window OPEL FRONTERA 1998 Workshop Manual

4C–26
DRIVE SHAFT SYSTEM
Reassembly
1. Install DOJ case to bracket.
2. Install oil seal and fix snap ring.
3. Install bearing and fix snap ring.
4. Install bracket to axle case. Tighten the bracket bolt to
the specified torque.
Torque: 116 Nꞏm (11.8 kgꞏm/85 lb ft)
5. Apply 150g of the specified grease in BJ .
6. Install dust seal .
7. Apply a thin coat of grease to the shaft for smooth
installation then install bellows.
8. Install band. Note the setting direction. After
installation, check that the bellows is free from
distortion.
412RS017
9. Install another bellows and fix band.
10. Install the ball guide with the smaller diameter side
ahead onto the shaft.
11. Install ball retainer.
12. Using snap ring pliers, install the snap ring (1)
securing the ball retainer to the shaft.
412RS013
13. Align the track on the ball (1) retainer with the window
in the cage, and install the six balls into position.
412RS018
14. Install spacer.
15. Install snap ring.
16. Enclose 150g of the specified grease in DOJ case,
then install drive shaft joint assembly. After
reassembly, move the DOJ longitudinally several
times to get to fit.
17. Install the circlip (1) so that open ends are positioned
away from the ball groove.

6A – 28 ENGINE MECHANICAL
ENGINE ASSEMBLY
For General Export
For Europe
F06R200004
REMOVAL
1. Remove battery.
2. Drain engine coolant
3. Disconnect window washer hose and remove
engine hood.
4. Radiator Hose
1) Disconnect upper and lower hoses from engine
side.
5. Fan Shroud
1) Disengage clips and remove upper and lower
fan shrouds.
6. Cooling Fan Assembly
1) Remove cooling fan assembly fixing nuts,
cooling fan assembly.
7. Radiator Assembly1) Remove bracket and radiator assembly.
8. Air Cleaner Cover & Air Duct
9. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
10. Engine Ground Cable
1) Disconnect ground cable from A/C compressor
bracket.
11. AC Generator Harness
1) Disconnect B terminal and harness connector
from AC generator.
12. A/C Compressor Assembly
1) Disconnect magnetic clutch harness connector.
2) Remove A/C compressor fixing bolt (rear under
side of compressor).
3) Remove fixing bolts (upper and front lower side
of compressor) and set A/C compressor
assembly with pipe lines on battery carrier.

ENGINE MECHANICAL 6A – 29
13 Vacuum Hose
1) Disconnect vacuum hose from vacuum pump.
14. Starter Harness
1) Disconnect B terminal and put cable harness
close to chassis side.
2) Disconnect S terminal connector.
15. Engine Harness
1) Disconnect engine harness close to engine side.
16. Fuel Pipe
1) Remove fuel pipe from fuel pump and take care
not to spill fuel and let dust enter.
17. Engine Ground Cable
1) Disconnect ground cable from left rear side of
timing gear case.
18. Vacuum Hose: Vacuum Tank
Disconnect vacuum hose from vacuum pump side.
19. Glow Plug Harness
20. Transmission Assembly
1) Set transmission support tool under the
transmission.
2) Remove transmission rear mount.
3) Remove transmission fixing bolt from rear of
engine assembly except two bolts.
4) Carefully hang up engine assembly with a hoist.
5) Remove remaining two transmission fixing bolts.
6) Remove transmission assembly.
7) Remove heater hose.
8) Disconnect wire harness connector for shift on
the fly.
9) Remove vacuum hose.
21. Prepare Engine Stand
22. Engine Assembly
1) Remove engine mount fixing bolts.
2) Carefully hang up the engine assembly.
3) Take out the engine assembly making sure not
to damage the brake oil pipe and other pipe etc.
INSTALLATION
1. Engine assembly
1) Install engine in mounting position by using
hoist.
2. Transmission Assembly
1) Refer to transmission installation steps in
section 7.
3. Engine Mounting
1) After all fixing bolts (left: two bolts, rights: two
bolts) were inserted in every hole, tighten fixing
bolts to the specified torque.
Torque: 40 Nꞏm (4 kgꞏm/29 lbꞏft)
4. Glow Plug Harness
5. Vacuum Hose
1) Connect Vacuum Hose to Vacuum Pump
6. Engine Ground Cable
7. Fuel Pipe
1) Install fuel pipe to fuel pump.
8. Engine Harness
9. Starter Harness
10. A/C Compressor Assembly
1) Tighten temporarily the fixing bolts (upper and
front lower sides of compressor.)2) Tighten fixing bolt (rear under side of
compressor) to the specified torque.
3) Tighten fixing bolts (front upper and lower sides
of compressor) to the specified torque.
To r q u e : 4 0 N ꞏm ( 4 k g ꞏm / 2 9 l b ꞏf t )
Legend
(1) Tensioner
(2) Bolt
(3) Bracket
(4) A/C compressor
(5) Bolt
11. A.C Generator Harness
12. Engine Ground Cable
1) Tighten ground cable to A/C compressor
bracket.
13. Air Cleaner cover & Duct
14. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
15. Radiator Assembly
1) Install rubber cushion in under left and right part
of radiator and position radiator.
2) Fix radiator with bracket.
16. Cooling Fan Assembly
1) Install cooling fan assembly and tighten fixing
bolts to the specified torque.
Torque: 8 Nꞏm (0.8 kgꞏm/5.8 lb ft)
17. Fan Shroud
18. Radiator Hose
1) Connect upper and lower hose to engine side.
2) Pour coolant into radiator.
19. Install battery.
20. Connect window washer hose and install engine
hood.
1
2
3
4
5
For E urope
F06R200005

7A–28
AUTOMATIC TRANSMISSION (4L30–E)
Removal
1. Disconnect battery ground cable.
2. Remove transfer control lever knob.
3. Remove front console.
Disconnect wiring harness connectors from front
console.
4. Disconnect shift lock cable (1) from the selector lever
assembly side.
256RW012
5. Disconnect shift control rod (2) from the selector lever
assembly side.
256RW013
6. Disconnect wiring harness connectors from the
selector lever assembly.
7. Remove selector lever assembly.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
Adjustment of select lever and control rod
1. Place the vehicle on a level surface.NOTE: If the vehicle is not on level surface, the shift
select cable set positions will vary with the movement of
engine. To prevent possible misadjustment of the cable,
the vehicle must be placed on a level surface.
2. Install the shift control rod (1) to the transmission
select lever (2), and then place the lever in the “N”
position.
3. Set select lever in the “N” position.
4. Push select lever forward (“R” position side) and
s e c u r e i t ( u s i n g a r u b b e r b a n d ( 3 ) , e t c . ) s o t h a t t h e p i n
comes into contact with the wall of the detent plate.
5. Install the shift control rod (1) to the selector lever arm
(4).
To r q u e : 3 2 N
m (3.3 kgꞏm/24 lb ft)
NOTE: Do not apply oil to the threaded portions.
256RW014
6. After adjustment, make sure that the selector lever
operates normally, and that each selector position is
properly indicated. (The red mark shows through the
window.)
Adjustment of shift lock cable
1. Set ignition key in “LOCK” position and selector lever
in “P” position.
2. Adjust cable screw cap on selector lever side to
provide a gap (slack for cable) of 1 – 2 mm between
rod on steering lock side and stopper.
Adjust cap as follows:
a. Pull screw cap (1) in arrow direction to remove
inner cable slack.
b. With cable kept as (a), adjust gap between nut (2)
and bracket to 5 mm (0.2 in).
c. Lock inner cable by turning nut (3) while holding nut
(2) in place.
Torque : 3.7 N
m (38 kgꞏcm/33 lb in)
NOTE: Clean the cable threads, and do not apply oil to
them.

3.0
W
3.0
L/R 3.0
L/B
0.5
O/G
AUDIO
CIGARETTE
LIGHTERBLOWER
MOTORMAGNETIC
CLUTCHPOWER
WINDOW
RELAY
(2)STOPLIGHT AUDIO
(14)
DOME LIGHTRR DEFOGGER
FRT DOOR LOCK &
POWER WINDOW SW C-11 10A
AUDIO
(ACC)
MIRROR
0.5
BRC-20 10A
AIR CON
0.85
G/WC-14 15A
STOP
A/T CONT
1.25
R/WC-15 20A
AUDIO (B)
3.0
L/OC-17 25A
RR
DEFOG
FUSE BOX
1.25
O/BC-12 20A
CIGAR
3.0
LC-19 25A
BLOWER
3.0
B/L 3.0
W5.0
W 5.0
W
5.0
W
C/B-2 30A
P/W,P/S,
S/R
0.5
R/WC-16 10A
CLOCK (B)
ROOM
1.25
LG/WC-18 20A
DOOR
LOCK
HEATER &
A/C RELAY
B-36
2
B-364
D08RWB16

3.0
W
3.0
L/R 3.0
L/B
0.5
O/G
AUDIO CIGARETTE
LIGHTERBLOWER
MOTORMAGNETIC
CLUTCHPOWER
WINDOW
RELAY
(2)STOPLIGHT AUDIO
(14)
DOME LIGHT FRT DOOR LOCK &
POWER WINDOW SW RR DEFOGGER C-11 10A
AUDIO
(ACC)
MIRROR
0.5
BRC-20 10A
AIR CON
0.85
G/WC-14 15A
STOP
A/T CONT
1.25
R/WC-15 20A
AUDIO (B)
3.0
L/OC-17 25A
RR
DEFOG
FUSE BOX
1.25
O/BC-12 20A
CIGAR
3.0
LC-19 25A
BLOWER
3.0
B/L 3.0
W5.0
W 5.0
W
5.0
W
C/B-2 30A
P/W,P/S,
S/R
0.5
R/WC-16 10A
CLOCK (B)
ROOM
1.25
LG/WC-18 20A
DOOR
LOCK
HEATER &
A/C RELAY
B-36
2
B-364
D08RWB21

FRT DOOR LOCK
ACTUATOR-RHFRT DOOR LOCK
ACTUATOR-LHRR DOOR LOCK
ACTUATOR-LHRR DOOR LOCK
ACTUATOR-RHTAIL GATE
ACTUATOR
24 24 2463
24 63
42 28 15 13
35 3 9
8
10 78
5
1.25
LG 1.25
LG 1.25
LG 1.25
LG 5.0
W
1.25
LG/W
1.25
LG/W2.0
L/B
1.25
LG/B
1.25
LG1.25
LG/B1.25
LG1.25
LG/B 1.25
LG1.25
LG/B1.25
LG1.25
LG/B 1.25
LG1.25
LG/B1.25
LG1.25
LG/B
1.25
LG1.25
LG/B 1.25
LG1.25
LG/B 1.25
LG1.25
LG/B 1.25
LG/B1.25
LG/B 1.25
LG/B
D-9 D-9 D-19 D-19 D-21 D-21H-28H-28
D-26 D-26 H-34 H-34
15 13410
H-32
H-32H-47 H-47
G-4 G-4 H-38 H-38 H-32 H-32
H-19 H-19 H-23 H-23D-5
D-5 D-5D-5
H-23 LOCK UNLOCK BATT. (+)
C-18 20A
DOOR LOCK
FRT DOOR LOCK &
POWER WINDOW SW-RHFRT DOOR LOCK &
POWER WINDOW SW-RH
POWER WINDOW
RELAY (4)
D08RW759

3 3 7
1 2 4
7
1 32 142 142 1
1 2
1 0.5
B 0.5
B 0.5
L/Y 0.5
LG/L
0.5
LG/R
1.25
B0.5
LG/R 0.5
LG/L
0.5
L/Y1.25
B
1.25
BD-8D-81 D-5
D-8
H-23 D-17D-17 D-17 D-14 D-14
D-14
H-19
B-1 H-18 H-19 H-22 H-23 D-30 D-30
H-19
7
H-23
B-18
BODY-RH 1.25
B 1.25
B0.5
LG/R 0.3
LG/L0.5
LG/R 0.5
LG/L0.5
LG/R 0.3
LG/L
2.0
B
BODY-LH
DOOR LOCK
KEY SW-RH DOOR LOCK
KEY SW-LHLOCK UNLOCKLOCK UNLOCK
LOCK
UNLOCK
LOCK UNLOCK
FRT DOOR LOCK &
POWER WINDOW
SW-LH
FRT DOOR LOCK & POWER WINDOW SW-RH
D08RW760

FRT DOOR LOCK
ACTUATOR-RHFRT DOOR LOCK
ACTUATOR-LHRR DOOR LOCK
ACTUATOR-LHRR DOOR LOCK
ACTUATOR-RHTAIL GATE
ACTUATOR
24 24 2415 13
24 410
42 28 15 13
35 9
8
10 78
1.25
LG
1.25
LG/B1.25
LG/B1.25
LG 1.25
LG 1.25
LG 5.0
W
1.25
LG/W
1.25
LG/W2.0
L/B
1.25
LG/B1.25
LG1.25
LG/B1.25
LG1.25
LG/B
1.25
LG1.25
LG/B1.25
LG1.25
LG/B 1.25
LG1.25
LG/B1.25
LG1.25
LG/B
1.25
LG1.25
LG/B 1.25
LG1.25
LG/B 1.25
LG1.25
LG/B 1.25
LG/B 1.25
LG/B1.25
LG/B
D-9 D-9 D-19 D-19 D-21 D-21H-32 H-32
D-26 D-26 H-47 H-47
6363
H-28H-28H-34 H-34
G-4 G-4 H-38 H-38 H-32 H-32H-23H-19
H-19
6
5
1.25
LG
H-233H-23
13
H-22
H-23D-5
D-5 D-5D-5 LOCK UNLOCK BATT. (+)
C-18 20A
DOOR LOCK
FRT DOOR LOCK &
POWER WINDOW SW-RHFRT DOOR LOCK &
POWER WINDOW SW-RH
POWER WINDOW
RELAY (4)
D08RW761

3 3 1
1 22 7
4
7
1 315 1415 142 1
1 22 7
0.5
B 0.5
B 0.5
L/Y0.5
LG/R0.5
LG/R 0.5
L/Y
1.25
BD-17
H-19H-19
D-17 D-17
H-23D-8D-8 D-8H-23 H-23
D-14 D-14
5 15
B-22 B-22
D-14
H-19
B-1 H-18 H-18 H-22 H-22 D-30 D-30
D-5
B-18
BODY-RH 1.25
B 1.25
B0.5
LG 0.3
LG/L0.5
LG/R
0.5
LG/R
1.25
B 0.3
LG/L
0.3
LG/L 0.5
LG/R 0.3
LG/L
2.0
B
BODY-LH
DOOR LOCK
KEY SW-LH DOOR LOCK
KEY SW-RHLOCK UNLOCKLOCK UNLOCK
LOCK
UNLOCK
LOCK UNLOCK
FRT DOOR LOCK &
POWER WINDOW
SW-LH
B
1
ANTI-THEFT &
KEYLESS ENTRY
CONTROL UNIT FRT DOOR LOCK & POWER WINDOW SW-RH
AB
A
D08RW762