oil OPEL FRONTERA 1998 Workshop Manual

6. Remove any excess oil resulting from installing the
new seal parts from the shaft and inside the
compressor neck.
7. Install the clutch plate and hub assembly as
described previously.8. Reinstall compressor belt and tighten bracket.
9. Evacuate and charge the refrigerant system.
COMPRESSOR PRESSURE RELIEF VALVE
Removal
1. Recover the refrigerant using Refrigerant Recovery
System.
2. Remove old pressure relief valve.
Installation
1. Clean valve seat area on rear head.2. Lubricate O-ring of new pressure relief valve and
O-ring assembly with new 525 viscosity refrigerant
oil. Install new valve and torque in place, 9.0 Nꞏm
(6.1 ft lbs)
3. Evacuate and recharge the system.
4. Leak test system.
COMPRESSOR OIL
Compressor Oil Check
The oil used to lubricate the compressor is circulating
with the refrigerant.
Whenever replacing any component of the system or a
large amount of gas leakage occurs, add oil to maintain
the original amount of oil.
Checking and Adjusting Oil Quantity for
Used Compressor
1. Perform oil return operation. Refer to Oil Return
Operation in this section.
2. Discharge and recover refrigerant and remove the
compressor.
3. Drain the compressor oil and measure the extracted
oil with a measuring cylinder.
4. If the amount of oil drained is much less than 90 cc
(3.0 fl. oz.), some refrigerant may have leaked out.
Conduct a leak tests on the connections of each
system, and if necessary, repair or replace faulty
parts.
5. Check the compressor oil contamination. (Refer to
Contamination of Compressor Oil in this section.)
6. Adjust the oil level following the next procedure
below.7. Install the compressor, then evacuate, charge and
perform the oil return operation.
8. Check system operation.
When it is impossible to preform oil return
operation, the compressor oil should be checked in
the following order:
1. Discharge and recover refrigerant and remove the
compressor.
2. Drain the compressor oil and measure the extracted
oil with a measuring cylinder.
3. Check the oil for contamination.
4. If more than 90 cc (3.0 fl. oz.) of oil is extracted from
the compressor, supply the same amount of oil to
the compressor to be installed. If the amount of oil
extracted is less than 90 cc (3.0 fl. oz.), recheck the
compressor oil in the following order:
5. Supply 90 cc (3.0 fl. oz.) of oil to the compressor
and install it onto the vehicle.
6. Evacuate and recharge with the proper amount of
refrigerant.
7. Perform the oil return operation.
8. Remove the compressor and recheck the amount of
oil.
9. Adjust the compressor oil, if necessary.
Checking and Adjusting for Compressor
Replacement
The oil is not charged in compressor (service parts). So
it is necessary to charge the proper amount of oil to the
new compressor. (Oil Capacity)
Capacity total in system 150 cc (5.0 fl.oz)
Compressor (Service 150 cc (5.0 fl.oz)
parts) charging amount
(Collected Amount) (Charging Amount)
more than 90 cc same as collected
(3.0 fl.oz) amount
less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)
(Collected Amount) (Charging Amount)
more than 90 cc same as collected
(3.0 fl.oz) amount
less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)

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)

14. Attach the compressor to the J-34992 holding
fixture and mount the compressor in a vise so that
the compressor will be in a horizontal position and
the shaft can be turned with a wrench.
15. Using a wrench, rotate the compressor crankshaft
or drive plate hub ten complete revolutions at a
speed of approximately one-revolution per second
turning the compressor at less than one-revolution
per second can result in a lower pump-up pressure
and disqualify a good pumping compressor.
16. Observe the reading on high-pressure gauge at the
completion of the tenth revolution of the
compressor. The pressure reading for a good
pumping compressor should be 690 kPa (100 psi)
or above. A pressure reading of less than 620 kPa
(90 psi) would indicate one or more suction and/or
discharge valves leaking an internal leak, or an
inoperative valve, and the refrigerant must be
recovered and the compressor disassembled and
checked for cause of leak. Repair as needed,
reassemble and repeat the pump-up test. Externally
leak test.
17. When the pressure pump-up test is completed,
recover the refrigerant from the high-side and
remove the test plate J-39893.
18. Tilt the compressor so that the compressor suction
and discharge ports are down. Drain the PAG
lubricant from the compressor.
19. Allow the compressor to drain for 10 minutes, then
refill with the proper amount of PAG lubricant, per
oil balance procedure described previously. The
PAG lubricant may be poured into the suction port.
If further assembly or processing is required, a
shipping plate or test plate J-39893 should be
installed to keep out air, dirt and moisture until the
compressor is installed.

4A1–1 DIFFERENTIAL (FRONT)
DRIVELINE/AXLE
CONTENTS
Differential (Front) 4A1. . . . . . . . . . . . . . . . . . . . . . .
Differential (Rear/220mm) 4A2A. . . . . . . . . . . . . . . .
Differential (Rear/244mm) 4A2B. . . . . . . . . . . . . . . .
Driveline Control System (Shift on the Fly) 4B1. . Driveline Control System (TOD) 4B2. . . . . . . . . . .
Driveshaft System 4C. . . . . . . . . . . . . . . . . . . . . . .
Transfer Case (Standard Type) 4D1. . . . . . . . . . .
Transfer Case (TOD) 4D2. . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL (FRONT)
CONTENTS
Service Precaution 4A1–1. . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 4A1–2. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal 4A1–3. . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal and Associated Parts 4A1–3
Removal 4A1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A1–4. . . . . . . . . . . . . . . . . .
Installation 4A1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle Assembly 4A1–5. . . . . . . . . . . . . . .
Front Drive Axle Assembly and
Associated Parts 4A1–5. . . . . . . . . . . . . . . . . . . . . .
Removal 4A1–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A1–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A1–9. . . . . . . . . . . . . . . . . . . .
Disassembled View 4A1–9. . . . . . . . . . . . . . . . . . . .
Disassembly 4A1–10. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A1–12. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A1–21. . . . . . . . . . . . . . .
Disassembled View 4A1–21. . . . . . . . . . . . . . . . . . . .
Disassembly 4A1–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A1–22. . . . . . . . . . . . . . . . . .
Reassembly 4A1–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A1–25. . . . . . . . . . .
Special Tools 4A1–28. . . . . . . . . . . . . . . . . . . . . . . . . .
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 REFORMING 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 specification. Following these
instructions can help you avoid damage to parts and
systems.

DIFFERENTIAL (FRONT) 4A1–2
Front Drive Axle
Diagnosis
ConditionPossible causeCorrection
Oil Leak At Front AxleWorn or defective oil seal.Replace the oil seal.
Front axle housing cracked.Repair or replace.
Oil Leak At Pinion ShaftToo much gear oil.Correct the oil level.
Oil seal worn or defective.Replace the oil seal.
Pinion flange loose or damaged.Tighten or replace.
Noises In Front Axle Drive Shaft
JointBroken or worn drive shaft joints and
bellows (BJ and DOJ).Replace the drive shaft joints and
bellows.
“Clank” When Accelerating From
“Coast”Loose drive shaft joint to output shaft
bolts.Tighten.
Damaged inner drive shaft joint.Replace.
Shudder or Vibration During
Acceleration
Excessive drive shaft joint angle.Repair.
AccelerationWorn or damaged drive shaft joints.Replace.
Sticking spider assembly (inner drive
shaft joint).Lubricate or replace.
Sticking joint assembly (outer drive
shaft joint).Lubricate or replace.
Vibration At Highway SpeedsOut of balance or out of round tires.Balance or replace.
Front end out of alignment.Align.
Noises in Front AxleInsufficient gear oil.Replenish the gear oil.
Wrong or poor grade gear oil.Replace the gear oil.
Drive pinion to ring gear backlash
incorrect.Adjust the backlash.
Worn or chipped ring gear, pinion
gear or side gear.Replace the ring gear, pinion gear or
side gear.
Pinion shaft bearing worn.Replace the pinion shaft bearing.
Wheel bearing worn.Replace the wheel bearing.
Differential bearing loose or worn.Tighten or replace.
Wanders and PullsWheel bearing preload too tight.Adjust the wheel bearing preload.
Incorrect front alignment.Adjust the front alignment.
Steering linkage loose or worn.Tighten or replace.
Steering gear out of adjustment.Adjust or replace the steering gear.
Tire worn or improperly inflated.Adjust the inflation or replace.
Front or rear suspension parts loose
or broken.Tighten or replace.
Front Wheel ShimmyWheel bearing worn or improperly
adjusted.Adjust or replace.
Incorrect front alignment.Adjust the front alignment.
Worn ball joint or bush.Replace the ball joint or bush.
Steering linkage loose or worn.Tighten or replace.
Steering gear out of adjustment.Tighten or replace.
Tire worn or improperly inflated.Replace or adjust the inflation.
Shock absorber worn.Replace the shock absorber.

4A1–3 DIFFERENTIAL (FRONT)
Pinion Shaft Oil Seal
Pinion Shaft Oil Seal and Associated Parts
415RW015
Legend
(1) Flange Nut
(2) Flange(3) Oil Seal
(4) Outer Bearing
(5) Collapsible Spacer
Removal
1. Raise the vehicle and support it at the frame.
The hoist must remain under the front axle housing.
2. Drain the front axle oil by loosening the drain plug(1).
412RS001

DIFFERENTIAL (FRONT) 4A1–4
3. Remove the front propeller shaft. Refer to Front
Propeller Shaft in this section.
4. Remove flange nut by using pinion flange holder
5–8840–2157–0.
425RW045
5. Remove flange.
6. Remove oil seal.
7. Remove outer bearing by using remover
5–8840–2323–0.
415RW022
8. Remove collapsible spacer.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal conditions are
found through inspection.
Check the following parts:
1. Seal surface of the pinion.
2. Cage bore for burns.
Installation
1. Install collapsible spacer. Discard the used
collapsible spacer and install a new one.
2. Install outer bearing.
NOTE: Do not drive in, but just temporarily set in the outer
bearing by hand, which should be indirectly pressed in
finally by tightening the flange nut.
3. Install oil seal, use oil seal installer 9–8522–1275–0 to
install a new oil seal that has been soaked in axle
lubricant.
415RW021
4. Install flange.
5. Install flange nut, refer to Differential Assembly for
flange nut reassembly in this section.
NOTE: Discard the used nut and install a new one.

DIFFERENTIAL (FRONT) 4A1–6
3. Remove the drain bolt to drain differential oil.
NOTE:
a. During the work, be sure that the diff case is
supported by the jack.
412RS003
b. Remove the brake caliper fixing bolt and hang the
caliper. Refer to Front Disc Brake Caliper Assembly
in Brake section.
c. Remove the antilock brake system speed sensor (if
equipped). Refer to Front Wheel Speed Sensor in
Brakes section.
4. Remove the hub assembly (Disc, back plate and
knuckle), refer to Front Hub and Disc in this section.
5. Disconnect the knuckle and the suspension arm.
Refer to Suspension section.
6. Remove steering link and arm assembly, refer to
Steering Linkage in Steering section.
7. Remove suspension crossmember.
8. Remove propeller shaft, refer to Front Propeller Shaft
in this section.
9. Remove protector (Shift on the fly model).
10. Remove the hose clip.
11. Disconnect breather hose from front drive axle tube.
(and disconnect housing : Shift on the fly model).
12. Disconnect vacuum hose from actuator (Shift on the
fly model).13. Disconnect shift switch connector (Shift on the fly
model).
412RS031
14. Remove VSV assembly (1) (Shift on the fly model).
NOTE: Be sure not to remove hose and connector from
VSV asm.
412RW002

4A1–9 DIFFERENTIAL (FRONT)
Differential Assembly
Disassembled View
415RW001
Legend
(1) Differential Assembly
(2) Flange Nut
(3) Flange
(4) Dust Cover
(5) Oil Seal
(6) Outer Bearing
(7) Outer Bearing Outer Race
(8) Damper
(9) Bracket
(10) Differential Carrier
(11) Bearing Cap(12) Bolt
(13) Inner Bearing Outer Race
(14) Collapsible Spacer
(15) Pinion Gear
(16) Inner Bearing
(17) Adjust Shim
(18) Diff Cage Assembly
(19) Side Bearing Outer Race
(20) Side Bearing
(21) Adjust Shim
(22) Bolt
(23) Axle Case

4A1–11 DIFFERENTIAL (FRONT)
12. Remove dust cover.
13. Remove the drive pinion assembly using a soft metal
rod and a hammer.
425RW041
14. Remove collapsible spacer.
15. Remove the inner bearing using a separator
5–8840–0015–0 and a press.
415RW033
16. Remove adjust shim.
17. Remove inner bearing outer race.
18. Remove oil seal.
19. Remove outer bearing.20. Remove the inner bearing outer race (1) and the outer
bearing outer race (2) by using a brass bar and a
hammer.
425RS014
425RS015