radiator OPEL FRONTERA 1998 Repair Manual

8A–4LIGHTING SYSTEM
Headlight
Headlight and Associated Parts
801RW003
Legend
(1) Radiator Grille
(2) Front End Lower Panel
(3) Headlight Assembly
(4) Headlight(5) Headlight Rim
(6) Headlight Bulb
(7) Rear Cover
(8) Bracket
(9) Front Combination Light
Removal
1. Disconnect the battery ground cable.
2. Remove the screw and pull out the two projecting
portions on the fender to remove the front
combination light.
3. Remove five clips and two screws to remove the
radiator grille.
4. Remove two screws to remove the front end lower
panel(2).
5. Remove two bolts and two nuts to remove the
headlight assembly (with bracket).
6. Remove the headlight bulb.
7. Remove two screws, two nuts and the spring for the
headlight aim adjustment to remove the bracket.
8. Remove four screws to remove the rear cover.
9. Remove the headlight rim.
10. Remove the headlight.
Installation
To install, follow the removal steps in the reverse order.
CAUTION: After installing the headlight, be sure to
adjust the headlight aim.
Headlight Adjustment
Preparation
Place the unloaded vehicle on a level surface and check
to see if the inflation pressure of the tires is correct, the
lenses are clean, and the battery is sufficiently charged.
Adjust the aim with the headlight tester, if necessary.
When adjusting, follow the procedure of the tester
manufacturer’s.
801RS009

8F–1 BODY STRUCTURE
BODY AND ACCESSORIES
BODY STRUCTURE
CONTENTS
Service Precaution 8F–3. . . . . . . . . . . . . . . . . . . . . .
Frame 8F–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 8F–3. . . . . . . . . . . . . . . . . . . . . .
Frame Dimensions (L W B) 8F–4. . . . . . . . . . . . . . .
Frame Dimensions (S W B) 8F–5. . . . . . . . . . . . . . .
General Description 8F–6. . . . . . . . . . . . . . . . . . . . .
Front Bumper 8F–6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F–6. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Bumper Slider Bracket 8F–7. . . . . . . . . . . . . .
Removal 8F–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Bumper 8F–8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F–8. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location (W/Rear Combination Light
and License Light) 8F–10. . . . . . . . . . . . . . . . . . . .
Removal 8F–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location (W/Rear Combination Light) 8F–12
Removal 8F–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Bumper Slider 8F–14. . . . . . . . . . . . . . . . . . . . .
Removal 8F–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 8F–15. . . . . . . . . . . . . . . . . . . . .
Cowl Cover 8F–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F–15. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Hood 8F–16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Bulge 8F–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F–17. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Hood Hinge 8F–18. . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F–18. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Hood Lock 8F–19. . . . . . . . . . . . . . . . . . . . . . . Parts Location 8F–19. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator Grille And Front End Lower Panel 8F–20.
Parts Location 8F–20. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Fender Panel 8F–22. . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F–22. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Mounting 8F–24. . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F–24. . . . . . . . . . . . . . . . . . . . . . . .
Removal (No.1 – No. 2) 8F–24. . . . . . . . . . . . . . . .
Removal (No. 3 — No. 6) 8F–25. . . . . . . . . . . . . . .
Installation 8F–26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 8F–27. . . . . . . . . . . . . . . . . . . . .
Body Dimension 8F–28. . . . . . . . . . . . . . . . . . . . . . . .
Instrument Panel Assembly 8F–48. . . . . . . . . . . . . . .
Parts Location 8F–48. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–53. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross Beam Assembly 8F–54. . . . . . . . . . . . . . . . . . .
Parts Location 8F–54. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–55. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Door Assembly 8F–56. . . . . . . . . . . . . . . . . . . .
Parts Location 8F–56. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–56. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–56. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Door Assembly 8F–57. . . . . . . . . . . . . . . . . . . . .
Parts Location 8F–57. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–58. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Strikers 8F–58. . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 8F–58. . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Check Arm Assembly (Front & Rear) 8F–59. .
Parts Location 8F–59. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–59. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F–60. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Window Regulator, Glass And Glass
Run 8F–60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F–60. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F–60. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8F–19 BODY STRUCTURE
Engine Hood Lock
Parts Location
610RW011
Legend
(1) Hood Lock Control Lever
(2) Control Cable(3) Engine Hood Lock Assembly
(4) Radiator Grille
(5) Inner Liner
Removal
1. Remove hood lock control lever.
2. Remove inner liner.
3. Remove control cable.
Remove the cable fixing clips from the body panel.
4. Remove radiator grille.
Refer to Radiator Grille And Front End Lower Panel
in this section.
5. Remove engine hood lock assembly.
Apply setting marks (1) to the hood lock assembly
and the body prior to removal.
610RW009

8F–20BODY STRUCTURE
Installation
To install, follow the removal steps in reverse order noting
the following points:
1. Reroute the control cable to its original position, and
check and see if the lock assembly and control lever
work normally.2. Tighten the hood lock assembly fixing bolts to the
specified torque.
Torque : 10 Nm (1.0kgꞏm/87 lb in)
Radiator Grille And Front End Lower Panel
Parts Location
603RW014
Legend
(1) Front End Lower Panel(2) Head light Wiper
(3) Radiator Grille
Removal
1. Open the hood.
2. Support the hood.
3. Remove headlight wiper.
Refer to Wiper/Washer System in this section.

8F–21 BODY STRUCTURE
4. Remove radiator grille.
Raise the clips (1) on the radiator grille and remove
two screws.
603RW012
5. Remove front end lower panel.
Remove two fixing bolts and remove the panel from
the fender.
Installation
To install, follow the removal steps in reverse order, noting
the following point.
1. Install the radiator grille clips remaining on the body
side in the radiator grille, and then install the radiator
grille on the body.

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–18
ENGINE MECHANICAL
Cylinder Head Cover LH
Removal
1. Disconnect battery ground cable.
2. Drain engine coolant from faucet bottom of radiator.
3. Remove engine cover from the dowels on the
common chamber.
F06RW018
4. Remove air cleaner duct assembly (3) and air cleaner
element (4).
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.5. Disconnect following wiring connectors and bonding
cable:
Manifold Absolute Pressure (MAP) sensor
Vacuum Switching Valve (VSV) for Induction Air
Control Valve (IACV) actuator
Ignition coils for left bank
Fuel injectors for left bank
Idle air control (IAC) valve
Throttle position sensor (TPS)
Bonding cable
Others as necessitated
6. Disconnect following vacuum hoses:
Brake master VAC
Canister
VSV for IACV actuator
Duty solenoid valve
PCV
7. Disconnect radiator upper and lower hoses
8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
F06RW019

6A–20
ENGINE MECHANICAL
5. Install auto tensioner assembly and tighten the fixing
bolts to the specified torque.
Torque :
Shorter Bolt : 20 Nꞏm (2.0 Kgꞏm/14 lb ft)
Longer Bolt : 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
6. Install idle pulley and bracket assembly and tighten
the fixing bolt to the specified torque.
Torque : 52 Nꞏm (5.3 Kgꞏm/38 lb ft)
7. Install fan pulley and bracket assembly and tighten
the fixing bolts and nut to the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
8. Install power steering oil pump pulley and tighten the
fixing bolt to the specified torque.
Torque : 78 Nꞏm (8.0 Kgꞏm/58 lb ft)
9. Install drive belt by pushing down the auto tensioner
using spanner as shown in the removal step of drive
belt.
10. Install cooling fan and clutch assembly and tighten
the fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/87 lb in)
11. Install upper fan guide and clip both side and tighten
the fixing bolts to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
12. Install engine harness and tighten the fixing bolts of
the retaining clip and bracket to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
13. Connect radiator upper and lower hoses and clip
them securely.
14. Connect vacuum hoses of those which were
disconnected in the removal step.
15. Connect wiring connectors and bonding cable of
those which were disconnected in the removal step.
16. Install air cleaner element and air cleaner duct
assembly, and clip the both end securely.
17. Connect MAF sensor connector, IAT sensor
connector and PCV hose.
18. Install engine cover mating with the dowels.

6A–21
ENGINE MECHANICAL
Cylinder Head Cover RH
Removal
1. Disconnect battery ground cable.
2. Remove battery from the vehicle.
3. Drain engine coolant from faucet bottom of radiator.
4. Remove engine cover from the dowels on the
common chamber.
F06RW018
5. Remove air cleaner duct assembly (3) and air cleaner
element (4).
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.
6. Disconnect following wiring connectors and bonding
cable:
Exhaust Gas Recirculation (EGR) valve
Fuel injectors for right bank
Ignition coils for right bank
Bonding cable
Othres as necessitated
7. Disconnect radiator upper and lower hoses.
8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
F06RW019
Legend
(1) Crankshaft Pulley
(2) Generator
(3) Auto Tensioner
(4) Idle Pulley
(5) Cooling Fan Pulley
(6) Power Steering Oil Pump
(7) Drive Belt
(8) Air Conditioner Compressor
12. Remove fan pulley and bracket assembly.
13. Remove idle pulley assembly.
14. Remove auto tensioner assembly.
15. Remove crankshaft pulley using 5–8840–0133–0
crankshaft holder.

6A–23
ENGINE MECHANICAL
6. Install idle pulley assembly and tighten the fixing bolt
to the specified torque.
Torque : 52 Nꞏm (5.3 Kgꞏm/38.4 lb ft)
7. Install fan pulley and bracket assembly and tighten
the fixing bolts and nut to the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16.2 lb ft)
8. Install drive belt by pushing down the auto tensioner
using spanner as shown in the removal step of drive
belt.
9. Install cooling fan clutch assembly and tighten the
fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in)
10. Install upper fan guide and clip both side and tighten
the fixing bolts to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35.4 lb in)
11. Install engine harness and tighten the fixing bolts of
the retaining clip and brackets to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35.4 lb in)
12. Connect radiator upper and lower hoses and clip
them securely.
13. Connect wiring connectors and bonding cable of
those which were disconnected in the removal step.
14. Install air cleaner element and air cleaner duct
assembly, and the clip both end securely.
15. Connect MAF sensor connector, IAT sensor
connector and PCV hose.
16. Install engine cover mating with the dowels.