transmission oil OPEL FRONTERA 1998 Workshop Manual

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

TRANSFER CASE (STANDARD TYPE)
4D1–39
14. Assemble the 2WD–4WD clutch hub and sleeve
assembly (7).
226RW140
15. Engage the springs in the same insert with the open
ends away from each other. (Shift On The Fly model)
226RW141
16. Place the snap ring (2), a new stopper plate (6) (Shift
On The Fly model) and the clutch sleeve and hub
assembly (7) on the front output shaft (5).
226RW135
Legend
(6) Front Output Gear
17. The clutch hub face (with the heavy boss) must be
facing the front output gear side.
18. Use a bench press to slowly force the clutch hub and
sleeve assembly (7) together with the stopper plate
(6) (Shift On The Fly model) into place.
19. Align the inserts with the block ring insert grooves.
Install the block ring (8) (Shift On The Fly model) to
the clutch sleeve and hub assembly (7).
20. Install the outside ring (9) (Shift On The Fly model),
inside ring (10) (Shift On The Fly model) and needle
bearing (12) to the front output gear (11) and bearing
collar (17).
NOTE: Coat all parts with transmission oil before
installing them.
226RW139

5A–39 BRAKE CONTROL SYSTEM
Diagnostic Trouble Codes
Choose and trace an appropriate flowchart by the
numbers listed below to find fault and repair.
Code
ItemDiagnosisChart No.
12Start CodeNormal—
14EHCU FunctionAbnormality in input/output, operational and
control circuitsB-2
15Power Voltage DropB-3
16CLASS–2 Communication Line Ab-
normalityB-4
21G-sensorWiring disconnectionB-5
23Transmission InputInput abnormalityB-6
24Transfer MonitorB-7
32Motor & Motor RelayShorted or disconnected coilB-8
35Valve RelayShorted or disconnected coil/wiringB-9
41FL Holding Solenoid ValveShorted or disconnected coil/wiringB-10
42FL Decompression Solenoid ValveShorted or disconnected coil/wiringB-11
43FR Holding Solenoid ValveShorted or disconnected coil/wiringB-12
44FR Decompression Solenoid ValveShorted or disconnected coil/wiringB-13
45Rear Holding Solenoid ValveShorted or disconnected coil/wiringB-14
46Rear Decompression Solenoid ValveShorted or disconnected coil/wiringB-15
51FL Wheel Speed SensorDisconnected coil/wiringB-16
52FR Wheel Speed SensorDisconnected coil/wiringB-17
53RL Wheel Speed SensorDisconnected coil/wiringB-18
54RR Wheel Speed SensorDisconnected coil/wiringB-19
61FL Wheel Speed SensorShorted coil/wiringB-20
62FR Wheel Speed SensorShorted coil/wiringB-21
63RL Wheel Speed SensorShorted coil/wiringB-22
64RR Wheel Speed SensorShorted coil/wiringB-23
65Sensor Signal InputWrong number of teethB-24

6A–14
ENGINE MECHANICAL
Condition CorrectionPossible cause
Trouble in emission control systemHeated Oxygen Sensor circuit openCorrect or replace
Heated Oxygen Sensor defectiveReplace
Signal vacuum hose loosely fitted or
defectiveCorrect or replace
EGR Valve circuit open or shortedCorrect or replace
Exhaust Gas Recirculation Valve
defectiveReplace
ECT Sensor circuit open or shortedCorrect or replace
Canister Purge Valve circuit open or
shortedCorrect or replace
Canister Purge Valve defectiveReplace
ECT Sensor defectiveReplace
Positive Crankcase Ventilation
(PCV) valve and hose cloggedCorrect or replace
Evaporator systemRefer to Section 6E
Trouble in ignition system————Refer to “Engine Lacks Power”
Trouble in cylinder head partsCarbon deposits in combustion
chamberRemove carbon
Carbon deposit on valve, valve seat
and valve guideRemove carbon
Engine Oil Consumption Excessive
ConditionPossible causeCorrection
Oil leakingOil pan drain plug looseRetighten or replace gasket
Crankcase fixing bolts loosenedRetighten
Oil pan setting bolts loosenedRetighten
Oil pan gasket brokenReplace gasket
Front cover retaining bolts loose or
gasket brokenRetighten or replace gasket
Head cover fixing bolts loose or
gasket brokenRetighten or replace gasket
Oil cooler adapter crackedReplace
Oil cooler center bolt looseRetighten
Oil cooler O–ring brokenReplace
Oil cooler piping loose or brokenRetighten or replace
Oil filter adapter crackedReplace
Oil filter attaching bolt loose or rubber
gasket brokenRetighten or replace oil filter
Oil cooler brokenReplace
Crankshaft front or rear oil seal
defectiveReplace oil seal
Oil pressure unit loose or brokenRetighten or replace
Blow–by gas hose brokenReplace hose
Positive Crankcase Ventilation Valve
cloggedClean
Engine/Transmission coupling failedReplace oil seal

6A–15
ENGINE MECHANICAL
Condition CorrectionPossible cause
Oil leaking into combustion
chambers due topoor seal in valve
Valve stem oil seal defectiveReplace
chambers due to oor seal in valve
systemValve stem or valve guide wornReplace valve and valve guide
Oil leaking into combustion
chambers due to poor seal in cylinder
t
Cylinders and pistons worn
excessivelyReplace cylinder body assembly and
pistons
partsPiston ring gaps incorrectly
positionedCorrect
Piston rings set with wrong side upCorrect
Piston ring stickingReplace cylinder body assembly and
pistons
Piston ring and ring groove wornReplace pistons and others
Return ports in oil rings cloggedClean piston and replace rings
Positive Crankcase Ventilation
System malfunctioningPositive Crankcase Ventilation Valve
cloggedClean
OthersImproper oil viscosityUse oil of recommended S.A.E.
viscosity
Continuous high speed driving
and/or severe usage such as trailer
towingContinuous high speed operation
and/or severe usage will normally
cause increased oil consumption
Fuel Consumption Excessive
ConditionPossible causeCorrection
Trouble in fuel systemMixture too rich or too lean due to
trouble in fuel injection systemRefer to “Abnormal Combustion”
Fuel cut function does not workRefer to “Abnormal Combustion”
Trouble in ignition systemMisfiring or abnormal combustion
due to trouble in ignition systemRefer to “Hard Start” or “Abnormal
Combustion”
OthersEngine idle speed too highReset Idle Air Control Valve
Returning of accelerator control
sluggishCorrect
Fuel system leakageCorrect or replace
Clutch slippingCorrect
Brake dragCorrect
Selection of transmission gear
incorrectCaution operator of incorrect gear
selection
Excessive Exhaust Gas
Recirculation flow due to trouble in
Exhaust Gas Recirculation systemRefer to “Abnormal Combustion”

6A–47
ENGINE MECHANICAL
Rear Oil Seal
Removal
1. Remove transmission assembly.
Refer to removal procedure for Transmission
section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil seal
retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal using
5–8840–2286–0.
015RS017
2. Install flywheel.
Clean tapped holes in the crankshaft.
Remove oil on the crankshaft and flywheel
mounting surface.
Tighten fixing bolts to the specified torque.
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
Torque : 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
015RS018
3. Install transmission.
See Transmission section in this manual.
CAUTION: W h e n a s s e m b l i n g t h e e n g i n e a n d
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
Otherwise, the transmission may be damaged.
012RS009

6A–50
ENGINE MECHANICAL
9. Install air conditioner compressor to engine and
tighten to the specified torque.
Torque :
M8 bolts : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
M10 bolts : 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
10. Install power steering pump, tighten fixing bolt to the
specified torque.
Torque :
M8 bolts : 22Nꞏm (2.2 Kgꞏm/16 lb ft)
M10 bolts : 46 Nꞏm (4.7 Kgꞏm/34 lb ft)
11. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt
12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of right
dash panel.19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.
24. Install air cleaner assembly.
25. Reconnect air duct.
26. Reconnect accelerator cable and automatic cruise
control cable to throttle valve on common chamber.
035RW007
Legend
(1) Throttle Valve Assembly
(2) Throttle Lever
(3) Idle Air Control Valve
(4) Throttle Position Sensor
27. Install engine hood to the original position.
Refer to installation procedure for Body section in
this manual.
Accelerator pedal cable adjustment
1. Loosen adjusting nut and lock nut.
2. Pull outer cable while fully closing the throttle
valve.
3. Tighten adjusting nut and lock nut temporarily.
4. Loosen adjusting nut by three turns and tighten
lock nut.
Then, manually operating the throttle valve, make
s u r e t h a t t h e v a l v e l e v e r r e t u r n s u p t o t h e s t o p p e r
screw.

6B–6
ENGINE COOLING
Draining and Refilling Cooling
System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order. The
engine coolant (EC) level should be between the “MIN”
and “MAX” lines of reserve tank when the engine is cold.
If low, check for leakage and add EC up to the “MAX” line.
There should not be any excessive deposit of rust or
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the
drain plug (2) at the bottom of the radiator.
110RW002
2. Remove the radiator cap.
WARNING: TO AVOID THE DANGER OF BEING
BURNED, DO NOT REMOVE THE CAP WHILE THE
ENGINE AND RADIATOR ARE STILL HOT.
SCALDING FLUID AND STEAM CAN BE BLOWN OUT
UNDER PRESSURE.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution
that is at least 50 percent antifreeze but no more than
70 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to “MAX” line when the engine
is cold.
6. Block the drive wheels and firmly apply the parking
brake. Shift an automatic transmission to “P” (Park)
or a manual transmission to neutral.
7. Remove the radiator cap. Start the engine and warm
it up at 2,500
3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck
and the EC level has gone down, replenish with the
EC. Repeat this procedure until the EC level does not
go down. Then stop the engine and install the radiator
cap. Let the engine cool down.9. After the engine has cooled, replenish with EC up to
the “MAX” line of the reserve tank.
10. Start the engine. With the engine running at 3,000
rpm, make sure there is no running water sound from
the heater core (behind the center console).
11. If the running water sound is heard, repeat steps 8 to
10.

ENGINE COOLING6B–9
Radiator
Radiator and Associated Parts
110RW003
Legend
(1) Oil Cooler Hose For Automatic Transmission
(2) Radiator Hose
(3) Fan Guide, Lower(4) Reserve Tank Hose
(5) Bracket
(6) Radiator Assembly
(7) Reserve Tank
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug(2) to drain EC.
3. Disconnect oil cooler hose(1) on automatic
transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from
the engine.
110RW002
5. Remove fan guide(1), clips(3) on both sides and the
bottom lock, then remove lower fan guide(3) with fan
shroud(4).
110RW001

ENGINE COOLING6B–11
Cap tester: 5–8840–0277–0
Adapter: 5–8840–2603–0
110RS005
Installation
1. Install rubber cushions on both sides of radiator
bottom.
2. Install radiator assembly with hose, taking care not to
damage the radiator core with a fan blade.
3. Install bracket (6) and support the radiator upper tank
with the bracket (5) and secure the radiator.
4. Connect reserve tank hose (4).
5. Install lower fan guide (3).
6. Connect radiator inlet hose and outlet hose to the
engine.
7. Connect oil cooler hose (1) to automatic
transmission.
110RW004
8. Connect battery ground cable.
9. Pour engine coolant up to filler neck of radiator, and
up to MAX mark of reserve tank.
111 R S 0 0 1Important operation (in case of 100% engine coolant
change) procedure for filling with engine coolant.
1. Make sure that the engine is cool.
2. Open radiator cap pour coolant up to filler neck.
3. Pour coolant into reservoir tank up to “MAX” line.
4. Tighten radiator cap and start the engine. After
idling for 2 to 3 minutes, stop the engine and
reopen radiator cap. If the water level is lower,
replenish.
WARNING: WHEN THE COOLANT IS HEATED TO A
HIGH TEMPERATURE, BE SURE NOT TO LOOSEN
OR REMOVE THE RADIATOR CAP. OTHERWISE YOU
MIGHT GET SCALDED BY HOT VAPOR OR BOILING
WATER. TO OPEN THE RADIATOR CAP, PUT A
PIECE OF THICK CLOTH ON THE CAP AND LOOSEN
THE CAP SLOWLY TO REDUCE THE PRESSURE
WHEN THE COOLANT HAS BECOME COOLER.
5. After tightening radiator cap, warm up the engine
at about 2000 rpm. Set heater adjustment to the
highest temperature position, and let the coolant
circulate also into heater water system.
6. Check to see the thermostat has opened through
the needle position of water thermometer,
conduct a 5–minute idling again and stop the
engine.
7. When the engine has been cooled, check filler
neck for water level and replenish if required.
Should extreme shortage of coolant is found,
check the cooling system and reservoir tank hose
for leakage.
8. Pour coolant into reservoir tank up tp “MAX” line.