ECU OPEL FRONTERA 1998 Workshop Manual

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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTRNTS
8A LIGHTING SYSTEM
8B WIPER / WASHER SYSTEM
8C ENTERTAINMENT
8D WIRING SYSTEM
8E METER AND GAUGE
8F BODY STRUCTURE
8G SEATS
8H SECURITY AND LOCKS
8I SUN ROOF/CONVERTIBLE TOP
8J EXTERIOR / INTERIOR TRIM
HOME
8A
8B
8C
8D
8E
8F
8G
8H
8I
8J

COMPRESSOR SHAFT SEAL
Service Precaution
When replacing the shaft seal assembly, pressure relief
valve or control switches, it will be necessary to recover
the refrigerant. Other than clutch repair procedures, the
same holds true for any disassembly of the compressor.
A clean workbench covered with a sheet of clean
paper, and a place (clean trays, etc) for all parts being
removed and replaced is important, as is the use of
proper clean service tools.
CAUTION: Any attempt to use makeshift or
inadequate service tools or equipment may result
in damage and/or improper compressor operation.
All parts required for servicing the internal compressor
are protected by a preservative process and packaged
in a manner which will eliminate the necessity of
cleaning, washing or flushing of the parts. The parts
can be used in the internal assembly just as they are
removed from the service package. Seals and
protective packaging should be left intact until just
prior to installation.
If the compressor rear head, front head or cylinder and
shaft assembly is to be serviced or replaced, the oil in
the compressor must be drained, measured, recorded
and replaced.
Legend
(1) Suction Port
(2) Discharge Port
(3) Mounting Boss
(4) Mounting Boss
(5) Pressure Relief Valve
(6) Mounting Boss
Seal Leak Detection
A shaft seal should not be changed because of small
amounts of oil found on an adjacent surface but only
after actual refrigerant leakage is found using an
approved leak detector.
CAUTION: Handling and care of seal protector is
important. If seal protector is nicked or the bottom
flared, the new seal may be damaged during
installation.
Removal
1. Recover the refrigerant using Refrigerant Recovery
System.
2. Loosen and reposition compressor in mounting
brackets, if necessary.
3. Remove clutch plate and hub assembly from
compressor as described previously.
4. Remove the shaft seal retainer ring, using snap ring
pliers.
5. Thoroughly clean inside of compressor neck area
surrounding the shaft, the exposed portion of the
seal, the retainer ring groove and the shaft itself.
Any dirt or foreign material getting into compressor
may cause damage.
6. Fully engage the knurled tangs of Seal Remover-
Installer J-23128-A into the recessed portion of the
Seal (1) by turning the handle clockwise. Remove
the Seal from the compressor with a rotary-pulling
motion.
Discard the seal. The handle must be hand-
tightened securely. Do not use a wrench or pliers.
1
2
3
456
871RW006
J-23128-A1
901RW008

DIFFERENTIAL (FRONT) 4A1–24
Thickness of thrust washers available:
1.00 mm, 1.05 mm, 1.10 mm (0.039 in, 0.041 in,
0.043 in)
425RS050
5. Install lock pin. After lock pin installation, stake the
cage to secure the lock pin.
425RS051
Legend
(1) Staked Portion
(2) Lock Pin
6. Clean the ring gear threaded holes to remove the
locking agent. When installing the ring gear, apply
LOCTITE 271 or equivalent to all the threaded area
and half of the unthreaded area of the bolt.7. Tighten the bolts in diagonal sequence as illustrated.
Torque: 108 Nꞏm (11kgꞏm/80 lb ft)
NOTE: Discard used bolts and install new ones.
415RS016

4A2A–24
DIFFERENTIAL (REAR 220mm)
Thickness of thrust washers available:
0.80 mm, 0.90 mm, 1.00 mm 1.10 mm, 1.20 mm,
1.30 mm (0.031 in, 0.035 in, 0.039 in,0.043 in,
0.047 in, 0.051 in)
425RS050
5. Install lock pin. After lock pin installation, stake the
cage to secure the lock pin.
425RS051
Legend
(1) Staked Portion
(2) Lock Pin
6. Clean the ring gear threaded holes to remove the
locking agent. When installing the ring gear, apply
LOCTITE 271 or equivalent to all the threaded area
and half of the unthreaded area of the bolt.7. Tighten the bolts in diagonal sequence as illustrated.
Torque: 108 Nꞏm (11.0kgꞏm/80 lb ft)
NOTE: Discard used bolts and install new ones.
415RW036

4A2B–22DIFFERENTIAL (REAR 244mm)
2. Install the pinion mate gear with thrust washer by
engaging it with the side gears while turning both
pinion mate gears simultaneously in the same
direction.
425RS048
3. Install differential shaft.
1 . B e s u r e t o i n s t a l l t h e d i f f e r e n t i a l s h a f t s o t h a t i t i s i n
alignment with the lock pin hole in the differential
cage.
425RS049
4. Install lock pin.
After lock pin installation, stake the case to secure the
lock pin.
5. Install ring gear.6. Tighten the bolts in diagonal sequence as illustrated.
Torque: 177Nꞏm (18.0kgꞏm/130 lb ft)
NOTE: Discard used bolts and install new ones.
425RW033

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–2
General Description
C07RW014–1
TOD (Torque on Demand) system is traction state control
system to vehicle.
Transfer Position and Drive Mode
Three drive modes can be selected through operation of
4WD switch and transfer lever.
Transfer Position
TOD SWModeDrive mode
HIGHON (NORMAL)2HRear wheel drive
OFF (PUSHED)TODElectronically controlled torque split
four wheel drive
4LON/OFF4LLow-speed mechanical lock-up four
wheel drive
The electronic control unit (ECU) judges the signals from
the transfer lever and controls the transfer drive mode
and shift-on-the-fly system status.
TOD Control
The TOD position usually drives the rear wheels, and
transmits the torque to the front wheels with the help of
electronically controlled torque split mechanism
according to running conditions encountered. The driving
force is directly transmitted to the rear wheels. This force
is split by the transfer and delivered to the front wheels.
The magnitude of the torque transmitted to the front
wheels is controlled by changing the pressing force of the
electromagnetic multi plate disk clutch built in the transfer
unit. The pressing force of the clutch is controlled bychanging the voltage to the electromagnetic coil mounted
to the rear of the clutch. When the clutch is completely
disengaged, the rear wheels are driven. When the clutch
is completely engaged, a rigid four wheel drive mode is
obtained. The torque split status is controlled
continuously between the rear wheel and four wheel drive
modes. This system includes front and rear speed
sensors, and throttle position sensor that monitors the
engine output.
The control unit receives signals sent from these sensors
and changes the pressing force of the electromagnetic
multi plate disk clutch to determine the torque distribution
on the front and rear wheels. Therefore, when the slip of
the rear wheels is increased against the current torque
level in the normal rear wheel drive mode, the control unit

4B2–7 DRIVE LINE CONTROL SYSTEM (TOD)
Check Lamp
Inform the following items.
Bulb check
Fail (fail alarm)
Trouble code
Diesel/gasoline MAP
821RW078
TOD ECU
This control unit is mounted to the front right hand seat via
a special bracket.
F07RW029

4B2–11 DRIVE LINE CONTROL SYSTEM (TOD)
The CHECK lamp also has the following functions.
D-G MAP recognition and display (The control unit
displays what type of vehicle, diesel or gasoline
vehicle, it recognizes.)
1. Short-circuit the self-diagnostic connector.
2. Turn on the starter switch. (Displays with respect to
the self-diagnosis begin to appear.)
NOTE: Do not start the engine.
3. Shift the transfer lever to the neutral position between
HIGH and 4L.
4. After all the conditions in 1 through 3 above are met,
set the throttle to the WOT (wide open throttle)
position (i.e., full open position). The display of the
self-diagnosis is temporarily suspended, and the
CHECK lamp begins to display that MAP is
recognized by the TPS (throttle position sensor)
according to the current conditions.NOTE: If the TPS has failed, this function might not work.
1. When the control unit recognizes the vehicle as
gasoline type, the CHECK lamp is turned on for five
seconds and this mode is repeated at an interval of
0.3 second.
2. When the control unit recognizes the vehicle as
diesel type, the CHECK lamp is turned off for five
seconds and this mode is repeated at an interval of
0.3 seconds.
3. Upon completion of step 4, the system resumes the
self-diagnosis. (The self-diagnosis is executed
from the beginning.)
5. Turn off the starter switch once. When above
conditions are met again in the future, the TPS MAP
control can be started.
C04RW010

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–14
How to Clear The Trouble Code
The trouble codes saved to the control unit can be deleted
by the following procedure if the starter switch is being in
the OFF position.
1. Shift the transfer lever to the neutral position between
HIGH and 4L, and short-circuit the self-diagnostic
connector.
NOTE: The neutral position between HIGH and 4L refers
to the point that turns off the TOD indicator lamps.
(However, be sure to check the position before
short-circuiting the self-diagnostic connector.)
C07RW011
2. Turn on the starter switch while maintaining the state
of step 1, and step on the brake pedal five times within
five seconds from the first step on. (Note that “five
times” includes the first step on). (The TOD indicator
lamps display the 4L mode whenever the brake pedal
is stepped on.)
3. If the conditions shown in steps 1 and 2 are met, clear
the trouble codes saved to the control unit. (After the
codes are completely deleted, the code 12 that
indicates the normal condition is continuously
displayed.)
Precautions on Diagnosis
Replacement of Control Unit
The control unit itself rarely fails. In most cases, the
harnesses have failed (e.q. short-circuit) to cause
secondary troubles. Other cases include that the cause
has been unknown due to intermittent occurrence of
troubles and the troubles are removed accidentally along
with replacement of control unit, resulting in misjudgment
of cause. Therefore, before replacing the control unit,
check the connector joints and whether the unspecified
current flows in the control unit due to short-circuit
between harnesses.Trouble Intermittently Observed
Troubles intermittently observed are mostly attributable
to temporary imperfect connection of harnesses and
connectors.
When such troubles are found, check the associated
circuit according to the following procedure.
1. Check whether improper connectors are plugged in
or connector terminals are completely engaged.
2. Check whether the terminals are deformed or
damaged. If yes, remove the deformation or damage
and connect the terminals securely.
3. It is likely that wires in the harness are falsely broken.
Therefore, in examination of failed harness circuit,
shake the harness for check to such extent that the
harness will not be damaged.
Test Run of Filed TOD Vehicle
If the TOD indicator lamps experienced faulty operation
even once in the past, the failed portion can be identified
by use of the procedure “Diagnosis from Trouble Codes”
or “Trouble Diagnosis Depending on The Status of TOD
Indicator”. If the troubles that are only recognized as
abnormal phenomena of the vehicle by the driver are
observed, conduct the test run in the following procedure
to reproduce the faulty phenomena and diagnose the fault
for each phenomenon.
1. Start the engine, and check that the TOD indicator
lamps are turned on for about two seconds for initial
check; the CHECK lamp goes off; and the TOD
indicator lamps display the specified drive mode. (If
the CHECK lamp starts blinking, read the trouble
codes and identify the failed portion.)
2. While keeping the vehicle standstill, operate the 4WD
switch and shift the transfer lever to change the
modes: 2H mode
TOD mode4L modeTOD
mode
2H mode. Check that the TOD indicator
lamps correctly display the status whenever the
mode is changed. If the transition status is displayed
during the shift operation, run the vehicle a little to
complete shifting.
3. Slowly start the vehicle in the TOD mode, and add the
power to accelerate to at least 40 km/h and maintain
the speed for about two minutes. Apply the brake to
completely stop the vehicle. Repeat this test pattern
at least three times.
4. Turn the steering to the right end (or left end) in the
TOD mode, and slowly start the vehicle and make a
c i r c l e f i v e t i m e s . N e x t , c o n d u c t t h e s a m e t e s t i n t h e 2 H
mode.
5. Slowly start the vehicle in the TOD mode, and
accelerate to at least 40 km/h. Keep the established
speed, carefully change the mode in the sequence
“TOD mode
2H mode TOD mode” while checking
that the shift is complete in each mode change. After
the test, apply the brake to completely stop the
vehicle.
6. Slowly start the vehicle in the TOD mode, and
accelerate to at least 40 km/h. Apply the brake
strongly so that the ABS works, and completely stop
the vehicle.

4B2–23 DRIVE LINE CONTROL SYSTEM (TOD)
Checking Failed Pin
Connector Pin Assignment
ECU pin assignment
D04RW032