oil OPEL FRONTERA 1998 Workshop Manual

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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTRNTS
3C FRONT SUSPENSION
3D REAR SUSPENSION; COIL SPRING
3E WHEELS AND TIRES
HOME
3C
3D
3E

Legend
(1) Drive Plate Bolt
(2) Drive Plate
(3) Snap Ring(4) Pulley Assembly
(5) Field Coil
(6) Shim(s)
(7) Lead Wire
Removal
1. Remove drive plate bolt by using drive plate holder
J-7624 (1) to prevent the drive plate from rotating.2. Remove drive plate by using drive plate puller
J-33944-A (2) and forcing screw J-33944-4 (1).
SERVICE PROCEDURE
DKV-14D TYPE COMPRESSOR
1
2
3
4
5
67
871RX012
1
901RX055
1
2
871RX016

3. Remove shim(s).
4. Remove snap ring (1) by using snap ring pliers.
5. Remove pulley assembly by using pulley puller pilot
J-38424 (2), pulley puller J-8433 (1) and pulley
puller leg J-24092-2 (3).6. Loosen screw and disconnect the coil lead wire
connector.
7. Loosen three screws and remove the field coil.
1
871RW016871RS010
3
1
2
871RX031
871RS011

Inspection and Repair
Drive Plate
If the frictional surface shows signs of damage due to
excessive heat, the drive plate and pulley should be
replaced.
Pulley Assembly
Check the appearance of the pulley assembly. If the
frictional surface of the pulley shows signs of excessive
grooving due to slippage, both the pulley and drive
plate should be replaced. The frictional surfaces of the
pulley assembly should be cleaned with a suitable
solvent before reinstallation.
Coil
Check coil for loose connector or cracked insulation.
Installation
1. Install field coil.
Align the located portion (1) of the field coil and
compressor.
Tighten the mounting screw to the specified torque.
Torque: 5Nꞏm (44 lb in)
2. Connect the lead wire connector with the rubber
hold and tighten the screw.3. Install pulley assembly by using pulley installer
J-33940-A (2) and drive handle J-8092 (1).
4. Install snap ring.
5. Install shim(s).
6. Install the drive plate to the compressor drive shaft
together with the original shim(s)(1). Press the drive
plate by hand.
1
2
871RX032
1
871RX010
1
871RX015

Legend
(1) Drive Plate Bolt
(2) Drive Plate
(3) Shim
(4) Snap Ring
(5) Pulley Assembly
(6) Screw
(7) Field Coil
(8) Through Bolt
(9) Shaft Seal Assembly
(10) Gasket
(11) Front Cylinder Head(12) O-Ring
(13) Gasket
(14) Front Valve Plate
(15) Front Suction Valve
(16) Pin
(17) Cylinder and Shaft Assembly
(18) Rear Valve Plate
(19) Gasket
(20) Rear Cylinder Head
(21) Bolt
(22) Oil Drain Plug
(23) O-Ring
DKS-15CH TYPE COMPRESSOR
16
23 2122 6
7
45
321 ('98)
('99~)
67
45
321
8
910111213141516
17
1518191220
871RY00015

6. Loosen three screws and remove the field coil.
7. Remove snap ring by using snap ring pliers.8. Remove shaft seal assembly (2) by using shaft seal
remover J-33942 (1).
Engage the remover hook with the shaft seal
assembly groove and slowly draw the shaft seal
assembly out.
NOTE
The shaft seal is precision-machined and its
critical parts are finished to extremely close
tolerances. The assembly must be handled
with great care, it slips face demanding
particularly careful handling.
The shaft seal can not be reused. Install a new
shaft seal at reassembly.
Take care not to scratch or otherwise damage
the shaft seal face.
Keep the shaft seal free from lint and dirt.
9. Remove through bolt.
871RY00006
871RY00017
871RY00018

Installation
1. Install cylinder and shaft assembly.
Clamp the cylinder shaft assembly in a vise.
The rear side of the cylinder shaft assembly must
be facing up.
2. Install rear suction valve.
Apply a coat of new compressor oil to the new
suction valve (2).
Install the suction valve by aligning it with the
spring pin and the cylinder valve relief grooves.
Legend
(1) Escape Groove
(2) Suction Valve
(3) Piston
3. Install rear valve plate.
Apply a coat of new compressor oil to the new
valve plate.
Install the valve plate to the suction valve by
aligning it with the spring pin.
NOTE
Do not mix up the front and rear valve plate.
4. Install gasket.
Apply a coat of new compressor oil to the new
gasket.
Install the gasket (3) to the valve plate (4).
5. Install o-ring (2).6. Install rear cylinder head (1).
Apply a coat of new compressor oil to the new o-
ring (2).
Install the o-ring (2) to the rear cylinder head (1).
Install the rear cylinder head.
Top the rear cylinder head (1) into place with a
plastic hammer.
7. Install front suction valve.
Set the cylinder shaft assembly with the front side
facing up.
Apply a coat of new compressor oil to the new
suction valve (2).
Install the suction valve (2) by aligning it with the
spring pin and the cylinder valve relief grooves.
Legend
(1) Escape Groove
(2) Suction Valve
(3) Piston
1
2
3
871RY00021
54321
871RY00022
1
2
3
871RY00021

8. Install front valve plate.
Apply a coat of new compressor oil to the new
valve plate.
Install the valve plate to the suction valve by
aligning it with the spring pin.
NOTE
Do not mix up the front and rear valve plates.
9. Install gasket
Apply new compressor oil to the new gasket.
Install the gasket to the valve plate by a aligning it
with the spring pin.
10. Install o-ring.
11. Install front cylinder head.
Apply a coat of new compressor oil to the new O-
ring.
Install the O-ring to the front cylinder head.
Install the front cylinder head.
Tap the front cylinder head into place with a
plastic hammer.
NOTE
When installing the cylinder head, be careful
that the end of the drive shaft does not
damage the shaft seal assembly surface in the
cylinder head.12. Install through bolt.
Gaskets cannot reused. Always replace new
ones. Tighten the bolts to the specified torque a
little at a time in the sequence shown in the
illustration.
Torque: 22Nꞏm (16 lbꞏft)
NOTE
Rotate the compressor drive shaft two or three
times to make sure that it moves smoothly.
1
4
5
2
3
6
871RY00016
871RY00023

13. Install shaft seal assembly.
Clean the sealing portion of the compressor and
shaft seal (2).
Install the shaft seal guide J-34614 (1) onto the
end of the drive shaft.
Apply new compressor oil to the shaft seal guide.
Install the shaft seal (2) onto the compressor drive
shaft head by using shaft seal installer J-33942 (3).
14. Install snap ring.
15. Install field coil.
16. Install lead wire connector.
Install the field coil to the compressor.
Lead wire must be facing up.
Tighten the field coil fixing screws to the specified
torque.
Torque: 5Nꞏm (44 lbꞏin)17. Install pulley assembly.
Using pulley installer J-33940 (2) and drive handle
J-8092 (1) to install the pulley assembly.
18. Install snap ring.
Install the snap ring with the inside indented
portion facing out.
871RY00006
32 1
871RY00024
A
871RY00025
1
2
871RY00008

3. Position puller crossbar J-8433-1 on the puller pilot
J-33023-A and assemble the two J-33026 through
bolts and washers through the puller bar slots and
thread them into the J-33026 holding fixture. The
thread of the through bolts should engage the full
thickness of the holding fixture.
4. Tighten the center screw in the J-8433-1 puller
crossbar to force the pulley rotor (1) and bearing
assembly onto the compressor front head. Should
the J-33017 pulley rotor and bearing installer slip off
direct in-line contact with the inner race of the
bearing, loosen the J-8433-1 center forcing screw
and realign the installer and pilot so that the J-
33017 installer will properly clear the front head.5. Install rotor and bearing assembly retainer ring,
using snap ring pliers.
6. Reinstall clutch plate and hub assembly as
described previously.
COMPRESSOR CLUTCH COIL
Removal
1. Perform Steps 1 through 4 of "Clutch Rotor and/or
Bearings" removal procedure. Mark clutch coil
terminal location (1) on compressor front head.
2. Install J-33023-A puller pilot on front head of
compressor. Also install J-8433-1 puller crossbar
with J-33025 puller legs as shown in figure.
3. Tighten J-8433-3 forcing screw against the puller
pilot to remove the clutch coil (2).
J-8433-3
J-33023
J-33026 J-8433-1
J-33017
1
901RW005
J-33023-AJ-8433-3
J-8433-1
J-33025
1 2
901RW006