1998 OPEL FRONTERA steering

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–88
StepActionYe sNo
1Are the front and rear tires in specified size?
Go to Step 2
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
2Is the tire pressure correct?
Go to Step 3
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
3Are the tires free from abnormal wear?
Go to Step 4
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
4Are different types of tires used?
Go to Step 5
Replace the tires
with specified
ones, and service
the new tires.
Go to Step 16
51. Start the engine.
2. Shift the transfer lever to the high (TOD) position.
3. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation.
Go to Step 6 Go to Step 11
61. Shift the transfer lever to the 2H position.
2. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation.
Go to Step 7 Go to Step 14
7Is an LSD mounted to the rear differential? Go to Step 8 Go to Step 9
8Is the genuine LSD oil used in the rear differential?
Go to Step 9
Replace the
differential oil.
Go to Step 16
9Does the engine output the power correctly?
Go to Step 10
Check the
engine.
Go to Step 16
10Do the speed sensors work correctly? (Check trouble codes.)The ECU has
failed. Replace
the ECU.
Go to Step 16
Replace the
speed sensors.
Go to Step 16
11Is the tight corner braking observed only when the brake is
applied?
Go to Step 12
Conduct full
steering under
WOT.
Go to Step 5
121. Turn off the starter switch.
2. Disconnect the ECU connector.
Is the battery voltage observed between terminals (B–68)6 and
(B–67)11?
Go to Step 13
Repair the circuit
of terminal 6
(ABS IN).
Go to Step 16

4B2–89 DRIVE LINE CONTROL SYSTEM (TOD)
StepNo Ye s Action
131. Apply the brake and fully turn the steering to the left (or right)
end, and start the creep run.
Does the voltage between terminals 4 and 20 range between 0.1
and 1.0V?Repair the
transfer
assembly.
Go to Step 16The ECU has
failed. Replace
the ECU.
Go to Step 16
141. Shift the transfer lever to the high (TOD) position.
2. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the voltage between terminals 4 and 20 range between 0.1
and 1.0V?
Go to Step 15 Go to Step 13
151. Select the 4WD SW to the 2WD position.
2. Jack up the right front wheel.
Does the front tire rotate smoothly?
Repair the
transfer
assembly.
Go to Step 16
The phenomenon
is not
reproduced.
Refer to
“Troubles
intermittently
observed”.
Go to Step 16
16Check that all the parts are mounted.
Is this step complete?Repeat the
“Diagnosis Flow”.
Return to Step 16
*NOTE: Before checking this item, run the vehicle more
than 10 meters with the steering wheel in straight position
so that the 4L mechanical lock sleeve can be released
certainly.

4B2–91 DRIVE LINE CONTROL SYSTEM (TOD)
StepActionYe sNo
1Is the trouble code 31 or 26 recorded?Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
Go to Step 7
Go to Step 2
2Is any of the trouble codes 28, 32 and 33 recorded?Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
Go to Step 7
Go to Step 3
3When the transfer lever is in the specified position, do the TOD
indicator lamps show the correct status?
Go to Step 4
Examine the
trouble based on
“Trouble
Diagnosis
Depending on
The Status of
TOD Indicator”.
Go to Step 7
4Shift the transfer lever to the 4L position, fully turn the steering to
the left (or right) end, and start the creep run. Does the tight
corner braking occur?
Go to Step 5
Repair the
transfer
assembly.
Go to Step 7
51. Shift the transfer lever to the high (TOD) position.
2. Turn on the starter switch.
Does the voltage between terminals 4 and 20 indicate at least
0.1V while the throttle is completely open?
Go to Step 6
The ECU has
failed. Replace
the ECU.
Go to Step 7
6Does the voltage between terminals 4 and 20 indicate at least 3V
while the throttle is completely closed?The TOD clutch
is worn. Repair
the transfer
assembly.
Go to Step 7
The ECU has
failed. Replace
the ECU.
Go to Step 7
7Check that all the parts are mounted.
Is this step complete?Repeat the
“Diagnosis Flow”.
Return to Step 7

4C–3 DRIVE SHAFT SYSTEM
Diagnosis
ConditionPossible causeCorrection
Oil Leak At Front AxleWorn or defective oil seal.Replace the oil seal.
Front axle housing cracked.Repair or replace.
Oil Leak At Pinion ShaftToo much gear oil.Correct the oil level.
Oil seal worn or defective.Replace the oil seal.
Pinion flange loose or damaged.Tighten or replace.
Noises In Front Axle Drive Shaft
JointBroken or worn drive shaft joints and
bellows (BJ and DOJ).Replace the drive shaft joints and
bellows.
“Clank” When Accelerating From
“Coast”Loose drive shaft joint to output shaft
bolts.Tighten.
Damaged inner drive shaft joint.Replace.
Shudder or Vibration During
Acceleration
Excessive drive shaft joint angle.Repair.
AccelerationWorn or damaged drive shaft joints.Replace.
Sticking spider assembly (inner drive
shaft joint).Lubricate or replace.
Sticking joint assembly (outer drive
shaft joint).Lubricate or replace.
Vibration At Highway SpeedsOut of balance or out of round tires.Balance or replace.
Front end out of alignment.Align.
Noises in Front AxleInsufficient gear oil.Replenish the gear oil.
Wrong or poor grade gear oil.Replace the gear oil.
Drive pinion to ring gear backlash
incorrect.Adjust the backlash.
Worn or chipped ring gear, pinion
gear or side gear.Replace the ring gear, pinion gear or
side gear.
Pinion shaft bearing worn.Replace the pinion shaft bearing.
Wheel bearing worn.Replace the wheel bearing.
Differential bearing loose or worn.Tighten or replace.
Wanders and PullsWheel bearing preload too tight.Adjust the wheel bearing preload.
Incorrect front alignment.Adjust the front alignment.
Steering linkage loose or worn.Tighten or replace.
Steering gear out of adjustment.Adjust or replace the steering gear.
Tire worn or improperly inflated.Adjust the inflation or replace.
Front or rear suspension parts loose
or broken.Tighten or replace.
Front Wheel ShimmyWheel bearing worn or improperly
adjusted.Adjust or replace.
Incorrect front alignment.Adjust the front alignment.
Worn ball joint or bush.Replace the ball joint or bush.
Steering linkage loose or worn.Tighten or replace.
Steering gear out of adjustment.Tighten or replace.
Tire worn or improperly inflated.Replace or adjust the inflation.
Shock absorber worn.Replace the shock absorber.

4C–4
DRIVE SHAFT SYSTEM
Rear Axle Shaft
Rear Axle Shaft and Associated Parts
420RW014
Legend
(1) Brake Caliper
(2) Brake Disc
(3) Wheel Pin
(4) Axle Shaft Assembly
(5) Back Plate
(6) Parking Brake Assembly
(7) Bearing Holder(8) Bearing
(9) Retainer
(10) Snap Ring
(11) Bolt
(12) Nut
(13) Antilock Brake System (ABS) Speed Sensor (if
so equipped)
Removal
1. Raise the vehicle.
2. Remove tires and wheels. Refer to Wheel in Steering
section.3. Remove brake caliper. Use a wire to attach the brake
caliper to the frame. Refer to Disk Brakes in Brake
section.
4. Remove brake disc.
5. Remove ABS sensor (if so equipped).
6. Remove Parking brake assembly. Refer to Parking
Brakes in Brake section.

6A–19
ENGINE MECHANICAL
Legend
(1) Crankshaft Pulley
(2) Generator
(3) Auto Tensioner
(4) Idle Pulley
(5) Cooling Fan Pulley
(6) Power Steering Oil Pump
(7) Drive Belt
(8) Air Conditioner Compressor
12. Remove power steering oil pump pulley.
13. Remove fan pulley and bracket assembly.
14. Remove idle pulley assembly.
15. Remove auto tensioner assembly.
16. Remove crankshaft pulley using 5–8840–0133–0
crankshaft holder.
17. Remove timing belt covers from the right bank side to
the left bank side in order.
18. Remove ignition coil assemblies for the left side bank.
060RW018
Legend
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies
19. Remove cylinder head cover assembly.
Installation
1. Install cylinder head cover.
Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area of
camshaft bracket on front and rear sides.
The cylinder head cover must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
014RW144
Tighten bolts to the specified torque.
Torque : 9 Nꞏm (0.9 Kgꞏm/78 lb in)
010RW008
2. Install ignition coil assemblies and tighten the fixing
bolts to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
3. Install timing belt covers from left bank side to right
bank side, and tighten the fixing bolts and nut to the
specified torque.
Torque : 19 Nꞏm (1.9 Kgꞏm/14 lb ft)
4. Install crankshaft pulley and tighten the fixing bolt
using 5–8840–0133–0 crankshaft holder to the
specified torque.
Torque : 167 Nꞏm (17.0 Kgꞏm/123 lb ft)

6A–20
ENGINE MECHANICAL
5. Install auto tensioner assembly and tighten the fixing
bolts to the specified torque.
Torque :
Shorter Bolt : 20 Nꞏm (2.0 Kgꞏm/14 lb ft)
Longer Bolt : 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
6. Install idle pulley and bracket assembly and tighten
the fixing bolt to the specified torque.
Torque : 52 Nꞏm (5.3 Kgꞏm/38 lb ft)
7. Install fan pulley and bracket assembly and tighten
the fixing bolts and nut to the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
8. Install power steering oil pump pulley and tighten the
fixing bolt to the specified torque.
Torque : 78 Nꞏm (8.0 Kgꞏm/58 lb ft)
9. Install drive belt by pushing down the auto tensioner
using spanner as shown in the removal step of drive
belt.
10. Install cooling fan and clutch assembly and tighten
the fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/87 lb in)
11. Install upper fan guide and clip both side and tighten
the fixing bolts to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
12. Install engine harness and tighten the fixing bolts of
the retaining clip and bracket to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
13. Connect radiator upper and lower hoses and clip
them securely.
14. Connect vacuum hoses of those which were
disconnected in the removal step.
15. Connect wiring connectors and bonding cable of
those which were disconnected in the removal step.
16. Install air cleaner element and air cleaner duct
assembly, and clip the both end securely.
17. Connect MAF sensor connector, IAT sensor
connector and PCV hose.
18. Install engine cover mating with the dowels.

6A–21
ENGINE MECHANICAL
Cylinder Head Cover RH
Removal
1. Disconnect battery ground cable.
2. Remove battery from the vehicle.
3. Drain engine coolant from faucet bottom of radiator.
4. Remove engine cover from the dowels on the
common chamber.
F06RW018
5. Remove air cleaner duct assembly (3) and air cleaner
element (4).
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.
6. Disconnect following wiring connectors and bonding
cable:
Exhaust Gas Recirculation (EGR) valve
Fuel injectors for right bank
Ignition coils for right bank
Bonding cable
Othres as necessitated
7. Disconnect radiator upper and lower hoses.
8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
F06RW019
Legend
(1) Crankshaft Pulley
(2) Generator
(3) Auto Tensioner
(4) Idle Pulley
(5) Cooling Fan Pulley
(6) Power Steering Oil Pump
(7) Drive Belt
(8) Air Conditioner Compressor
12. Remove fan pulley and bracket assembly.
13. Remove idle pulley assembly.
14. Remove auto tensioner assembly.
15. Remove crankshaft pulley using 5–8840–0133–0
crankshaft holder.