roof 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

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–6
High-Low Planetary Gear Set
Establishes an auxiliary transmission mechanism. When
the transfer shift lever is set to the 2H or TOD position, the
reduction gear ratio is 1.000 and the corresponding
driving force is generated. When the transfer shift lever is
set to the 4L position, the reduction gear ratio is 2.480 and
the corresponding driving force is generated.
262RW030
4H and 4L Switches
Detects the shift position of the transfer from the
movement of the transfer lever and outputs signals to the
TOD control unit.
261RW002
Transfer Connector
Transmits the input and output signals of the speed
sensors, electromagnetic coil, and 4H and 4L switches to
the vehicle harness. A waterproof 12-pin type is used.
261RW046
TOD Indicator Lamps (on the instrument
panel)
Inform the following items.
Bulb check
Drive mode
ABS IN status
BRAKE ON status
821RW049

6A–3
ENGINE MECHANICAL
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.
Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance:
When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick–up unit.
The 12–volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.
Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum die–cast casting
for 75
V–type six cylinders. It has a rear plate integrated
structure and employs a deep skint. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width of No.3 bearing
on the body side is different in order to support the thrust
bearing. The bearing cap is made of nodular cast iron and
each bearing cap uses four bolts and two side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent–roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V–type design. The ports are cross–flow
type.
Va l v e Tr a i n
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast–iron. Pins and
journals are graded for correct size selection for their
bearing.
Engine Lubrication
The oil discharged by a trochoid–type oil pump driven by
the crankshaft is fed through full–flow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.

6A–90
ENGINE MECHANICAL
Main Data and Specification
General Specification
ItemSpecificationsItem6VD16VE1
Engine type, number of cylinders and arrangementWater cooled, four cycle V6
Form of combustion chamberPent roof type
Valve mechanism4-Cams, 4-Valves, DOHC Gear & Belt Drive
Cylinder liner typeCasted in cylinder drive
Total piston displacement3165 cc3494 cc
Cylinder bore x stroke93.4mm x 77.0mm93.4mm x 85.0mm
(3.6772 in x 3.0315 in)(3.6772 in x 3.3465 in)
Compression ratio9.1 : 1
Compression pressure at 300rpm14.0 Kg/cm
Engine idling speed rpmNon adjustable (750)
Valve clearanceIntake: 0.28 mm (0.11 in)
Exhaust: 0.30mm (0.12in)
Oil capacity5.3 liters
Ignition timingNon adjustableNon adjustable
16 BTDC at idle rpm)(20 BTDC at idle rpm)
Spark plugK16PR–P11, PK16PR11, RC10PYP4
Plug gap1.0 mm–1.1 mm(0.0394 in – 0.0433 in)

LIGHTING SYSTEM8A–1
BODY AND ACCESSORIES
CONTENTS
Lighting System 8A. . . . . . . . . . . . . . . . . . . . . . . . .
Wiper/Washer System 8B. . . . . . . . . . . . . . . . . . .
Entertainment 8C. . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring System 8D. . . . . . . . . . . . . . . . . . . . . . . . . .
Meter and Gauge 8E. . . . . . . . . . . . . . . . . . . . . . . Body Structure 8F. . . . . . . . . . . . . . . . . . . . . . . . . .
Seats 8G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Security and Locks 8H. . . . . . . . . . . . . . . . . . . . . .
Sun Roof/Convertible Top 8I. . . . . . . . . . . . . . . .
Exterior/Interior Trim 8J. . . . . . . . . . . . . . . . . . . . .
LIGHTING SYSTEM
CONTENTS
Service Precaution 8A–2. . . . . . . . . . . . . . . . . . . . . .
Headlight Bulb 8A–3. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight 8A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight and Associated Parts 8A–4. . . . . . . . .
Removal 8A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight Adjustment 8A–4. . . . . . . . . . . . . . . . . .
Fog Light Bulb 8A–5. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog Light Assembly 8A–6. . . . . . . . . . . . . . . . . . . . .
Removal 8A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog Light Adjustment 8A–6. . . . . . . . . . . . . . . . . .
Clarence Light Bulb 8A–6. . . . . . . . . . . . . . . . . . . . . .
Removal 8A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Fog Light Bulb (RHD) 8A–7. . . . . . . . . . . . . . .
Removal 8A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taillight Bulb (Body) 8A–7. . . . . . . . . . . . . . . . . . . . .
Removal 8A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taillight Bulb (Bumper) 8A–8. . . . . . . . . . . . . . . . . . .
Removal 8A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
License Plate Light Bulb (Body) 8A–8. . . . . . . . . . .
Removal 8A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
License Plate Light Bulb (Bumper) 8A–9. . . . . . . . .
Removal 8A–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stoplight Bulb 8A–9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation 8A–9. . . . . . . . . . . . . . . High Mount Stoplight 8A–10. . . . . . . . . . . . . . . . . . . .
Removal 8A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Turn Signal Light Bulb 8A–10. . . . . . . . . . . . . .
Removal 8A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Turn Signal Light Bulb 8A–11. . . . . . . . . . . . . . .
Removal 8A–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Turn Signal Light Bulb 8A–11. . . . . . . . . . . . . .
Removal 8A–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–11. . . . . . . . . . . . . . . . . . . . . . . . . . .
Backup Light Bulb 8A–12. . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–12
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Dome Light Bulb 8A–12. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Luggage Room Light Bulb 8A–13. . . . . . . . . . . . . . . .
Removal 8A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Courtesy Light Bulb 8A–13. . . . . . . . . . . . . . . . . . . . . .
Removal 8A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Map Light Switch/Bulb 8A–14. . . . . . . . . . . . . . . . . . .
Removal 8A–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cigarette Lighter Illumination Bulb 8A–14. . . . . . . . .
Removal 8A–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Ashtray Illumination Bulb 8A–15. . . . . . . . . . . . . . . . .
Removal 8A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glove Box Illumination Bulb 8A–15. . . . . . . . . . . . . . .
Removal 8A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

8A–14LIGHTING SYSTEM
Map Light Switch/Bulb
Removal
1. Disconnect the battery ground cable.
2. Pull the map light body downward to release the lock.
3. Disconnect the connectors of the map light and the
sun roof switch.
4. Remove the map light switch.
5. Turn the socket counterclockwise to remove it.
6. Pull out the bulb from the socket.
805RS008
Installation
To install, follow the removal steps in the reverse order.
Cigarette Lighter Illumination Bulb
Removal
1. Disconnect the battery ground cable.
2. Remove eight screws to remove the instrument
cluster panel(2).
3. Turn the socket counterclockwise to remove it then
pull out the bulb(1).
826RS013
Installation
To install, follow the removal steps in the reverse order.

Waterproof Connector Inspection
It is not possible to insert the test probes (2) into the
connector wire side of a waterproof connector.
Use one side of a connector (1) with its wires cut to make
the test. Connect the test connector to the connector to
be tested (3). Connect the test probes to the cut wires to
check the connector continuity.
Connector Pin Removal – Connector
Housing Tang Lock Type
1. Insert a slender shaft (1) into the connector housing
open end (5).
2. Push the tang lock (2) up (in the direction of the arrow
in the illustration).
Pull the wire (3) with pin (4) free from the wire side of
the connector.
Connector Pin Removal – Pin Tang Lock
Ty p e
1. Insert a slender shaft (1) into the connector housing
open end (5).
2. Push the tang lock (2) flat (toward the wire (3) side of
the connector.
Pull the wire with pin (4) free from the wire side of the
connector.
Connector Pin Insertion
1. Check that the tang lock (1) is fully up.
2. Insert the pin (3) from the connector wire (2) side.
Push the pin in until the tang lock closes firmly.
3. Gently pull on the wires to make sure that the
connector pin is firmly set in place.
1
3
21
2
3
5
4
1
2
3
4 51
2
3

A
B
D
E
VANITY
MIRROR
-LH
1H-2114
H-16
(W/SUN ROOF) 0.5
B0.5
B
0.5
B 0.5
G/R
0.5
G/R
0.5
G/R0.85
G/R
0.85
G/R
0.3
R/G0.3
R/G 0.85
G/R
0.3
R/G 0.85
G/R
0.3
R/G 0.85
G/R
0.3
R/G 0.85
G/R
4
H-214H-21
CIGARE-
TTE
LIGHTER
1
2
2.0
B2.0
B
B-2
BODY-LH
HAZARD
SW
3
1I-11
I-11FOG
LIGHT
SW
6
2I-5
I-5RR
DEFOGGER
SW
6
2I-17I-20
I-20 I-17
AUDIO
11
3I-15
I-15
1L-4
2 L-4
VANITY
MIRROR
-RH
1L-6
2 L-6
D08RW656

D08RW 730
BODY-LH BODY-LH TAIL RELAY
(4)
(W/O SUNROOF) STARTER SW
(ACC)AMBIENT TEMPERATURE
SENSOR
0.5
B
2.0
B 2.0
B 2.0
B 0.5
P/G0.5
G/R0.5
G/R
0.5
O/G0.5
O/G3.0
L/B
0.5
P/G 0.5
P/L0.5
P/L
0.5
P/G 0.5
P/L0.85
B
4
H-21 4 6
H-21 H-21H-21
H-7
C-9L-5
5
8
H-212
3
H-78
2
C-91L-5
4 L-53
L-51 1
H-213
L-5
B-2 B-2
MULTI METER
C-11 10A
AUDIO(ACC), MIRROR

D08RW 730
BODY-LH BODY-LH TAIL RELAY
(4)
(W/O SUNROOF) STARTER SW
(ACC)AMBIENT TEMPERATURE
SENSOR
0.5
B
2.0
B 2.0
B 2.0
B 0.5
P/G0.5
G/R0.5
G/R
0.5
O/G0.5
O/G3.0
L/B
0.5
P/G 0.5
P/L0.5
P/L
0.5
P/G 0.5
P/L0.85
B
4
H-21 4 6
H-21 H-21H-21
H-7
C-9L-5
5
8
H-212
3
H-78
2
C-91L-5
4 L-53
L-51 1
H-213
L-5
B-2 B-2
MULTI METER
C-11 10A
AUDIO(ACC), MIRROR