

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–60
StepActionYe sNo
11. Clear the trouble code.
2. Start the engine
3. Set the TOD mode.
Is there DTC31 (P1721)?
Go to Step 2
Refer to “Trouble
intermittently
observed”.
21. Turn off the starter switch.
2. Disconnect the ECU connector from ECU.
Is the continuity established between terminals (B–67)4 and
(B–67)12?
Go to Step 3Go to Step 5
31. Connect the ECU connector.
2. Start the engine.
3. Set the TOD mode.
Does the voltage between terminals 4 and 20 indicate at least
0.4V?
Go to Step 4Go to Step 6
4Is the battery voltage always observed between terminals 4 and
20?The harness is
short–circuited on
the battery.
Repair the circuit.
Go to
Step 8Go to Step 6
51. Disconnect the A–3 connector.
Is the continuity established between transfer connector
terminals (A–3)8 and (A–3)7?
The harness is
broken. Repair
the circuit.
Go to
Step 8
Replace the
transfer
electromagnetic
coil (solenoid
clutch).
Go to
Step 8
61. Turn off the starter switch.
2. Disconnect the ECU connector from ECU.
Is the resistance between the connector (B–67) terminal 4 and 12
1.0
5.0?
The ECU has
failed. Replace
the ECU
Go to
Step 8Go to Step 7
7Is the resistance between the transfer connector (A–3) terminal 8
and 7 1.0
5.0?The harness is
disconnection or
short to GND.
Repair the circuit.
Go to
Step 8
Replace the
transfer
electromagnetic
coil (solenoid
clutch).
Go to
Step 8
81. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
Repeat the
“Diagnosis Flow”.
Return to Step 8

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–62
StepActionYe sNo
11. Turn off the starter switch.
2. Disconnect the ECU connector from ECU.
Does the resistance between terminals (B–67)4 and (B–67)12?
indicate 1.0 to 5.0 ohm?
Go to Step 2Go to Step 3
21. Connect the ECU connector.
2. Start the engine.
3. Set the TOD mode.
When the throttle is operated between full close and full open
positions, does the voltage between terminals 4 and 20 indicate
0.1 to 1.0 V?The phenomenon
is not
reproduced.
Refer to
“Troubles
intermittently
observed”.
The ECU has
failed. Replace
the ECU.
Go to Step 4
3Does the resistance between transfer connector terminals (A–3)8
and (A–3)7 indicate 1.0 to 5.0ohm?
The harness is
broken. Repair
the circuit.
Go to Step 4
Replace the
transfer
electromagnetic
coil.
Go to Step 4
41. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
Repeat the
“Diagnosis Flow”.
Return to Step 4

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–116
StepActionYe sNo
1Are the front and rear tires in specified size?
Go to Step 2
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
2Is the tire pressure correct?
Go to Step 3
In flate tries to
recommended
pressure.
Go to Step 16
3Are the tires free from abnormal wear?
Go to Step 4
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
4Are different types of tires used?
Go to Step 5
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
51. Start the engine.
2. Shift the transfer lever to the high position and switch the 4WD
AUTO SW to 4WD position.
3. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation.
Go to Step 6 Go to Step 11
61. Shift the transfer lever to the high position and switch the 4WD
AUTO SW to the 2H position.
2. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation.
Go to Step 7 Go to Step 14
7Is an LSD mounted to the rear differential? Go to Step 8 Go to Step 9
8Is the genuine LSD oil used in the rear differential?
Go to Step 9
Replace the
differential oil.
Go to Step 16
9Does the engine output the power correctly?
Go to Step 10
Check the
engine.
Go to Step 16
10Do the speed sensors work correctly? (Check trouble codes.)The ECU has
failed. Replace
the ECU.
Go to Step 16
Replace the
speed sensors.
Go to Step 16
11Is the tight corner braking observed only when the brake is
applied?
Go to Step 12
Conduct full
steering under
WOT.
Go to Step 5
121. Turn on the starter switch.
Is the battery voltage observed between terminals 11 and 19?
Go to Step 13
Repair the circuit
of terminal 11
(ABS IN).
Go to Step 16

4D1–8
TRANSFER CASE (STANDARD TYPE)
Transfer Rear Oil Seal
Removal
1. Disconnect the rear propeller shaft from the transfer
case side.
2. Remove end nut and rear companion flange, using
the companion flange holder 5–8840–0133–0
(J–8614–11).
266RW026
3. Use the universal puller to remove the rear
companion flange and O–ring.
4. Remove the oil seal from the transfer case.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Install oil seal and apply engine oil to the oil seal outer
surfaces.
2. Apply the recommended grease (BESCO L2) or
equivalent to the oil seal lip.
3. Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear seal to the transfer rear case.
220RW105
4. Install the rear companion flange and O–ring.
5. Use the companion flange holder 5–8840–0133–0
(J–8614–11) to install a new end nut and tighten to the
specified torque.
Torque: 167 Nꞏm (17.0kgꞏm/123 lb ft)
6. Use the punch 5–8840–2293–0 (J–39209) to stake
the end nut at two spots.
NOTE: Be sure to confirm that there is no crack at the
staked portion of the end nut after staking.
266RW027

TRANSFER CASE (STANDARD TYPE)
4D1–17
2. Remove the rear output shaft assembly (1) from the
transfer rear cover (with oil seal).
3. Remove ball bearing (8), using a bench press and the
bearing remover 5–8840–0015–0 (J–22912–01) .
226RW186
4. Remove the speedometer drive gear (7).
5. Remove the ball (6).
6. Remove the bearing snap ring (5), using a pair of snap
ring pliers.
7. Remove the ball bearing (4) from the rear output
shaft, using a bench press and the bearing remover
5–8840–0015–0 (J–22912–01).
226RW187
Inspection and Repair
Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.
Reassembly
1. Install transfer rear cover (with oil seal).
Oil seal replacement
Remove the oil seal from the transfer rear cover.
Apply engine oil to the oil seal outer surfaces.
Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.
Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear oil seal to the transfer rear cover.
220RW104
2. Set the snap ring (3), and install ball bearing (4) to the
rear output shaft (2), using the ball bearing installer
5–8840–2159–0 (J–37223) and the adapter
5–8840–2192–1 (J–37486–A).
262RW068

4D1–24
TRANSFER CASE (STANDARD TYPE)
2. Remove the rear output shaft assembly (1) from the
transfer rear cover (with oil seal).
3. Remove ball bearing (8), using a bench press and the
bearing remover 5–8840–0015–0 (J–22912–01) .
226RW186
4. Remove the speedometer drive gear (7).
5. Remove the ball (6).
6. Remove the bearing snap ring (5), using a pair of snap
ring pliers.
7. Remove the ball bearing (4) from the rear output
shaft, using a bench press and the bearing remover
5–8840–0015–0 (J–22912–01).
226RW187
Inspection and Repair
Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.
Reassembly
1. Install transfer rear cover (with oil seal).
Oil seal replacement
Remove the oil seal from the transfer rear cover.
Apply engine oil to the oil seal outer surfaces.
Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.
Use the oil seal installer 5–8840–2292–0 (J–39208)
to install the rear oil seal to the transfer rear cover.
220RW104
2. Set the snap ring (3), and install ball bearing (4) to the
rear output shaft (2), using the ball bearing installer
5–8840–2159–0 (J–37223) and the adapter
5–8840–2192–1 (J–37486–A).
262RW068