1998 OPEL FRONTERA Front ach

RESTRAINT CONTROL SYSTEM 9J1–42
DTC 71 Internal SDM Fault
WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST
BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE
TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE
NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY.
CAUTION: When DTC 19 or 25 has been set, it is necessary to replace the SDM. Setting DTC 19 and 25 or 51
or 53 will also cause DTC 71 to set. When a scan tool “CLEAR CODES” command is issued and the
malfunction is no longer present, DTC 51 or 53 and DTC 71 will remain current. Ensure that the short to voltage
condition DTC 19, 25 is repaired prior to installing a replacement SDM to avoid damaging the SDM.
Step
ActionYe sNo
1Was the “SRS Diagnostic System Check” performed?
Go to Step 2
Go to the “SRS
Diagnostic
System Check”
2Note SRS “Diagnostic System Check.”
IS DTC 19 OR 25 OR 51 OR 53 ALSO SET (CURRENT OR
HISTORY)? (REFER TO NOTICE ABOVE.)Go to DTC 19 if
DTC 19 is set
Go to DTC 25 if
DTC 25 is set
Go to DTC 51 if
DTC 51 is set
Go to DTC 53 if
DTC 53 is set
Ignition switch
“OFF”
Replace SDM
Repeat the “SRS
Diagnostic
System Check”

RESTRAINT CONTROL SYSTEM 9J1–64
DTC 52 Deployment Event Commanded
WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE PRETENSIONER
WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET
FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT
OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE PRETENSIONER. THE SDM COULD BE
ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL INJURY.
Step
ActionYe sNo
1Was the “SRS Diagnostic System Check” performed?
Go to Step 2.
Go to the “SRS
Diagnostic
System Check”
2Ignition switch “OFF.”
Have pretensioner assemblies deployed?Replace
components and
perform
inspections as
directed in
“repairs and
inspections
required after an
accident” in this
section
clear diagnostic
trouble codes
Repeat “SRS
Diagnostic
System Check”
Go to Step 3
3Inspect front of vehicle and undercarriage for sings of impact.
Were signs of impact found?Replace
components and
perform
inspections as
directed in
“Repairs and
Inspections
Required After An
Accident” in this
section
Clear diagnostic
trouble codes
Repeat “SRS
Diagnostic
System Check”
Ignition switch
“OFF”
Replace SDM
Reconnect all
SRS system
components,
ensure all
components are
properly mounted
Repeat “SRS
Diagnostic
System Check”

HD6 TYPE COMPRESSOR
Metric Thread Size Information
Compressor to mounting bracket bolts (Front)
M10
1.5 – 6H
Compressor to mounting bracket bolts (Rear)
M8
1.25 – 6H
Suction-discharge port screw
M10
1.5 – 6HCompressor shaft
M9
1.25 – 6H
Internal hub-clutch drive assembly
M22
1.5 – 6H
COMPRESSOR CLUTCH PLATE AND HUB
ASSEMBLY
Removal
1. Clamp the holding fixture J-33026 in a vise and
attach compressor to holding fixture with thumb
screws J-33026-1.
2. With center screw forcing tip in place to thrust
against the end of the shaft, thread the Clutch Plate
and Hub Assembly Installer-Remover J-33013-B into
the hub. Hold the body of the remover with a wrench
and turn the center screw into the remover body to
remove the clutch plate and hub assembly (1).
CAUTION: Do not drive or pound on the clutch hub
or shaft. Internal damage to compressor may
result. The forcing tip on J-33013-B remover-
installer center screw must be flat or the end of the
shaft/axial plate assembly will be damaged.
3. Remove the shaft key and retain for reassembly.
Installation
1. Install the shaft key into the hub key groove. Allow
the key to project approximately 3.2 mm (1/8 in) out
of the keyway. The shaft key is curved slightly to
provide an interference fit in the hub key groove.2. Be sure the frictional surface of the clutch plate and
the clutch rotor (2) are clean before installing the
clutch plate and hub assembly (1).
3. Align the shaft key (4) with the shaft keyway (3) and
place the clutch plate and the hub assembly onto
the compressor shaft.
4. Remove the forcing tip on J-33013-B clutch plate
and hub assembly installer-remover center screw
and reverse the body direction on the center screw,
as shown in Figure.
5. Install the clutch plate and hub installer-remover J-
33013-B with bearing as shown in Figure.
The body of the J-33013-B installer-remover should
be backed off sufficiently to allow the center screw to
be threaded onto the end of the compressor shaft.
6. Hold the center screw with a wrench. Tighten the
hex portion of the installer-remover J-33013-B body
to press the hub onto the shaft. Tighten the body
several turns, remove the installer and check to see
that the shaft key is still in place in the keyway
before installing the clutch plate and hub
assembly to its finial position.The air gap (2)
between frictional surfaces of the clutch plate and
clutch rotor should be 0.50–0.76 mm (.020–.030 in).
1
J-33013-B
J-33026-1
J-33026
901RW001
4
31
2
871RW003

1. Perform oil return operation.
2. Discharge and recover the refrigerant and remove
the compressor.
3. Drain the compressor oil and measure the extracted
oil.
4. Check the compressor oil for contamination.
5. Adjust the oil level as required.
6. Evacuate, charge and perform the oil return
operation.
7. Check the system operation.
Contamination of Compressor Oil
Unlike engine oil, no cleaning agent is added to the
compressor oil. Even if the compressor runs for a long
period of time (approximately one season), the oil never
becomes contaminated as long as there is nothing
wrong with the compressor or its method of use.
Inspect the extracted oil for any of the following
conditions:
The capacity of the oil has increased.
The oil has changed to red.
Foreign substances, metal powder, etc., are present
in the oil.
If any of these conditions exists, the compressor
oil is contaminated. Whenever contaminated
compressor oil is discovered, the receiver/drier
must be replaced.
Oil Return Operation
There is close affinity between the oil and the
refrigerant. During normal operation, part of the oil
recirculates with the refrigerant in the system. When
checking the amount of oil in the system, or replacing
any component of the system, the compressor must be
run in advance for oil return operation. The procedure
is as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to "ON"
and set the fan control knob at its highest position.
3. Run the compressor for more than 20 minutes
between 800 and 1,000 rpm in order to operate the
system.
4. Stop the engine.
Replacement of Component Parts
When replacing the system component parts, supply
the following amount of oil to the component parts to be
installed.
Compressor Leak Testing (External and
Internal)
Bench-Check Procedure
1. Install test plate J-39893 on rear head of compressor.
2. Using Refrigerant Recovery System, attach center
hose of manifold gage set on charging station to a
refrigerant drum standing in an upright drum.
3. Connect charging station high and low pressure
lines to corresponding fittings on test plate J-39893.
Suction port (low-side) of compressor has large
internal opening. Discharge port (high-side) has
smaller internal opening into compressor and
deeper recess.
4. Open low pressure control, high pressure control
and refrigerant control on charging station to allow
refrigerant vapor to flow into compressor.
5. Using a leak detector, check for leaks at pressure
relief valve, rear head switch location, compressor
front and rear head seals, center cylinder seal,
through bolt head gaskets and compressor shaft
seal. After checking, shut off low pressure control
and high-pressure control on charging station.
6. If an external leak is present, perform the necessary
corrective measures and recheck for leaks to make
certain the leak has been connected.
7. Recover the refrigerant.
8. Disconnect both hoses from the test plate J-39893.
9. Add 90 ml (3 oz.) new PAG lubricant to the
compressor assembly. Rotate the complete
compressor assembly (not the crankshaft or drive
plate hub) slowly several turns to distribute oil to all
cylinder and piston areas.
10. Install a M9
1.25 threaded nut on the compressor
crankshaft if the drive plate and clutch assembly are
not installed.
11. Using a box-end wrench or socket and handle,
rotate the compressor crankshaft or clutch drive
plate on the crankshaft several turns to insure
piston assembly to cylinder wall lubrication.
12. Using Refrigerant Recovery System, connect the
charging station high-pressure line to the test plate
J-39893 high-side connector.
13. Using Refrigerant Recovery System, connect the
charging station low-pressure line to the low
pressure port of the test plate J-39893. Oil will drain
out of the compressor suction port if the compressor
is positioned with the suction port downward. (Component parts to be (Amount of Oil)
installed)
Evaporator 50 cc (1.7 fl. oz.)
Condenser 30 cc (1.0 fl. oz.)
Receiver/dryer 30 cc (1.0 fl. oz.)
Refrigerant line (one 10 cc (0.3 fl. oz.)
piece)
(Amount of oil drained (Charging amount of oil
from used compressor) to new compressor)
more than 90 cc same as drained amount
(3.0 fl.oz)
less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)

DIFFERENTIAL (FRONT) 4A1–14
7. Record the pinion depth code on the head of the
drive pinion.
The number indicates a necessary change in the
pinion mounting distance. A plus number indi-
cates the need for a greater mounting distance
(which can be achieved by decreasing the shim
thickness). A minus number indicates the need
for a smaller mounting distance (which can be
achieved by increasing the shim thickness). If ex-
amination reveals pinion depth code “0”, the pin-
ion is “nominal”.
425RS023

4A1–17 DIFFERENTIAL (FRONT)
NOTE: When staking, be sure to turn the nut to insure
that there is no change in bearing preload. Make sure of
preload again as instructed in 3).
415RW019
Legend
(1) 1.3mm or less
12. Install adjust shim.
1. Attach the side bearing to the differential
assembly without shims. Support the opposite
side using a pilot to prevent bearing damage.
425RS029
Legend
(1) Drive handle:5–8840–0007–0
(2) Installer:9–8522–1164–0
(3) Pilot:9–8521–1743–0
2. Insert the differential cage assembly with bearing
outer races into the side bearing bores of the
carrier.
425RS030
3. Using two sets of feeler gauges, insert a feeler
stock of sufficient thickness between each
bearing outer race and the carrier to remove all
end play. Make certain the feeler stock is pushed
to the bottom of the bearing bores.
Mount the dial indicator 5–8840–0126–0 on the
carrier so that the indicator stem is at right angles
to a tooth on the ring gear.
425RW049

DIFFERENTIAL (FRONT) 4A1–18
4. Adjust feeler gauge thickness from side to side
until ring gear backlash is in the specified range.
Backlash: 0.13–0.18 mm(0.005 –0.007 in)
425RS032With zero end play and correct backlash estab-
lished, remove the feeler gauge packs, determine
the thickness of the shims required and add 0.05
mm (0.002 in) to each shim pack to provide side
bearing preload. Always use new shims.
5. Use bearing remover 5–8840–0013–0 and
5–8840–0014–0 and pilot 9–8521–1743–0 to
remove side bearing.
415RW020
13. Install the side bearings together with the selected
shims.
425RS029
Legend
(1) Drive Handle:5–8840–0007–0
(2) Installer: 9–8522–1164–0
(3) Pilot: 9–8521–1743–0
14. Install side bearing outer race.
15. Install differential cage assembly.
16. Install bearing cap then align the setting marks(1)
applied at disassembly.
425RS035

DIFFERENTIAL (FRONT) 4A1–20
425RS039
18. Install differential assembly.
1. Clean the faces of the front axle case and
differential carrier.
Apply Three Bond TB1215 or equivalent to the
sealing side of the axle case and the carrier.
2. Attach the differential case and the carrier
assembly to the front axle case and tighten the
nuts and bolts.
To r q u e : 2 5 N ꞏm ( 2 . 5 k g ꞏm / 1 9 l b f t )
415RS014
3. Fill the axle case with hypoid gear lubricant, to just
below the filler hole.
Lubricant capacity: 1.4 liter(1.2 Imp qt/1.5 US qt)
19. Install damper.
1. Clean the faces and bolt thread hole of differential
carrier.
2. Install the bracket with new bolts.
3. Install the damper to the bracket with new bolts.
Torque: 25 Nꞏm (2.5kgꞏm/19 lb ft)
425RW042