1998 OPEL FRONTERA Gas

SUPPLEMENTAL RESTRAINT SYSTEM9J–25
TO ANY POWER SOURCE BEFORE CONNECTING
DEPLOYMENT WIRES TO THE PRETENSIONER
SEAT BELT ASSEMBLY LEADS. DEPLOYMENT
WIRES SHALL REMAIN SHORTED AND NOT BE
CONNECTED TO A POWER SOURCE UNTIL THE
PRETENSIONER SEAT BELT IS TO BE DEPLOYED.
THE PRETENSIONER SEAT BELT ASSEMBLY WILL
IMMEDIATELY DEPLOY THE PRETENSIONER SEAT
BELT WHEN A POWER SOURCE IS CONNECTED TO
IT. WEAR SAFETY GLASSES THROUGHOUT THIS
ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
1. Turn ignition switch to “LOCK,” remove key and put
on safety glasses.
2. Remove all loose objects from front seats.
3. Disconnect pretensioner seat belt assembly, yellow
2–pin connector located at the base of the seat.
4. Prepare SRS deployment harness.
5. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other.
6. Deployment harness shall remain shorted and not be
connected to a power source until the pretensioner
seat belt is to be deployed.
7. Route deployment harness out the driver side of the
vehicle.
8. Verify that the inside of the vehicle and the area
surrounding the vehicle are clear of all people and
loose or flammable objects.
9. Stretch the SRS deployment harness to their full
length.
10. Connect the deployment harness to the pretensioner
seat belt assembly, yellow 2-pin connector at the
base of the seat.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE PRETENSIONER SEAT BELT IS
TO BE DEPLOYED. THE PRETENSIONER SEAT
BELT ASSEMBLY WILL IMMEDIATELY DEPLOY THE
PRETENSIONER SEAT BELT WHEN A POWER
SOURCE IS CONNECTED TO IT. CONNECTING THE
DEPLOYMENT WIRES TO THE POWER SOURCE
SHOULD ALWAYS BE THE FINAL STEP IN THE
PRETENSIONER SEAT BELT ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
PROCEDURES IN THE ORDER LISTED COULD
RESULT IN PERSONAL INJURY.
11. Notify all people in the immediate area that you intend
to deploy the pretensioner seat belt. The deployment
will be accompanied by a substantial noise which may
startle the uninformed.
12. Separate the two banana plugs on the SRS
deployment harness.
NOTE: When the pretensioner seat belt deploys, the
rapid gas expansion will create a substantial noise. Notify
all people in the immediate area that you intend to deploy
the pretensioner seat belt.13. Connect the SRS deployment harness wires to a
power source to immediately deploy the pretensioner
seat belt assembly. Recommended application: 12
volts minimum, 2 amps minimum. A vehicle battery is
suggested.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A POWER
SOURCE UNTIL THE PRETENSIONER SEAT BELT IS
TO IS TO BE DEPLOYED. THE PRETENSIONER
SEAT BELT ASSEMBLY WILL IMMEDIATELY
DEPLOY THE PRETENSIONER SEAT BELT WHEN A
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT WIRES SHOULD
ALWAYS BE THE FINAL STEP IN THE
PRETENSIONER SEAT BELT ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
PROCEDURES IN THE ORDER LISTED COULD
RESULT IN PERSONAL INJURY.
14. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other.
15. Disconnect the deployment harness to the
pretensioner seat belt assembly, yellow 2-pin
connector at the base of the seat.
16. In the unlikely event that the pretensioner seat belt
assembly did not deploy after following these
procedures, proceed immediately with Steps 18
through 19. If the pretensioner seat belt assembly
deployed as intended, proceed with Steps 14 through
17.
17. With both air bags and pretensioner seat belt
deployed, the vehicle may be scrapped in the same
manner as a non–SRS equipped vehicle.
NOTE: The remaining steps are to be followed in the
unlikely event that the pretensioner seat belt assembly
did not deploy after following these procedures.
18. Remove the undeployed pretensioner seat belt
assembly (s) from the vehicle. For pretensioner seat
belt assembly refer to in the “Pretensioner Seat Belt
Assembly Removal” in this manual.
19.Temporarily store the pretensioner seat belt
assembly with the deployment device facing up, away
from the surface upon which it rests.

Ignition swich
"ON"
Time
Blower voltage to turn
on the cooling
7 SEC maximum3 SEC
100%
(MAX HI)
33.5%
(LO)5.32%/S
C06RY00001
33.5%
(LO)
2.63%/S
Mode
DEF
Auto
Mode
100%
(MAX HI)
Ignition
switch "ON"
Thermo Unit 58¡C(Gasoline)
52¡C(Diesel) Time
840RY00009

Legend
(1) Drive Plate Bolt
(2) Drive Plate
(3) Shim
(4) Snap Ring
(5) Pulley Assembly
(6) Screw
(7) Field Coil
(8) Through Bolt
(9) Shaft Seal Assembly
(10) Gasket
(11) Front Cylinder Head(12) O-Ring
(13) Gasket
(14) Front Valve Plate
(15) Front Suction Valve
(16) Pin
(17) Cylinder and Shaft Assembly
(18) Rear Valve Plate
(19) Gasket
(20) Rear Cylinder Head
(21) Bolt
(22) Oil Drain Plug
(23) O-Ring
DKS-15CH TYPE COMPRESSOR
16
23 2122 6
7
45
321 (’98)
(’99~)
67
45
321
8
910111213141516
17
1518191220
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10. Remove front cylinder head.
11. Remove o-ring.
Alternately tap the projections on the
circumference of the front cylinder head with a
screwdriver and a plastic hammer to remove the
front cylinder head.
12. Remove gasket.
13. Remove front valve plate.
14. Remove front suction valve.
NOTE
Check the front valve plate for scratching and
bending.
Check the front valve plate and the front
cylinder head for nicks and burrs on the
sealing surface.
Buff or replace the valve plate and cylinder
head if nicks and burrs are present.
Check that the front valve plate passage is free
from obstructions.
Check the front valve plate and the cylinder
head for cracks.
Replace the valve plate and cylinder head if
cracks are present.15. Remove rear cylinder head.
16. Remove o-ring.Alternately tap the projections on the
circumference of the rear cylinder head with a
screwdriver and a plastic hammer to remove the
rear cylinder head.
17. Remove gasket.
18. Remove rear valve plate.
19. Remove rear suction valve.
20. Remove cylinder and shaft assembly.
NOTE
Check the rear valve plate for scratching and
bending.
Check the rear valve plate and the rear
cylinder head for nicks and burrs on the
sealing surface.
Buff or replace the valve plate and cylinder
head if nicks and burrs are present.
Check that the rear valve plate passage is free
from obstructions.
Check the rear valve plate and the cylinder
head for cracks.
Replace the valve plate and cylinder head if
cracks are present.
871RY00019871RY00020

Installation
1. Install cylinder and shaft assembly.
Clamp the cylinder shaft assembly in a vise.
The rear side of the cylinder shaft assembly must
be facing up.
2. Install rear suction valve.
Apply a coat of new compressor oil to the new
suction valve (2).
Install the suction valve by aligning it with the
spring pin and the cylinder valve relief grooves.
Legend
(1) Escape Groove
(2) Suction Valve
(3) Piston
3. Install rear valve plate.
Apply a coat of new compressor oil to the new
valve plate.
Install the valve plate to the suction valve by
aligning it with the spring pin.
NOTE
Do not mix up the front and rear valve plate.
4. Install gasket.
Apply a coat of new compressor oil to the new
gasket.
Install the gasket (3) to the valve plate (4).
5. Install o-ring (2).6. Install rear cylinder head (1).
Apply a coat of new compressor oil to the new o-
ring (2).
Install the o-ring (2) to the rear cylinder head (1).
Install the rear cylinder head.
Top the rear cylinder head (1) into place with a
plastic hammer.
7. Install front suction valve.
Set the cylinder shaft assembly with the front side
facing up.
Apply a coat of new compressor oil to the new
suction valve (2).
Install the suction valve (2) by aligning it with the
spring pin and the cylinder valve relief grooves.
Legend
(1) Escape Groove
(2) Suction Valve
(3) Piston
1
2
3
871RY00021
54321
871RY00022
1
2
3
871RY00021

8. Install front valve plate.
Apply a coat of new compressor oil to the new
valve plate.
Install the valve plate to the suction valve by
aligning it with the spring pin.
NOTE
Do not mix up the front and rear valve plates.
9. Install gasket
Apply new compressor oil to the new gasket.
Install the gasket to the valve plate by a aligning it
with the spring pin.
10. Install o-ring.
11. Install front cylinder head.
Apply a coat of new compressor oil to the new O-
ring.
Install the O-ring to the front cylinder head.
Install the front cylinder head.
Tap the front cylinder head into place with a
plastic hammer.
NOTE
When installing the cylinder head, be careful
that the end of the drive shaft does not
damage the shaft seal assembly surface in the
cylinder head.12. Install through bolt.
Gaskets cannot reused. Always replace new
ones. Tighten the bolts to the specified torque a
little at a time in the sequence shown in the
illustration.
Torque: 22Nꞏm (16 lbꞏft)
NOTE
Rotate the compressor drive shaft two or three
times to make sure that it moves smoothly.
1
4
5
2
3
6
871RY00016
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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)

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)