1998 OPEL FRONTERA belt

9J1–61
RESTRAINT CONTROL SYSTEM
DTC 46 Driver Pretensioner Loop Short To Voltage
D09RW014
Circuit Description:
When the ignition switch is turned “ON”, the SDM will
perform tests to diagnose critical malfunctions within
itself. Upon passing these tests, “Ignition 1”, and
pretensioner loop voltages are measured to ensure they
are within their respective normal voltage ranges.
The SDM monitors the voltage at “Driver Belt Low”
terminal “22” and “Passenger Belt Low” terminal “10” to
detect shorts to B+ in the pretensioner assembly circuits.
DTC Will Set When:
“Ignition 1” is in the normal operating voltage range. This
test is run once each ignition cycle and “Continuous
monitoring”. Once these conditions are met and the
voltage at “Driver Belt Low” is above a specified value,
DTC 46 will set.
Action Taken:
SDM turns “ON” the “AIR BAG” warning lamp and sets
DTC 46.
DTC Will Clear When:
The malfunction is no longer occurring and the ignition is
turned “OFF”.
DTC Chart Test Description:
Number(s) below refer to step number(s) on the
diagnostic chart:
2. This test determines whether the SDM is
malfunctioning.
3. This test isolates the malfunction to one side of the
driver pretensioner assembly yellow 2–pin
connector at the base of the driver seat.
4. This test determines whether the malfunction is in
IB13–BLU/RED.
5. This test determines whether the malfunction is in
IB14–BLU/YEL.
Diagnostic Aids:
An intermittent condition is likely to be caused by a short
to B+ in the driver pretensioner assembly circuit. Inspect
IB13–BLU/RED and IB14–BLU/YEL carefully for cutting
or chafing. If the wiring pigtail of the driver pretensioner
assembly is damaged, the components must be
replaced. A careful inspection of IB13–BLU/RED and
IB14–BLU/YEL, including the driver pretensioner
assembly is essential to ensure that the replacement
SDM will not be damaged.

RESTRAINT CONTROL SYSTEM 9J1–62
DTC 46 Driver Pretensioner Loop Short To Ignition
StepActionYe sNo
1Was the “SRS Diagnostic System Check” performed?
Go to Step 2
Go to the “SRS
Diagnostic
System Check”
21. When measurements are requested in this chart use
5–8840–0285–0 DVM with correct terminal adapter from
5–8840–0385–0.
Ignition switch “OFF.”
Connect scan tool data link connector. follow directions as
given in the scan tool operator’s manual.
2. Ignition switch “ON.”
3. Read driver belt sense LO .
Is driver belt sense LO more than 3.5 volts?
Go to Step 3Go to Chart A
31. Ignition switch “OFF.”
2. Disconnect driver pretensioner assembly yellow 2–pin
connector at the base of the driver seat, leave passenger
pretensioner assembly connected.
3. Connect SRS driver /passenger load tool 5–8840–2421–0 and
appropriate adapter to driver pretensioner assembly harness
connector.
4. Ignition switch “ON.”
Is DTC 46 current?
Go to Step 4
Ignition switch
“OFF”
Replace driver
pretensioner
assembly
Go to Step 6
41. Ignition switch “OFF.”
2. Disconnect SDM.
3. Disconnect SRS driver /passenger load tool.
4. Measure resistance on SDM harness connector “21” to
terminal “12” (ignition).
Does 5–8840–0285–0 display “OL” (infinite)?
Go to Step 5
Replace SRS
harness or repair
chassis harness
Go to Step 6
5Measure resistance on SDM harness connector from terminal
“22” to terminal “12” (ignition).
Does 5–8840–0285–0 display “OL” (infinite)?
Go to Chart A
Replace SRS
harness or repair
chassis harness
Go to Step 6
61. Reconnect all components ensure all component are properly
mounted.
2. Clear diagnostic trouble codes.
Was this step finished?
Go to the “SRS
Diagnostic
System Check”
Go to Step 6

9J1–63
RESTRAINT CONTROL SYSTEM
DTC 52 Pretensioner Deployment Event Commanded
D09RW014
Circuit Description:
The SDM contains a sensing device which converts
vehicle velocity changes to an electrical signal. The
electrical signal generated is processed by the SDM and
then compared to a value stored in memory. When the
generated signal exceeds the stored value, the SDM will
cause current to flow through the pretensioner assembly
deploying the pretensioners and causing DTC 52 to set.
DTC Will Set When:
The SDM detects a frontal crash, up to 30 degrees off the
centerline of the vehicle, of sufficient force to warrant
deployment of the air bags and pretensioner seat belt.
Action Taken:
SDM turns “ON” the “AIR BAG” warning lamp records
“Crash Data”, and sets a diagnostic trouble code.
DTC Will Clear When:
The SDM is replaced.
DTC Chart Test Description:
Number(s) below refer to step number(s) on the
diagnostic chart:
2. If pretensioner assembly (s) has not deployed, DTC
52 may have falsely set.
3. If DTC 52 has set with no signs of frontal impact, the
diagnostic trouble code has falsely set.

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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTRNTS
9A SEAT BELT SYSTEM
9J SUPPLEMENTAL RESTRAINT SYSTEM
9J1 RESTRAINT CONTROL SYSTEM
HOME
9A
9J
9J1

6. Remove any excess oil resulting from installing the
new seal parts from the shaft and inside the
compressor neck.
7. Install the clutch plate and hub assembly as
described previously.8. Reinstall compressor belt and tighten bracket.
9. Evacuate and charge the refrigerant system.
COMPRESSOR PRESSURE RELIEF VALVE
Removal
1. Recover the refrigerant using Refrigerant Recovery
System.
2. Remove old pressure relief valve.
Installation
1. Clean valve seat area on rear head.2. Lubricate O-ring of new pressure relief valve and
O-ring assembly with new 525 viscosity refrigerant
oil. Install new valve and torque in place, 9.0 Nꞏm
(6.1 ft lbs)
3. Evacuate and recharge the system.
4. Leak test system.
COMPRESSOR OIL
Compressor Oil Check
The oil used to lubricate the compressor is circulating
with the refrigerant.
Whenever replacing any component of the system or a
large amount of gas leakage occurs, add oil to maintain
the original amount of oil.
Checking and Adjusting Oil Quantity for
Used Compressor
1. Perform oil return operation. Refer to Oil Return
Operation in this section.
2. Discharge and recover refrigerant and remove the
compressor.
3. Drain the compressor oil and measure the extracted
oil with a measuring cylinder.
4. If the amount of oil drained is much less than 90 cc
(3.0 fl. oz.), some refrigerant may have leaked out.
Conduct a leak tests on the connections of each
system, and if necessary, repair or replace faulty
parts.
5. Check the compressor oil contamination. (Refer to
Contamination of Compressor Oil in this section.)
6. Adjust the oil level following the next procedure
below.7. Install the compressor, then evacuate, charge and
perform the oil return operation.
8. Check system operation.
When it is impossible to preform oil return
operation, the compressor oil should be checked in
the following order:
1. Discharge and recover refrigerant and remove the
compressor.
2. Drain the compressor oil and measure the extracted
oil with a measuring cylinder.
3. Check the oil for contamination.
4. If more than 90 cc (3.0 fl. oz.) of oil is extracted from
the compressor, supply the same amount of oil to
the compressor to be installed. If the amount of oil
extracted is less than 90 cc (3.0 fl. oz.), recheck the
compressor oil in the following order:
5. Supply 90 cc (3.0 fl. oz.) of oil to the compressor
and install it onto the vehicle.
6. Evacuate and recharge with the proper amount of
refrigerant.
7. Perform the oil return operation.
8. Remove the compressor and recheck the amount of
oil.
9. Adjust the compressor oil, if necessary.
Checking and Adjusting for Compressor
Replacement
The oil is not charged in compressor (service parts). So
it is necessary to charge the proper amount of oil to the
new compressor. (Oil Capacity)
Capacity total in system 150 cc (5.0 fl.oz)
Compressor (Service 150 cc (5.0 fl.oz)
parts) charging amount
(Collected Amount) (Charging Amount)
more than 90 cc same as collected
(3.0 fl.oz) amount
less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)
(Collected Amount) (Charging Amount)
more than 90 cc same as collected
(3.0 fl.oz) amount
less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)

4D2–2
TRANSFER CASE (TOD)
Transfer Case Assembly
Removal
F07RW083
Legend
(1) Transfer Protector
(2) Rear Propeller Shaft
(3) Front Propeller Shaft
(4) Front Console
(5) Selector Lever Assembly
(6) Transfer Control Lever(7) Breather Hose
(8) Exhaust Pipe
(9) Seat Belt Tension Rod
(10) Speed Sensor Harness Connector
(11) Transfer Harness Connector
(12) Transfer Case Bolt
(13) Transfer Case
1. Disconnect the ground cable.
2. Remove the transfer protector.
3. Remove the rear propeller shaft from the transfer
case.
4. Remove the front propeller shaft from the transfer
case.
5. Remove the shift control rod from the selector lever
assembly.

4D2–3 TRANSFER CASE (TOD)
6. Disconnect the wiring harness connector, transfer
control lever knob and shift lock cable and then
remove the front console.
7 . R e m o v e t h e s e l e c t o r l e v e r a s s e m b ly a n d p u t i t a s i d e .
8. Remove the transfer control lever.
9. Disconnect the breather hose.
10. Remove the left front exhaust pipe fixing bolts and
nuts, and put the exhaust pipe aside.
11. Remove the left seat belt tension rod and put the rear
proper shaft aside.
260RW006
12. Disconnect the transfer harness connector from the
top of the transfer case.
13. Disconnect the speed sensor harness connector.
14. Remove the fuel pipe clip fixing bolt on the transfer
case.
15. Support the transmission with a jack.
16. Remove the seven bolts from the transfer case.
17. Remove the transfer case assembly.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Apply a thin coat of grease (Besco L2) or equivalent to
the input shaft spline.
261RW024
2. Mount the transfer case.

6A–1
ENGINE MECHANICAL
ENGINE
CONTENTS
Engine Mechanical 6A. . . . . . . . . . . . . . . . . . . . . .
Engine Cooling 6B. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Fuel 6C. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical 6D1. . . . . . . . . . . . . . . . . . . . . . . .
Ignition System 6D2. . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Charging System 6D3. . . . . . . . . . . . Driveability and Emissions 6E. . . . . . . . . . . . . . . .
Engine Exhaust 6F. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication 6G. . . . . . . . . . . . . . . . . . . . . .
Engine Speed Control System 6H. . . . . . . . . . . .
Inducton 6J. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MECHANICAL
CONTENTS
Service Precaution 6A–2. . . . . . . . . . . . . . . . . . . . . .
General Description 6A–3. . . . . . . . . . . . . . . . . . . . .
Engine Diagnosis 6A–4. . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover LH 6A–18. . . . . . . . . . . . . . . . .
Removal 6A–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover RH 6A–21. . . . . . . . . . . . . . . . .
Removal 6A–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Chamber 6A–24. . . . . . . . . . . . . . . . . . . . . .
Removal 6A–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold LH 6A–26. . . . . . . . . . . . . . . . . . . . .
Removal 6A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold RH 6A–27. . . . . . . . . . . . . . . . . . . .
Removal 6A–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Pulley 6A–28. . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 6A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 6A–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 6A–37. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–37. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Oil Controller , Valve Spring and
Valve Guide 6A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Ring and Connecting Rod 6A–40. . . Removal 6A–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Main Bearings 6A–42. . . . . . . . . . . .
Removal 6A–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal 6A–47. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–47. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly 6A–48. . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 6A–52. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Associated Parts 6A–52. . . . .
Disassembly 6A–52. . . . . . . . . . . . . . . . . . . . . . . . . .
Clean 6A–53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–53
. . . . . . . . . . . . . . . . . .
Reassembly 6A–53. . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve,
Valve Guide 6A–56. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve,
Valve Guide and Associated Parts 6A–56. . . . . . .
Disassembly 6A–56. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–57. . . . . . . . . . . . . . . . . .
Reassembly 6A–60. . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Clearance Adjustments 6A–61. . . . . . . . . . . . .
Camshaft 6A–63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Associated Parts 6A–63. . . . . . . . .
Disassembly 6A–63. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–64. . . . . . . . . . . . . . . . . .
Reassembly 6A–66. . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 6A–69. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Associated Parts 6A–69. . . . . . . .
Disassembly 6A–69. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–70. . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–71. . . . . . . . . . . . . . . . . .
Reassembly 6A–73. . . . . . . . . . . . . . . . . . . . . . . . . .