window OPEL FRONTERA 1998 Repair Manual

8J–12EXTERIOR/INTERIOR TRIM
2. Pass the inside handle through the mounting hole of
the trim panel. Assemble the trim panel. Engage
securely seven clips into the door panel. Also, leave
the connector of the power window drawn out to its
prescribed position, so that it will not caught.
3. Put back the inside handle(3) to the original position
of the link(5). Fit the claw(4) of the inside handle
securely into the hole of the door panel. Fix the
handle with the screw.
632RW011

EXTERIOR/INTERIOR TRIM8J–39
Power Window System
General Description
The circuit consists of the starter switch, (door lock &)
power window switch for each of the front windows,
p o w e r w i n d o w s w i t c h f o r r e a r w i n d o w s a n d p o w e r w i n d o w
motors.
When the starter switch is turned on, the battery voltage is
applied to each of the power window switches through the
circuit breaker and the power window relay on the circuit.
The “Down” switch of the driver’s power window switch
has a built-in function which can be operated by just
touching it.
Accordingly, the window will roll down automatically by
just setting the switch to the “AUTO” position.
When the driver’s power lock switch at the driver side is
depressed, the power source to the passenger’s power
window switches are shut off. So, even if these switches
are operated, the power window motor will not operate.
Power Window Switch Removal and
Installation
Driver Seat Side
Removal
1. Disconnect the battery ground cable.
2. Remove the switch(1).
Pull out the switch by pushing the spring with the tip
of a screwdriver.
Disconnect two connectors.
825RS052
Installation
To install, follow the removal steps in the reverse order.
Front Passenger Seat Side
Removal
1. Disconnect the battery ground cable.2. Remove the switch(1).
Pull out the switch by pushing the spring with the tip
of a screwdriver.
Disconnect the connector.
825RW046
Installation
To install, follow the removal steps in the reverse order.
Rear-Left and Right Sides
Removal
1. Disconnect the battery ground cable.
2. Remove the switch(1).
Pull out the switch by pushing the spring with the tip
of a screwdriver.
Disconnect the connector.
825RS057
Installation
To install, follow the removal steps in the reverse order.

8J–40EXTERIOR/INTERIOR TRIM
Power Window Motor Removal and
Installation
Driver Seat Side
Removal
1. Disconnect the battery ground cable.
2. Remove the window regulator assembly (1).
Refer to the Window Regulator and Glass removal
steps in Body Structure section.
3. Remove the power window motor(2).
Remove three screws.
CAUTION: When removing the motor from the
regulator(1), be careful not to get injured by the
strong repellent force of the regulator spring.
631RS018
Installation
To install, follow the removal steps in the reverse order.
Front Passenger Seat Side
Removal
1. Disconnect the battery ground cable.
2. Remove the window regulator assembly (1).
Refer to the Window Regulator and Glass removal
steps in Body Structure section.
3. Remove the power window motor(2).
Remove three screws.
CAUTION: When removing the motor from the
regulator(1), be careful not to get injured by the
strong repellent force of the regulator spring.
631RS015
Installation
To install, follow the removal steps in the reverse order.
Rear-Left Side
Removal
1. Disconnect the battery ground cable.
2. Remove the rear window regulator assembly.
Refer to the Rear Window Regulator and Glass
removal steps in Body Structure section.
3. Remove the power window motor(1).
Remove four screws.
651RW014
Installation
To install, follow the removal steps in the reverse order.
Rear-Right Side
Removal and Installation
Refer to the Rear Power Window Motor-Left Side removal
and installation steps in this section.

SUPPLEMENTAL RESTRAINT SYSTEM 9J–12
Deployed Air Bag Assembly (Driver Side)
“You should wear gloves and glasses. After the air bag
assembly has been deployed, the surface of the air bag
may contain solid particulate. This solid particulate
c o n s i s t s p r i m a r i l y o f b y p r oducts of the chemical reaction,
Potassium Chloride and copper metal dust. Compounds
of Potassium Borate, Strontium Chloride, Copper
Chloride, and Ammonium Chloride may be found in
amounts of about 1% (each) of the total particulate.”
Deployed Pretensioner Seat Belt.
You should wear gloves and safety glasses. After the
pretensioner seat belt has been deployed, the surface of
the pretensioner seat belt cylinder may heating up.
Air Bag Assembly and/or Pretensioner
Seat Belt Scrapping Procedure.
During the cause of vehicle’s useful life, certain situations
may arise which will necessitate the disposal of a live air
bag and/or pretensioner seat belt. (This information
covers proper procedures for disposing of a live air bag
assembly and/or pretensioner seat belt.)
Before a live air bag assembly can be dispose off, it must
be deployed.
A live air bag assembly and/or pretensioner seat belt
must not be disposed of though normal refuse channels.
WARNING: FAILURE TO FOLLOW PROPER
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR
BAG ASSEMBLY DISPOSAL PROCEDURES CAN
RESULT IN AIR BAG DEPLOYMENT WHICH MAY
CAUSE PERSONAL INJURY. AN UNDPLOYED AIR
BAG ASSEMBLY MUST NOT BE DISPOSED OF
THROUGH NORMAL REFUSE CHANNELS. THE
UNDEPLOYED AIR BAG ASSEMBLY CONTAINS
SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS
OR PERSONAL INJURY IF THE SEALED CONTAINER
IS DAMAGED DURING DISPOSAL. DISPOSAL IN
ANY MANNER INCONSISTENT WITH PROPER
PROCEDURES MAY BE A VIOLATION OF LOCAL
LAW.
In situations which require deployment of a live air bag
assembly, deployment may be accomplished inside or
outside the vehicle. The method employed depends
upon the final disposition of the particular vehicle, as
noted in “Deployment Outside Vehicle” and “Deployment
Inside Vehicle” in this section.
Cautions About Air Bag Deployment And
Disposal
Failure to follow proper procedures could result in
erroneous air bag deployment which may cause personal
injury be sure to follow proper procedures.
1. Turn off (Lock) the ignition switch and disconnect the
minus terminal of the battery, then start the work 15 or
more sec later. (Air bag is designed to work by the
back-up power source even if the battery power
source is cut off at vehicle collision).
2. Be sure not to disassemble the air bag.
3. Do not give an impact to the air bag and bring the air
bag close to magnet. (The air bag could deploy
unexpectedly).4. Place the air bag with its trim cover up.
5. Do not let the air bag deploy directly on the floor. (The
air bag may be blown off 2
3 m (6.5 or 10 feet)).
6. Be sure to install the air bag firmly to a deployment
tool (fixing tool).
7. Set a battery 10 m (33 feet) or more away from the air
bag.
8. Before disconnecting air bag harness, ground the
worker by touching the vehicle outer panel with bare
hand.
9. When connecting or disconnecting the harness, do
not work just in front of the air bag.
10. As deployment gives rise to big sound, warn the
people around against it. Further, try to reduce the
sound by covering the steering wheel or tires, and
shut the vehicle windows in case of deployment
inside the vehicle.
11. As deployment generates smoke, select a well
ventilated place. (In case of deployment indoors,
avoid deployment just under a fire alarm, smoke
sensor, and fluorescent lamps).
12. Be careful not to inhale the smoke after deployment.
13. If part of the vehicle glass is damaged, cover the
vehicle with a car cover to prevent the glass from
braking at the time of deployment.
14. Do not touch the air bag immediately after
deployment, since it remains hot for 30 minutes.
15. Do not water the air bag immediately after
deployment.
16. Wear safety glasses and gloves throughout the work
and wash the glasses and gloves after the work.
17. Do not reuse the removed air bag for another vehicle.
(Deployment characteristic is different with vehicle
types).
Deployment Outside Vehicle (Driver Air
Bag Assembly)
Deployment outside the vehicle is proper when the
vehicle is to be returned to service. This includes, for
example, situations in which the vehicle will be returned to
useful service after a functionally or cosmetically deficient
air bag assembly is replaced. Deployment and disposal
of a malfunctioning air bag assembly is, of course, subject
to any required retention period.
For deployment of a live (undeployed) air bag assembly
outside the vehicle, the deployment procedure must be
followed exactly. Always wear safety glasses during this
deployment procedure until a deployed air bag assembly
is scrapped or until an undeployed air bag assembly is
shipped. Before performing the procedures you should
be familiar with servicing the SRS and with proper
handling of the air bag assembly. Procedures should be
read fully before they are performed.
The following procedure requires use of 5–8840–2468–0
SRS deployment harness with appropriate pigtail
adapter. Do not attempt procedure without
5–8840–2468–0 adapter.
WARNING: FAILURE TO FOLLOW PROCEDURES IN
THE ORDER LISTED MAY RESULT IN PERSONAL
INJURY. NEVER CONNECT DEPLOYMENT

SUPPLEMENTAL RESTRAINT SYSTEM9J–21
THROUGHOUT THIS ENTIRE DEPLOYMENT AND
DISPOSAL PROCEDURE.
9. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure.
10. Bend twisted connection made in the previous step
flat and wrap tightly with electrical tape to insulate and
secure.
11. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment
wire.
12. Connect the deployment harness to the driver air bag
assembly, yellow 2–pin connector at the base of the
steering column. Route deployment harness out the
driver side of the vehicle.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED.
THE AIR BAG ASSEMBLY WILL IMMEDIATELY
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS
CONNECTED TO IT.
CONNECTING THE DEPLOYMENT WIRES TO THE
POWER SOURCE SHOULD ALWAYS BE THE FINAL
STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT
PROCEDURE.
FAILURE TO FOLLOW PROCEDURES IN THE
ORDER LISTED COULD RESULT IN PERSONAL
INJURY.
13. Disconnect passenger air bag assembly, yellow 2–pin
connector located behind glove box assembly.
14. Cut the passenger air bag assembly harness
connector from the vehicle leaving at least 15 cm (six
inches) of wire at the connector.
15. Strip 13 mm (1/2 inch) of insulation from blue–white
and pink–blue wire lead of the connector.
16. Cut two 900 cm (30 feet) deployment wires from 0.8
mm
(18 gauge) or thicker multi–strand wire. These
wires will be used to fabricate the passenger
deployment harness.
17. Strip 13 mm (1/2 inch) of insulation from both ends of
the wires cut in the previous step.
18. Short the wires by twisting together one end from
each. Deployment wires shall remain shorted and not
be connected to a power source until the air bag is to
be deployed.
WARNING: FAILURE TO FOLLOW PROCEDURES IN
THE ORDER LISTED COULD RESULT IN PERSONAL
INJURY. NEVER CONNECT DEPLOYMENT WIRES
TO ANY POWER SOURCE BEFORE CONNECTING
DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY
LEADS. DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED.
THE AIR BAG ASSEMBLY WILL IMMEDIATELY
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS
CONNECTED TO IT. WEAR SAFETY GLASSES
THROUGHOUT THIS ENTIRE DEPLOYMENT AND
DISPOSAL PROCEDURE.19. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure.
20. Bend twisted connection made in the previous step
flat and wrap tightly with electrical tape to insulate and
secure.
21. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment
wire.
22. Connect the deployment harness to the passenger air
bag assembly, yellow 2–pin connector located behind
the glove box assembly. Route deployment harness
out the passenger side of the vehicle.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED.
THE AIR BAG ASSEMBLY WILL IMMEDIATELY
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS
CONNECTED TO IT. CONNECTING THE
DEPLOYMENT WIRES SHOULD ALWAYS BE THE
FINAL STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
PROCEDURES IN THE ORDER LISTED COULD
RESULT IN PERSONAL INJURY.
23. Verify that the inside of the vehicle and the area
surrounding the vehicle are clear of all people and
loose or flammable objects.
24. Stretch the driver and passenger deployment
harness to their full length.
25. Completely cover windshield area and front door
window openings with a drop cloth, blanket or similar
item. This reduces the possibility of injury due to
possible fragmentation of the vehicle’s glass or
interior.
26. Notify all people in the immediate area that you intend
to deploy the air bags. The deployment will be
accompanied by a substantial noise which may
startle the uninformed.
27. Separate the two ends of the driver deployment
harness wires.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE AIR BAG IS TO A POWER
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED.
THE AIR BAG ASSEMBLY WILL IMMEDIATELY
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS
CONNECTED TO IT. CONNECTING THE
DEPLOYMENT WIRES TO THE POWER SOURCE
SHOULD ALWAYS BE THE FINAL STEP IN THE AIR
BAG ASSEMBLY DEPLOYMENT PROCEDURE.
FAILURE TO FOLLOW PROCEDURES IN THE
ORDER LISTED COULD RESULT IN PERSONAL
INJURY.
NOTE: When the air bag deploys, the rapid gas
expansion will create a substantial noise. Notify all
people in the immediate area that you intend to deploy the
air bags.

4C–26
DRIVE SHAFT SYSTEM
Reassembly
1. Install DOJ case to bracket.
2. Install oil seal and fix snap ring.
3. Install bearing and fix snap ring.
4. Install bracket to axle case. Tighten the bracket bolt to
the specified torque.
Torque: 116 Nꞏm (11.8 kgꞏm/85 lb ft)
5. Apply 150g of the specified grease in BJ .
6. Install dust seal .
7. Apply a thin coat of grease to the shaft for smooth
installation then install bellows.
8. Install band. Note the setting direction. After
installation, check that the bellows is free from
distortion.
412RS017
9. Install another bellows and fix band.
10. Install the ball guide with the smaller diameter side
ahead onto the shaft.
11. Install ball retainer.
12. Using snap ring pliers, install the snap ring (1)
securing the ball retainer to the shaft.
412RS013
13. Align the track on the ball (1) retainer with the window
in the cage, and install the six balls into position.
412RS018
14. Install spacer.
15. Install snap ring.
16. Enclose 150g of the specified grease in DOJ case,
then install drive shaft joint assembly. After
reassembly, move the DOJ longitudinally several
times to get to fit.
17. Install the circlip (1) so that open ends are positioned
away from the ball groove.

6A – 26 ENGINE MECHANICAL
ENGINE ASSEMBLY
F06RW048
REMOVAL
1. Remove battery.
2. Drain engine coolant
3. Disconnect window washer hose and remove
engine hood.
4. Radiator Hose
1) Disconnect upper and lower hoses from engine
side.
5. Fan Shroud
1) Disengage clips and remove upper and lower
fan shrouds.
6. Cooling Fan Assembly
1) Remove cooling fan assembly fixing nuts,
cooling fan assembly.
7. Radiator Assembly
1) Remove bracket and radiator assembly.
8. Air Cleaner Cover & Air Duct
9. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
10. Engine Ground Cable
1) Disconnect ground cable from A/C compressor
bracket.
11. AC Generator Harness
1) Disconnect B terminal and harness connector
from AC generator.12. A/C Compressor Assembly
1) Disconnect magnetic clutch harness connector.
2) Remove A/C compressor fixing bolt (rear under
side of compressor).
3) Remove fixing bolts (upper and front lower side
of compressor) and set A/C compressor
assembly with pipe lines on battery carrier.
13 Vacuum Hose
1) Disconnect vacuum hose from vacuum pump.
14. Starter Harness
1) Disconnect B terminal and put cable harness
close to chassis side.
2) Disconnect S terminal connector.
15. Engine Harness
1) Disconnect engine harness close to engine side.
16. Fuel Pipe
1) Remove fuel pipe from fuel pump and take care
not to spill fuel and let dust enter.
17. Engine Ground Cable
1) Disconnect ground cable from left rear side of
timing gear case.
18. Vacuum Hose: Vacuum Tank
Disconnect vacuum hose from vacuum pump side.
19. Glow Plug Harness
20. Transmission Assembly
1) Set transmission support tool under the
transmission.

ENGINE MECHANICAL 6A – 27
2) Remove transmission rear mount.
3) Remove transmission fixing bolt from rear of
engine assembly except two bolts.
4) Carefully hang up engine assembly with a hoist.
5) Remove remaining two transmission fixing bolts.
6) Remove transmission assembly.
7) Remove heater hose.
8) Disconnect wire harness connector for shift on
the fly.
9) Remove vacuum hose.
21. Prepare Engine Stand
22. Engine Assembly
1) Remove engine mount fixing bolts.
2) Carefully hang up the engine assembly.
3) Take out the engine assembly making sure not
to damage the brake oil pipe and other pipe etc.
INSTALLATION
1. Engine assembly
1) Install engine in mounting position by using
hoist.
2. Transmission Assembly
1) Refer to transmission installation steps in
section 7.
3. Engine Mounting
1) After all fixing bolts (left: two bolts, rights: two
bolts) were inserted in every hole, tighten fixing
bolts to the specified torque.
Torque: 40 Nꞏm (4 kgꞏm/29 lbꞏft)
4. Glow Plug Harness
5. Vacuum Hose
1) Connect Vacuum Hose to Vacuum Pump
6. Engine Ground Cable
7. Fuel Pipe
1) Install fuel pipe to fuel pump.
8. Engine Harness
9. Starter Harness
10. A/C Compressor Assembly
1) Tighten temporarily the fixing bolts (upper and
front lower sides of compressor.)
2) Tighten fixing bolt (rear under side of
compressor) to the specified torque.
3) Tighten fixing bolts (front upper and lower sides
of compressor) to the specified torque.
Torque: 40 Nꞏm (4 kgꞏm/29 lbꞏft)Legend
(1) Tensioner
(2) Bolt
(3) Bracket
(4) A/C compressor
(5) Bolt
11. A.C Generator Harness
12. Engine Ground Cable
1) Tighten ground cable to A/C compressor
bracket.
13. Air Cleaner cover & Duct
14. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
15. Radiator Assembly
1) Install rubber cushion in under left and right part
of radiator and position radiator.
2) Fix radiator with bracket.
16. Cooling Fan Assembly
1) Install cooling fan assembly and tighten fixing
bolts to the specified torque.
Torque: 8 Nꞏm (0.8 kgꞏm/5.8 lb ft)
17. Fan Shroud
18. Radiator Hose
1) Connect upper and lower hose to engine side.
2) Pour coolant into radiator.
19. Install battery.
20. Connect window washer hose and install engine
hood.
1
2
3
4
5
F06RW054

7A–30
AUTOMATIC TRANSMISSION (4L30–E)
Removal
1. Disconnect battery ground cable.
2. Remove transfer control lever knob.
3. Remove front console.
Disconnect wiring harness connectors from front
console.
4. Disconnect shift lock cable (1) from the selector lever
assembly side.
256RW012
5. Disconnect shift control rod (2) from the selector lever
assembly side.
256RW013
6. Disconnect wiring harness connectors from the
selector lever assembly.
7. Remove selector lever assembly.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
Adjustment of select lever and control rod
1. Place the vehicle on a level surface.
NOTE: If the vehicle is not on level surface, the shift
select cable set positions will vary with the movement of
engine. To prevent possible misadjustment of the cable,
the vehicle must be placed on a level surface.
2. Install the shift control rod (1) to the transmission
select lever (2), and then place the lever in the “N”
position.
3. Set select lever in the “N” position.
4. Push select lever forward (“R” position side) and
s e c u r e i t ( u s i n g a r u b b e r b a n d ( 3 ) , e t c . ) s o t h a t t h e p i n
comes into contact with the wall of the detent plate.
5. Install the shift control rod (1) to the selector lever arm
(4).
To r q u e : 3 2 N
m (3.3 kgꞏm/24 lb ft)
NOTE: Do not apply oil to the threaded portions.
256RW014
6. After adjustment, make sure that the selector lever
operates normally, and that each selector position is
properly indicated. (The red mark shows through the
window.)
Adjustment of shift lock cable
1. Set ignition key in “LOCK” position and selector lever
in “P” position.
2. Adjust cable screw cap on selector lever side to
provide a gap (slack for cable) of 1 – 2 mm between
rod on steering lock side and stopper.
Adjust cap as follows:
a. Pull screw cap (1) in arrow direction to remove
inner cable slack.
b. With cable kept as (a), adjust gap between nut (2)
and bracket to 5 mm (0.2 in).
c. Lock inner cable by turning nut (3) while holding nut
(2) in place.
Torque : 3.7 N
m (38 kgꞏcm/33 lb in)