dimensions OPEL FRONTERA 1998 Workshop Manual

DIFFERENTIAL (REAR 220mm)
4A2A–29
Measure the length between the plates over the
V–groove. (D)
425RS065
3. After measuring dimensions A,B,C and D, make
adjustment in the following manner:
Measure the thickness (E) of the spring disc.
1.75mm (0.069in)
4discs
4. Select the friction disc & plate so as to satisfy the
following equation:
{(A-B)+C}-(D+E)=0.06-0.20mm (0.002-0.008in)
Also, the total size difference of the friction disc &
plate and spring disc should be 0.05mm (0.02in) or
less.
Thickness :1.75–1.85mm(0.069–0.073 in)
Backlash adjustment of the side gear in
the direction of the shaft
1. Measuring the depth of the differential cage.
(F–B): 82.03 mm (3.23 in)
(G): 12.03 mm (0.47 in)
425RS066
2. Measuring the dimension between the thrust washers
at both ends.
Assemble the side gear, pinion, pinion shaft,
pressure ring and thrust washer, and pressing the
pressure ring to–the pinion shaft in the direction of
the shaft to make the clearance 0.
Have the side gear contact to the pinion to make the
backlash 0.
Measure the dimension (H) between thrust
washers at both ends.
425RS067

4A2A–30
DIFFERENTIAL (REAR 220mm)
3. After measuring dimensions of each of the above
sections, proceed with the adjustment in the following
manner:
Adjust the clearance to satisfy the equation below.
{(F – B) + G – H}=0.05 – 0.20 mm
Also, select the thrust washers so that the
dimensional difference between the back surfaces of
the left and right pressure rings to the thrust washers
is 0.05mm or less.
Thickness : 1.5mm (0.059 in)
1.6 mm(0.063 in)
1.7 mm(0.067 in)
NOTE: When assembling the parts, apply recommended
gear oil sufficiently to each of the parts, especially, to the
contact surfaces and sliding surfaces.
1. Install Differential cage B.
2. Install Thrust washer.
3. Install Spring disc.
When assembling the spring disc, make sure the
mounting direction is correct as shown in figure.
425RS068
Legend
(1) Friction Plate
(2) Spring Disc
(3) Friction Disc
4. Inatall Spring disc.
5. Inatall Friction plate.
6. Inatall Friction disc.
7. Inatall Friction plate.
8. Inatall Friction disc.
9. Inatall Pressure ring.
10. Inatall Side gear.
11. Inatall Pinion and pinion shaft.
12. Inatall Side gear.
13. Inatall Pressure ring.
14. Inatall Friction disc.15. Inatall Friction plate.
16. Inatall Friction disc.
17. Inatall Friction plate.
18. Inatall Spring disc.
When assembling the spring disc, make sure the
mounting direction is correct.
19. Inatall Spring disc.
20. Inatall Thrust washer.
21. Inatall Differential cage A.
22. Inatall Screw.
Matching the guide marks of the differential cages A
and B, tighten the screws evenly in the diagonal
order.
425RS055

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–4BODY STRUCTURE
Frame Dimensions (L W B)
This illustration is based on the gasoline engine and A/T
model.
501RW013

8F–5 BODY STRUCTURE
Frame Dimensions (S W B)
This illustration is based on the gasoline engine and A/T
model.
501RW014

8F–56BODY STRUCTURE
Front Door Assembly
Parts Location
630RS001
Legend
(1) Door Check Arm Pin
(2) Front Door Assembly(3) Door Hinge Assembly
(4) Hinge Bolt
(5) Door Harness Connection
Removal
1. Disconnect the battery ground cable.
2. Remove door check arm pin (1).
630RS002
3. Remove hinge bolt.
Align the hinge bolt to the door side hinge and put a
marker on it.
4. Remove door harness connection (2).
Pull the door harness grommet out in order to
disconnect the harness connection.
810RS001
5. Remove front door assembly.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Align the door fitting to the body by referring to Body
Dimensions in this section.
2. Tighten the door hinge bolts to the specified torque.
Torque : 34 N
m (3.5kgꞏm/25 lb ft)
3. Apply chassis grease to the door check arm pin and
the door hinge moving surface.

8F–58BODY STRUCTURE
5. Remove door harness connection (3).
Pull the door harness grommet out in order to
disconnect the door harness connection.
810RS002
6. Remove door assembly
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Align the door fitting to the body by refer to Body
Dimensions in this section.
2. Tighten the door hinge bolts to the specified torque.
Torque : 34 N
m (3.5kgꞏm/25 lb ft)
3. Apply chassis grease to the check arm pin and the
door hinge moving surface.
Door Strikers
Adjustment
632RS001
1. Loosen the striker (1) screws.
2. Tap with a plastic hammer to align.
3. Tighten the striker screws.
Torque : 15 N
m (1.5kgꞏm/11 lb ft)

4A2A–32
DIFFERENTIAL (REAR 220mm)
2. Measuring the overall length of the pressurering,
friction disc and friction plate.
Mount the pinion shaft in the pressurering and then
install the friction disc & plate.
Measure the length between the plates over the
V–groove. (D)
425RS065
3. After measuring dimensions A,B,C and D, make
adjustment in the following manner:
Measure the thickness (E) of the spring disc.
1.75mm (0.069in)
2discs
4. Select the friction disc & plate so as to satisfy the
following equation:
{(A-B)+C}-(D+E)=0.06-0.20mm (0.002-0.008in)
Also, the total size difference of the friction disc &
plate and spring disc should be 0.05mm (0.02in) or
less.
Thickness
:1.65–1.75–1.85mm(0.065–0.069–0.073 in)
Backlash adjustment of the side gear in
the direction of the shaft
1. Measuring the depth of the differential cage.
(F–B): 95.63 mm (3.76 in)
(G): 15.63 mm (0.62 in)
425RS066
2. Measuring the dimension between the thrust washers
at both ends.
Assemble the side gear, pinion, pinion shaft,
pressure ring and thrust washer, and pressing the
pressure ring to–the pinion shaft in the direction of
the shaft to make the clearance 0.
Have the side gear contact to the pinion to make the
backlash 0.
Measure the dimension (H) between thrust
washers at both ends.
425RS067

DIFFERENTIAL (REAR 220mm)
4A2A–33
3. After measuring dimensions of each of the above
sections, proceed with the adjustment in the following
manner:
Adjust the clearance to satisfy the equation below.
{(F – B) + G – H}=0.05 – 0.20 mm
Also, select the thrust washers so that the
dimensional difference between the back surfaces of
the left and right pressure rings to the thrust washers
is 0.05mm or less.
Thickness : 1.5mm (0.059 in)
1.6 mm(0.063 in)
1.7 mm(0.067 in)
NOTE: When assembling the parts, apply recommended
gear oil sufficiently to each of the parts, especially, to the
contact surfaces and sliding surfaces.
1. Install Differential cage B.
2. Install Thrust washer.
3. Install Spring disc.
When assembling the spring disc, make sure the
mounting direction is correct as shown in figure.
425RY004
Legend
(1) Friction Plate
(2) Spring Disc
(3) Friction Disc
4. Install Friction disc.
5. Install Friction plate.6. Install Friction plate.
7. Install Friction disc.
8. Install Friction plate.
9. Install Friction disc.
10. Install Friction plate.
11. Install Pressure ring.
12. Install Side gear.
13. Install Pinion and pinion shaft.
14. Install Side gear.
15. Install Pressure ring.
16. Install Friction plate.
17. Install Friction disc.
18. Install Friction plate.
19. Install Friction disc.
20. Install Friction plate.
21. Install Friction plate.
22. Install Friction plate.
23. Install Spring disc.
When assembling the spring disc, make sure the
mounting direction is correct.
24. Install Spring disc.
25. Install Thrust washer.
26. Install Differential cage A.
27. Install Screw.
Matching the guide marks of the differential cages A
and B, tighten the screws evenly in the diagonal
order.
425RS055

4A2B–32DIFFERENTIAL (REAR 244mm)
2. Measuring the overall length of the pressurering,
friction disc and friction plate.
Mount the pinion shaft in the pressurering and then
install the friction disc & plate.
Measure the length between the plates over the
V–groove. (D)
425RS065
3. After measuring dimensions A,B,C and D, make
adjustment in the following manner:
Measure the thickness (E) of the spring disc.
1.75mm (0.069in)
2discs
4. Select the friction disc & plate so as to satisfy the
following equation:
{(A-B)+C}-(D+E)=0.06-0.20mm (0.002-0.008in)
Also, the total size difference of the friction disc &
plate and spring disc should be 0.05mm (0.02in) or
less.
Thickness
:1.65–1.75–1.85mm(0.065–0.069–0.073 in)
Backlash adjustment of the side gear in
the direction of the shaft
1. Measuring the depth of the differential cage.
(F–B): 95.63 mm (3.76 in)
(G): 15.63 mm (0.62 in)
425RS066
2. Measuring the dimension between the thrust washers
at both ends.
Assemble the side gear, pinion, pinion shaft,
pressure ring and thrust washer, and pressing the
pressure ring to–the pinion shaft in the direction of
the shaft to make the clearance 0.
Have the side gear contact to the pinion to make the
backlash 0.
Measure the dimension (H) between thrust
washers at both ends.
425RS067