1998 OPEL FRONTERA wheel

CLUTCH7C–9
Clutch Assembly
Clutch Assembly and Associated Parts
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Legend
(1) Flywheel Assembly and Crankshaft Bearing
(2) Driven Plate Assembly (6VE1)
(3) Driven Plate Assembly (4JX1)
(4) Pressure Plate Assembly (5) Transmission Assembly
(6) Front Cover
(7) Shift Fork
(8) Release Bearing
Removal
1. Remove transmission assembly, refer to ”MANUAL
TRANSMISSION” of Section 7B for ”Removal AND
INSTALLATION” procedure.
2. Mark the flywheel, clutch cover and pressure plate lug
for alignment when installing.
3. Remove pressure plate assembly (3).
4. Remove driven plate assembly (1) or (2). Use the pilot
aligner 5-85253-001-0 (J-24547) to prevent the
driven plate assembly from falling free.
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7C–10CLUTCH
5. Mark the flywheel, clutch cover and pressure plate lug
for alignment when installing.
6. Remove the release bearing (3) from the
transmission case .
7. Remove the shift fork snap pin.
8. Remove the shift fork pin and shift fork (4) from the
front cover.
9. Remove the front cover bolts.
10. Remove the front cover (5) from the transmission
case.
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11. Remove flywheel assembly and crankshaft bearing.
Do not remove except for replacement.
12. Use the remover 5–8840–2000–0 (J–5822) and
sliding hammer 5–8840–0019–0 (J–23907) to
remove the crankshaft bearing
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Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, or any other abnormal condition are found
through inspection.
Pressure Plate Assembly
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1. Visually check the pressure plate friction surface for
excessive wear and heat cracks.
2. If excessive wear or deep heat cracks are present,
the pressure plate must be replaced.
Pressure Plate Warpage
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CLUTCH7C–11
1. Use a straight edge and a feeler gauge to measure
the pressure plate friction surface flatness in four
directions.
2. If any of the measured values exceeds the specified
limit, the pressure plate must be replaced.
Pressure Plate Warpage
Limit: 0.3 mm (0.012 in)
Clutch Cover
201RS004
1. Visually check the entire clutch cover for excessive
wear, cracking, and other damage.
2. The clutch cover must be replaced if any of these
conditions are present.
Clutch Set Force
201RS005
1. Invert the pressure plate assembly.2. Place a new driven plate over the pressure plate. A
metal sheet with “A” thickness of 8.3 mm (0.327 in)
may be used in place of the driven plate.
3. Compress the pressure plate assembly until the
distance “B” becomes 12 mm (0.472 in).
4. Note the pressure gauge reading.
5. If the measured value is less than the specified limit,
the pressure plate assembly must be replaced.
Clutch Set Force
Standard: 7208 N ( 1621 lb)
Limit: 6468 N (1454 lb)
Diaphragm Spring Finger Height
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Legend
(1) Release Side
1. Place a new driven plate or a 8.3 mm (0.327 in)
spacer beneath the pressure plate.
2. Fully compress the pressure plate and diaphragm
spring.
3. There are two ways to do this.
4. Use a bench press to press down on the assembly
from the top.
5. Tighten the fixing bolts.
NOTE: Preload on diaphragm spring finger must be 49 –
98 N (11 – 22 lb) in direction of release, when clutch cover
assembly is bolted to the flywheel.
6. Measure the spring height from base to spring tip “A”.
If the measured value exceeds the specified limit, the
pressure plate assembly must be replaced.
Diaphragm Spring Finger Height
Standard: 49.9 mm – 51.9 mm (1.965 in –
2.043 in)

CLUTCH7C–13
Driven Plate Splined Hub Spline Wear
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Legend
(1) Driven Plate Assembly (6VE1)
(2) Driven Plate Assembly (4JX1)
1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear
shaft spline.
3. Set a surface gauge to the driven plate outside
circumference.
4. Slowly turn the driven plate counterclockwise.
5. Measure the spline rotation play as you turn the
driven plate.
6. If the measured value exceeds the specified limit, the
driven plate assembly must be replaced.
Driven Plate Splined Hub Spline Wear
Standard: 0.5 mm (0.020 in)
Limit: 1.0 mm (0.039 in)
Rivet Head Depression
201RS010
1. Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression 1 from the facing
surface 2.
2. Be sure to measure the rivet head depression on both
sides of the driven plate.
3. If the measured value is less than the specified limit,
the driven plate assembly must be replaced.
Rivet Head Depression
Standard:
Flywheel sidePressure plate side
6VE11.95mm (0.077 in)1.95mm (0.077 in)
4JX11.60mm (0.063 in)1.60mm (0.063 in)
Limit: 0.2 mm (0.008 in)

CLUTCH7C–15
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Install flywheel assembly and crankshaft bearing.
Use the installer 5-8840-0125-0 (J-26516-A) and
driver handle 5-8840-0007-0 (J-8092) to install the
crankshaft bearing then clean and lubricate with
grease.
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2. Install new flywheel fixing bolts in the order illustrated
and tighten them to the specified torque.
Torque:
6VE1: 54 Nꞏm (5.5 kgꞏm/40 lb ft)
4JX1: 60 Nꞏm (6.1 kgꞏm/44 lb ft)+60
NOTE: Do not reuse the bolt and do not apply oil or thread
lock to the bolt.
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3. Install the front cover (5) to the transmission case.
4. Tighten eight front cover bolts to the specified torque.
Torque: 17 Nꞏm (1.7 kgꞏm/12 lb ft)
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5. Apply molybednum disulfide type grease to the pin
hole inner circumferences and thrust surfaces.
6. Attach the shift fork to the front cover and insert the
pin from below of the front cover.
7. Install the washer and snap pin.
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7C–20CLUTCH
2. Adjust clutch padel adjusting bolt by backing it out
half a turn, and measure the clearance (
)
between the clutch pedal arm and the adjusting
bolt.
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Legend
(9) Bracket
(10) Clutch Pedal Adjusting Bolt
(11) Lock Nut
(12) Clutch Pedal Arm
3. Lock the lock nut.
Clutch Switch and Clutch Pedal Clearance (
)
0.5 mm – 1.5 mm (0.020 in – 0.059 in)
5. After adjusting the clutch pedal height, push the
clutch pedal by hand rightly to check the clutch pedal
free play (4) to within specification.
Pedal Free Play (4)
5 mm – 15 mm (0.20 in – 0.59 in)
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6. Clutch pedal engagement height inspection:
1. Operate the parking brake lever and block the
wheels.
2. Start the engine, fully step on the clutch pedal,
and move the shift lever to 1st position.
3. With the engine idling, release the clutch pedal
slowly and measure its stroke just prior to its
clutching position.
Clutch Pedal Engagement Height (14)
MIN. 30 mm (1.18 in)
7. If the measured value exceeds the specified limit,
check the following points. Repair if necessary:
Hydraulic circuit for fluid leakage or air in circuit.
Clutch disc warped.
Diaphragm spring weakened or tip of fingers worn.
Driven plate sticking on sprines.
Release bearing worn or damaged.
Master cylinder and slave cylinder worn.
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Legend
(3) Floor Panel
(14) Clutch Pedal Engagement Height

8A–18LIGHTING SYSTEM
Lighting Switch (Combination Switch)
Removal
1. Disconnect the battery ground cable.
2. Remove the instrument panel driver lower cover(5).
Refer to the Instrument Panel Assembly in Body
Structure section.
3. Remove seven screws to remove the steering
cowl(4).
4. Disconnect the SDM (air bag controller) connector
located at lower of the instrument panel driver lower
cover.
5. Remove four fixing screws and disconnect the driver
inflator module connector to remove the driver inflator
module(3).
CAUTION: When carrying a live inflator module,
make sure the bag opening is pointed away from
y o u . I n c a s e o f a n a c c i d e n t a l d e p l o y m e n t , t h e b a g w i l l
then deploy with minimal chance of injury. Never
carry the inflator module by the wires or connector
on the underside of the module.
When placing a live inflator module on a bench or
other surface, always face the bag and trim cover up,
away from the surface. This is necessary so that a
free space is provided to allow the air bag to expand
in the unlikely event of accidental deployment.
6. Remove the steering wheel(2).
Refer to the Steering Wheel in Steering section.
7. Disconnect the SRS coil assembly connector,
remove four fixing screws to remove the SRS coil
assembly(1).
8. Disconnect the lighting switch connector, remove four
fixing screws to remove the lighting switch(6).
825RS039
Installation
To install, follow the removal steps in the reverse order,
noting the following points.1. Check to see if the vehicle is in the straight driving
condition and turn the rotary section of the SRS coil
assembly provided to the upper surface of the lighting
switch (combination switch) counterclockwise fully
until it stops.
Then from where it stops, turn it back about 3
rotations to set the alignment marks(7) together
before installing the steering wheel.
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2. Tighten the steering shaft nut to the specified torque.
Torque: 34 Nꞏm (3.5 kgꞏm/25 lb ft)
3. When connect the double lock type of inflator module
connector, insert the connector completely and lock
at outside.
Imperfect locking may cause malfunction of SRS
system circuit.
4. When installing the steering cowl(11), be sure to pass
the harnesses through the route as shown in the
figure so that the starter switch harness(8), the
combination switch harness(9) and inflator module
harness(10) will not get caught.
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8D–404 WIRING SYSTEM
STEP OPERATION ITEM TO BE CHECKEDITEM OF
REMARKS
MALFUNCTION
Activate alarm
device. Check to see if indicator light
goes off after about 10 seconds.
Check to see if alarm operates.
Check to see if alarm stops. Wait about 10 seconds.
Open engine hood with engine
hood release handle.
Insert key into starter switch and
turn it to “ACC” position.C
I
J 45
46
47
NOTE:When the connector of the anti–theft & keyless entry control unit is disconnected, the starter is inoperative.
In the checking of short wheel base model, Step Nos. 16 through 21 and Step Nos. 31 through 36 are omitted.