1998 OPEL FRONTERA ECU

4D2–1 TRANSFER CASE (TOD)
DRIVELINE/AXLE
TRANSFER CASE (TOD)
CONTENTS
Service Precaution 4D2–1. . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly 4D2–2. . . . . . . . . . . . . . . . .
Removal 4D2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal 4D2–5. . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal and Associated
Parts 4D2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 4D2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD ECU 4D2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 4D2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D2–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 4D2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 4D2–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case 4D2–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4D2–9. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–10. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Cover Assembly 4D2–12. . . . . . . . . . . . . . . .
Disassembled View 4D2–12. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–12. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–14. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly Clutch Pack and
Clutch Cam 4D2–16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4D2–16. . . . . . . . . . . . . . . . . . . . Disassembly 4D2–16. . . . . . . . . . . . . . . . . . . . . . . . . .
Sprocket and Mechanical Lock 4D2–18. . . . . . . . . . . .
Disassembled View 4D2–18. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–18. . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shafts and Shift Control Shaft 4D2–20. . . . . .
Disassembled View 4D2–20. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case 4D2–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4D2–23. . . . . . . . . . . . . . . . . . . .
Disassembly 4D2–24. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4D2–26. . . . . . . . . . . . . . . . . .
Transfer Case 4D2–30. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4D2–30. . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–30. . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shafts and Shift Control Shaft 4D2–34. . . . . .
Disassembled View 4D2–34. . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–34. . . . . . . . . . . . . . . . . . . . . . . . . .
Sprocket and Mechanical Lock 4D2–37. . . . . . . . . . . .
Disassembled View 4D2–37. . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–37. . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pack and Clutch Cam 4D2–39. . . . . . . . . . . . .
Disassembled View 4D2–39. . . . . . . . . . . . . . . . . . . .
Reassembly 4D2–39. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4D2–41. . . . . . . . . . . . .
Special Tools 4D2–43. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

4D2–7 TRANSFER CASE (TOD)
TOD ECU
Removal
1. Disconnect the ground cable.
2. Move the right-hand seat forward and remove the
second seat foot rest (1).
3. Disconnect the connector from the ECU (2).
4. Remove the bolts and detach the ECU (2) from the
bracket.
F07RW021
Installation
1. Perform the removal step in reverse order.

4D2–11 TRANSFER CASE (TOD)
2. Tighten the sixteen bolts to the specified torque.
Torque : 31 Nꞏm (3.2 kgꞏm/23 lb ft)
3. Wind the sealing tape around the drain plug thread
and tighten the plug to the specified torque.
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
4. Mount the offset lever to the transfer shift and install
the spring pin.
261RW016
5. Attach the O-ring and washer to the companion
flange.
NOTE: Securely push the O-ring to the hollow of the
companion flange, and then attach the washer.
6. Use the flange holder 5-8840-0133-0 (J-8614-11) to
tighten the flange nut.
7. Tighten the flange nut to the specified torque.
Torque : 167 Nꞏm (17.0 kgꞏm/123 lb ft)
8. Using the punch 5-8840-2293-0 (J-39209), securely
stake the flange nut at two spots.
NOTE: Check the staked flange nut is free from cracks.
266RW028
260RW007
9. Fix the harness with the clip.
10. Tighten the 4L and 4H switch to the specified torque.
Torque : 24 Nꞏm (2.4 kgꞏm/17 lb ft)
11. Fill the transfer case with ATF II or III (1.9 liters).
12. Wind the sealing tape around the filler plug thread and
tighten the plug to the specified torque.
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)

4D2–15 TRANSFER CASE (TOD)
4. Apply a thin coat of grease to the seal ring of each
front and rear speed sensor, and mount the sensors
carefully.
5. Tighten the bolts to the specified torque.
Torque : 5 Nꞏm (0.5 kgꞏm/43 lb in)
NOTE: Pay attention not to mount the front (or rear)
sensor to the rear (or front) sensor position.
6. Install the ball bearing (1) for the front output shaft as
flat as shown in the figure.
261RW008
7. Mount the coil assembly and tighten the nuts to the
specified torque.
Torque : 10 Nꞏm (1.0 kgꞏm/87 lb in)
8. Connect the terminal in the central connector.
NOTE: Be careful not to damage other terminals.
9. Install speed gear and tone wheel.
10. Mount the ball bearing (2) as flat as shown in the
figure.
261RW009–1
11. Using snap ring pliers, install the snap ring to the
transfer cover assembly.NOTE: Securely install the snap ring to the groove of the
transfer cover assembly.

4D2–33 TRANSFER CASE (TOD)
14. Using the snap ring pliers, expand the snap ring
through the opening between the ring gear and carrier
assembly and securely install the input shaft and
carrier assembly.
261RW038
15. Install the ball bearing (for front output shaft)

5A–47 BRAKE CONTROL SYSTEM
Chart B-7 Transfer Monitor (DTC 24)
StepActionYe sNo
11. Turn the key off.
2. Disconnect EHCU connector.
Is the EHCU connector terminal 9 line normally?
Go to Step 2
Repair
Go to Step 3
2Is the TOD ECU or 4WD controller normal?
Replace EHCU.
Go to Step 3
Repair or replace
TOD ECU or
4WD contrder.
Go to Step 3
31. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Repeat the “Basic
diagnostic flow
chart.”
Go to Step 3
Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32)
StepActionYe sNo
11. Turn the key off.
2. Disconnect EHCU connector.
3. Measure voltage between EHCU connector terminal 13 and
body ground.
Is the voltage equal to battery voltage?
Go to Step 2
Repair
fuse/harness
between battery
and EHCU
connector
terminal 13.
Go to Step 3
2Is there continuity between EHCU connector terminal 12 and
ground?
Go to Step 3
Repair between
EHCU connector
terminal 12 and
ground.
Go to Step 3
31. Reconnect all components and ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Repeat the “Basic
diagnostic flow
chart.”
Go to Step 3
Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35)
StepActionYe sNo
11. Turn the key off.
2. Disconnect EHCU connector.
3. Measure voltage between EHCU connector terminal 14 and
body ground.
Is the voltage equal to battery voltage?
Replace EHCU.
Go to Step 2
Repair fuse and
harness EHCU
connector
terminal 14 and
battery.
Go to Step 2
21. Reconnect all components and ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Repeat the “Basic
diagnostic flow
chart.”
Go to Step 2

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–23
ENGINE MECHANICAL
6. Install idle pulley assembly and tighten the fixing bolt
to the specified torque.
Torque : 52 Nꞏm (5.3 Kgꞏm/38.4 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/16.2 lb ft)
8. Install drive belt by pushing down the auto tensioner
using spanner as shown in the removal step of drive
belt.
9. Install cooling fan clutch assembly and tighten the
fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in)
10. Install upper fan guide and clip both side and tighten
the fixing bolts to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35.4 lb in)
11. Install engine harness and tighten the fixing bolts of
the retaining clip and brackets to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35.4 lb in)
12. Connect radiator upper and lower hoses and clip
them securely.
13. Connect wiring connectors and bonding cable of
those which were disconnected in the removal step.
14. Install air cleaner element and air cleaner duct
assembly, and the clip both end securely.
15. Connect MAF sensor connector, IAT sensor
connector and PCV hose.
16. Install engine cover mating with the dowels.