lock OPEL FRONTERA 1998 Workshop Manual
[x] Cancel search | Manufacturer: OPEL, Model Year: 1998, Model line: FRONTERA, Model: OPEL FRONTERA 1998Pages: 6000, PDF Size: 97 MB
Page 2381 of 6000

MANUAL TRANSMISSION7B–63
3. Stand the transmission by the wood blocks.
4. Using a plastic hammer, tap the transmission
case and attach it to the intermediate plate.
NOTE: Be careful not to add over force to bearing.
220RW022
5. Using a snap ring expander, install the front
bearing shaft snap ring (1) and counter gear shaft
bearing snap ring (2).
226RW004
6. Turn over the transmission.
35. Install the front cover.
1. Clean up the fitting surface.
2. Apply recommended liquid gasket (THREE
BOND 1281 or equivalent), as shown.NOTE:
Don’t dry the liquid gasket.
220RW025
3. Clean up and dry the bolts.
4. Apply thread sealant (THREE BOND 1344 or
equivalent) to the 8 bolts.
5. Using 8 bolts, install the front cover to the
transmission case.
Torque: 17 Nꞏm (1.7 kgꞏm/12 lb ft)
NOTE:
Tighten the all bolts evenly.
Be careful not to damage the oil seal.
220RW018
Page 2511 of 6000

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.
Page 2517 of 6000

7C–8CLUTCH
Diagnosis
ConditionPossible causeCorrection
DraggingFluid leakage.Repair
Air in hydraulic line.Bleed
Master cylinder and slave cylinder
seals worn. Replace master cylinder.
Replace slave cylinder seals.
Driven plate warped.Replace driven plate.
Diaphragm spring weakened or tip of
fingers worn. Replace pressure plate
Driven plate sticking on splines.Lubricate with grease or replace.
Clutch spline worn. Repair
Release bearing worn or damaged.Replace release bearing.
SlippingDriven plate facing worn or
oil–soaked.Replace driven plate and check for
leaks.
Diaphragm spring weakened.Replace pressure plate.
Pressure plate or flywheel warped.Correct or replace.
Master cylinder and slave cylinder
seals worn.Replace master cylinder.
Replace slave cylinder seals.
ChatteringEngine mounts loose or damaged.Tighten or replace.
Driven plate facing warped.Replace driven plate.
Surface of facing hardened.Replace driven plate
Driven plate facing oil soaked. Replace driven plate and check for
leaks.
Damper springs weakened or
broken. Replace.
Pressure plate or flywheel warped.Correct or replace.
NoisyReplace bearing binding.Correct, or replace if damaged, and
lubricate.
Replace bearing worn or damaged. Replace release bearing.
Release bearing poorly lubricated. Lubricate.
Pilot bearing worn.Replace pilot bearing.
Damper springs weakened or
broken.Replace driven plate.
Rivets of driven plate exposed.Replace driven plate.
Replace driven plate.Hydraulic line blocked.Clean out or replace.
Master or slave cylinders binding.Repair or replace as needed.
Page 2522 of 6000

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)
Page 2524 of 6000

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.
201RW019
Page 2528 of 6000

CLUTCH7C–19
Installation
1. Install damper cylinder assembly (except V6 LHD).
2. Install master cylinder assembly.
3. Install slave cylinder assembly and heat protector.
4. Install oil line pipe.
5. Install pedal assembly.
6. Install pin and jaw joint pin.
Adjustment
Clutch Pedal Adjustment
1. Loosen the clutch pedal adjusting bolt so that there is
enough gap between the clutch pedal and the
adjusting bolt to allow push rod adjustment.
203RW011
Legend
(1) Push Rod
(2) Adjusting Bolt
2. Loosen clutch master cylinder push rod lock nut. Turn
push rod by hand to set clutch pedal height (5) to
within specification.
Clutch pedal height (5):
LHD: 217 mm – 227 mm (8.543 in – 8.937 in)
RHD:
(6VE1) 238.5 mm – 248.5 mm (9.390 in – 9.783 in)
(4JX1) 231 mm – 241 mm (9.094 in – 9.488 in)
203RW004
Legend
(3) Floor Panel
(4) Pedal Free Play
(5) Clutch Pedal Height
3. Tighten push rod lock nut.
4. Adjusting bolt adjustment.
1. Turn the adjusting bolt until it just touches the
clutch pedal arm.
203RW012
Legend
(6) Blacket
(7) Adjusting Bolt
(8) Clutch Pedal Arm
Page 2529 of 6000

7C–20CLUTCH
2. Adjust clutch padel adjusting bolt by backing it out
half a turn, and measure the clearance (
)
between the clutch pedal arm and the adjusting
bolt.
203RW010
Legend
(9) Bracket
(10) Clutch Pedal Adjusting Bolt
(11) Lock Nut
(12) Clutch Pedal Arm
3. Lock the lock nut.
Clutch Switch and Clutch Pedal Clearance (
)
0.5 mm – 1.5 mm (0.020 in – 0.059 in)
5. After adjusting the clutch pedal height, push the
clutch pedal by hand rightly to check the clutch pedal
free play (4) to within specification.
Pedal Free Play (4)
5 mm – 15 mm (0.20 in – 0.59 in)
203RW004
6. Clutch pedal engagement height inspection:
1. Operate the parking brake lever and block the
wheels.
2. Start the engine, fully step on the clutch pedal,
and move the shift lever to 1st position.
3. With the engine idling, release the clutch pedal
slowly and measure its stroke just prior to its
clutching position.
Clutch Pedal Engagement Height (14)
MIN. 30 mm (1.18 in)
7. If the measured value exceeds the specified limit,
check the following points. Repair if necessary:
Hydraulic circuit for fluid leakage or air in circuit.
Clutch disc warped.
Diaphragm spring weakened or tip of fingers worn.
Driven plate sticking on sprines.
Release bearing worn or damaged.
Master cylinder and slave cylinder worn.
203RW007
Legend
(3) Floor Panel
(14) Clutch Pedal Engagement Height
Page 2540 of 6000

LIGHTING SYSTEM8A–1
BODY AND ACCESSORIES
CONTENTS
Lighting System 8A. . . . . . . . . . . . . . . . . . . . . . . . .
Wiper/Washer System 8B. . . . . . . . . . . . . . . . . . .
Entertainment 8C. . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring System 8D. . . . . . . . . . . . . . . . . . . . . . . . . .
Meter and Gauge 8E. . . . . . . . . . . . . . . . . . . . . . . Body Structure 8F. . . . . . . . . . . . . . . . . . . . . . . . . .
Seats 8G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Security and Locks 8H. . . . . . . . . . . . . . . . . . . . . .
Sun Roof/Convertible Top 8I. . . . . . . . . . . . . . . .
Exterior/Interior Trim 8J. . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM
CONTENTS
Service Precaution 8A–2. . . . . . . . . . . . . . . . . . . . . .
Headlight Bulb 8A–3. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight 8A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight and Associated Parts 8A–4. . . . . . . . .
Removal 8A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight Adjustment 8A–4. . . . . . . . . . . . . . . . . .
Fog Light Bulb 8A–5. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog Light Assembly 8A–6. . . . . . . . . . . . . . . . . . . . .
Removal 8A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog Light Adjustment 8A–6. . . . . . . . . . . . . . . . . .
Clarence Light Bulb 8A–6. . . . . . . . . . . . . . . . . . . . . .
Removal 8A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Fog Light Bulb (RHD) 8A–7. . . . . . . . . . . . . . .
Removal 8A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taillight Bulb (Body) 8A–7. . . . . . . . . . . . . . . . . . . . .
Removal 8A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taillight Bulb (Bumper) 8A–8. . . . . . . . . . . . . . . . . . .
Removal 8A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
License Plate Light Bulb (Body) 8A–8. . . . . . . . . . .
Removal 8A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
License Plate Light Bulb (Bumper) 8A–9. . . . . . . . .
Removal 8A–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stoplight Bulb 8A–9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation 8A–9. . . . . . . . . . . . . . . High Mount Stoplight 8A–10. . . . . . . . . . . . . . . . . . . .
Removal 8A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Turn Signal Light Bulb 8A–10. . . . . . . . . . . . . .
Removal 8A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Turn Signal Light Bulb 8A–11. . . . . . . . . . . . . . .
Removal 8A–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Turn Signal Light Bulb 8A–11. . . . . . . . . . . . . .
Removal 8A–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Backup Light Bulb 8A–12. . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–12
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Dome Light Bulb 8A–12. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Luggage Room Light Bulb 8A–13. . . . . . . . . . . . . . . .
Removal 8A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Courtesy Light Bulb 8A–13. . . . . . . . . . . . . . . . . . . . . .
Removal 8A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Map Light Switch/Bulb 8A–14. . . . . . . . . . . . . . . . . . .
Removal 8A–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cigarette Lighter Illumination Bulb 8A–14. . . . . . . . .
Removal 8A–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Ashtray Illumination Bulb 8A–15. . . . . . . . . . . . . . . . .
Removal 8A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glove Box Illumination Bulb 8A–15. . . . . . . . . . . . . . .
Removal 8A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 2541 of 6000

8A–2LIGHTING SYSTEM
Vanity Mirror Illumination Bulb 8A–16. . . . . . . . . . . . .
Removal 8A–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Switch 8A–17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighting Switch (Combination Switch) 8A–18. . . . . .
Removal 8A–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog Light Switch 8A–19. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stoplight Switch (W/O Cruise Control) 8A–20. . . . . .
Removal 8A–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Switch (W/Cruise Control) 8A–21. . . . . . . . . .
Removal 8A–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal Switch (Combination Switch) 8A–21. . .
Removal and Installation 8A–21. . . . . . . . . . . . . . .
Hazard Warning Switch 8A–22. . . . . . . . . . . . . . . . . .
Removal 8A–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 8A–22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate Switch 8A–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Switch 8A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Defogger Switch 8A–24. . . . . . . . . . . . . . . . . . .
Removal 8A–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Heater Switch 8A–25. . . . . . . . . . . . . . . . . . . . . .
Removal 8A–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key Remind Switch (Starter Switch) 8A–25. . . . . . .
Removal and Installation 8A–25. . . . . . . . . . . . . . .
Illumination Controller 8A–26. . . . . . . . . . . . . . . . . . . .
Removal 8A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–26. . . . . . . . . . . . . . . . . . . . . . . . . . .
Power/Winter Switch 8A–27. . . . . . . . . . . . . . . . . . . . .
Removal 8A–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–27. . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 8A–28. . . . . . . . . . . . .
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.
Page 2542 of 6000

LIGHTING SYSTEM8A–3
Headlight Bulb
Removal
1. Disconnect the battery ground cable.
2. Disconnect the connector.
3. Remove the cap(3) while turning it counter clockwise.
4. Remove the cover(2).
5. Pull the bulb(1) out from the headlight body.
CAUTION: The halogen bulb develops a very high
temperature. Do not touch the glass portion. If any
stain is on the glass surface, It will scorch and the
glass will be damaged.
801RW014
Installation
To install, follow the removal steps in the reverse order.