1998 OPEL FRONTERA clutch

7C–16CLUTCH
8. Apply molybdenum disulfide type grease to the areas
shown in illustration.
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9. Install the release bearing in the proper direction.
NOTE: Ensure release bearing is properly positioned
during installation, as shown in illustration.
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10. Install driven plate assembly. Use the pilot aligner
5-85253-001-0 (J-24547) to install the driven plate
assembly.
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11. Install pressure plate assembly and tighten the bolts
holding the pressure plate assembly in the order
shown in illustration.
Torque: 18 Nꞏm (1.8 kgꞏm/13 lb ft)
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12. Remove the aligner.
NOTE: Do not strike the aligner with a hammer to remove
it.
13. Install transmission assembly.

CLUTCH7C–17
Clutch Control
Clutch Control Parts
(6VE1 LHD)
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Legend
(1) Master Cylinder Assembly
(2) Pedal Assembly(3) Pin and Jaw Joint Pin
(4) Oil Line Pipe
(5) Slave Cylinder Assembly and Heat Protector

7C–18CLUTCH
(Except 6VE1 LHD)
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Legend
(1) Master Cylinder Assembly
(2) Pedal Assembly
(3) Pin and Joint Pin (4) Oil Line Pipe
(5) Slave Cylinder Assembly and Heat Protector
(6) Damper Cylinder Assembly
Removal
1. Remove pin and jaw joint pin.
2. Remove pedal assembly.
3. Remove oil line pipe.
4. Remove slave cylinder assembly and heat protector.
5. Remove master cylinder assembly.
6. Remove damper cylinder assembly (except V6 LHD).
Inspection and Repair
Make necessary adjustments, repairs, and part
replacement if wear, damage or other problems are
discovered during inspection.

CLUTCH7C–19
Installation
1. Install damper cylinder assembly (except V6 LHD).
2. Install master cylinder assembly.
3. Install slave cylinder assembly and heat protector.
4. Install oil line pipe.
5. Install pedal assembly.
6. Install pin and jaw joint pin.
Adjustment
Clutch Pedal Adjustment
1. Loosen the clutch pedal adjusting bolt so that there is
enough gap between the clutch pedal and the
adjusting bolt to allow push rod adjustment.
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Legend
(1) Push Rod
(2) Adjusting Bolt
2. Loosen clutch master cylinder push rod lock nut. Turn
push rod by hand to set clutch pedal height (5) to
within specification.
Clutch pedal height (5):
LHD: 217 mm – 227 mm (8.543 in – 8.937 in)
RHD:
(6VE1) 238.5 mm – 248.5 mm (9.390 in – 9.783 in)
(4JX1) 231 mm – 241 mm (9.094 in – 9.488 in)
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Legend
(3) Floor Panel
(4) Pedal Free Play
(5) Clutch Pedal Height
3. Tighten push rod lock nut.
4. Adjusting bolt adjustment.
1. Turn the adjusting bolt until it just touches the
clutch pedal arm.
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Legend
(6) Blacket
(7) Adjusting Bolt
(8) Clutch Pedal Arm

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

CLUTCH7C–21
Torque Specifications
Master cylinder to dash panel
Torque: 16 Nꞏm (1.6 kgꞏm/12 lb ft)
Clutch pedal to dash panel
Torque: 21 Nꞏm (2.1 kgꞏm/15 lb ft)
Master cylinder push rod to yoke
Torque: 17 Nꞏm (1.7 kgꞏm/12 lb ft)
Clutch pipe to master cylinder
Torque: 20 Nꞏm (2.0 kgꞏm/14 lb ft)
Clutch pipe to flex, hose
Torque:
M 10: 16 Nꞏm (1.6 kgꞏm/12 lb ft)
M 12: 20 Nꞏm (2.0 kgꞏm/14 lb ft)
Slave cylinder to case
Torque: 43 Nꞏm (4.4 kgꞏm/32 lb ft)
Slave cylinder bleeder screw
Torque: 8 Nꞏm (0.8 kgꞏm/69 lb in)
Flexible hose to slave cylinder
Torque: 20 Nꞏm (2.0 kgꞏm/14 lb ft)
Clutch pipe to damper cylinder
Torque: 12 Nꞏm (1.2 kgꞏm/104 lb in)
Damper cylinder bleeder screw
Torque: 8 Nꞏm (0.8 kgꞏm/69 lb in)
Bleeding
1. Check the level of clutch fluid in the reservoir and
replenish if necessary.
Bleeding the damper cylinder (except V6 LHD
model).
2. Remove the rubber cap from the bleeder screw and
wipe clean the bleeder screw. Connect a vinyl tube to
the bleeder screw and insert the other end of the vinyl
tube into a transparent container.
3. Pump the clutch pedal repeatedly and hold it
depressed.
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4. Loosen the bleeder screw to release clutch fluid with
air bubbles into the container, then tighten the bleeder
screw immediately.5. Release the clutch pedal carefully. Repeat the above
operation until air bubbles disappear from the clutch
fluid being pumped out into the container. During the
bleeding operation, keep the clutch fluid reservoir
filled to the specified level. Reinstall the rubber cap.
Bleeding the slave cylinder
6. Repeat step 2 through 5 for bleeding the slave
cylinder.
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Legend
(1) Slave Cylinder
(2) Bleeder Screw
(3) Vinyl Tube

7C–22CLUTCH
Master Cylinder
Disassembled View
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Legend
(1) Master Cylinder Assembly
(2) Gasket(3) Damper Cylinder Assembly
(4) Nut
(5) Push Rod Damper

CLUTCH7C–23
Disassembly
(4JX1)
1. Remove damper cylinder assembly and gasket.
2. Remove push rod damper.
NOTE: The master cylinder assembly cannot be
disassembled because of point–staked rod stopper.
Inspection and Repair
Clean and inspect the removed parts.
Make necessary parts replacement if any abnormalities
such as wear, oil leaks or other damage are found through
inspection.
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
1.Push rod set length
RHD: 117.5 mm (4.626 in)
LHD: 119 mm (4.685 in)
2.Push rod nut torque
17 Nꞏm (1.7 kgꞏm/12 Ib ft)
3.Damper cylinder torque
47 Nꞏm (4.8 kgꞏm/35 Ib ft)