1998 OPEL FRONTERA lock

X-2124
13X-21
X-21 THERMO SW RELAY
0.5BR 0.5BR
0.5G/Y
QWS THE R MO S W 0.5G/BX-21
B-2BODY-RH
B-19 BODY-LH
I-32 I-33I-32 I-32 I-33 I-33
847111213
12
B-36 B-36
B-36 B-3634
7
H-26
5W 3W
5W
3L/R
C-16
CLOCK, ROOM
10AC-19
25A
BLOWERC-20
10A A/C
0.5Y/B 0.5Y/B 0.5Y/B0.5R/W 0.3R/W0.5R/W 0.5R/W
0.5BR
0.5BR0.5L/B
0.3GR/W
2B
0.3GR/L
0.5BR
HEATER AND
A/C RELAY STARTER
SW (ACC)
P-1
P-5
P-2
P-7P-10P-6
5B
2L/B30B8B
8B/R
FL-1
80A MAIN
+
�ー
I-32
H-481.25B
0.5B
151.25B
I-33
7 21 14 12 2233 34 19 18 1714
I-49
4612
M
I-49 I-49 I-49
I-493
5
I-49
16
0.5L/O
0.5L/W
0.3L/R
0.3L/Y
0.3B/L
1.25B0.3B
0.5BR
C-25
I-3317I-3319
H-9
3L 2L/B
0.3BR 0.3BR
0.5BR
0.5BR
C-25
2 1 19
0.5G/W 0.5LGPRESSURE SW
INTAKE
ACTUATOR
MAX
HI
RELAY ELECTRONIC
THERMOSTAT
THERMO UNIT
H-141
I-502 0.5O/G
5W
0.3B
BODY ENG FRAME
H-167
3
H-4
E-23
1
H-9
ENGINE
0.5BR
3W/LFL-3
40A C/HEATER
2H-420.5G/Y
ECM(J1-23)
12
H-17
B-51
H-2614
I-501
B-5
2
I-50
3
15
H-48
4
H-48
MBLOWER
MOTOR
I-51
2
I-511
43I-51
I-51
AUTO A/C CONTROL UNIT
I-3212
11
H-48
D08RY00116

12
43
860RW026
C01RX016
M
N 3
2
7
6
8
98 43
65 21
7
Potentiometer
ConnectionPosition
Detection
Block Automatic Heater / Air
Conditioner Control Unit
Controller
Sliding Contact
Full Heat PositionTerminal PlateFull Cool PositionDriver
Cool Side Heat Side
C01RY00016
Full cool
Full cool0 0 0.5 1.0
50 100%
Aperture of air mix doorVoltage ratio VM/VDD
Full heat Full heat
VDD
VM +
–

DriverController
DEF side
VENT
side
Position
detection
block Control unit
Sliding
contact
Actuator side42
983
7
78910
HLHL
HHHL
HHLL
HHLH
HLLH
HLHH
LLHH
LHHH
LHLH 61
5
Interconnected
motor
VENTVENT
Mid point between VENT - B/L
B/L
Mid point between B/L - FOOT
FOOT
Mid point between FOOT - D/F
D/F
Mid point between D/F - DEF
DEFDEF
7
8
9
10 2 6
7
8
3
4
9
5
1
C01RX017
M
+6 1 2
65 4 3
REC
MIX
FRESH
Com1
2
5
3
4++
—
Terminal PlateAuto A/C
Control Unit (Actuator Side)
Driver Controller
Sliding Contact
Connected
C01RX006

CAUTION: If the center screw is threaded fully onto
the end of the compressor shaft. or if the body of
the installer is held and the center screw is rotated,
the key will wedge and will break the clutch hub.7. Remove installer J-33013-B, check for proper
positioning of the shaft key (even or slightly above
the clutch hub).
8. Spin the pulley rotor by hand to see that the rotor is
not rubbing the clutch drive plate.
COMPRESSOR CLUTCH ROTOR AND/OR
BEARING
Removal
1. Remove the clutch plate and hub assembly as
described previously.
2. Remove rotor (1) and bearing assembly retaining
ring (2), using snap ring pliers.
3. Install pulley rotor and bearing puller guide J-33023-A
to the front head and install J-41552 pulley rotor and
bearing puller down into the inner circle of slots (1) in
the rotor. Turn the J-41552 puller clockwise in the
slots in the rotor.4. Hold the J-41552 puller in place and tighten the
puller screw against the puller guide to remove the
pulley rotor and bearing assembly.
Installation
1. With the compressor mounted to the J-34992
holding fixture, position the rotor and bearing
assembly on the front head.
2. Position the J-33017 pulley, rotor and bearing
installer and J-33023-A puller pilot directly over the
inner race of the bearing.
1
2 J-33013-B
901RW002
1
2
901RW003
J-41552
1
871RW007

COMPRESSOR SHAFT SEAL
Service Precaution
When replacing the shaft seal assembly, pressure relief
valve or control switches, it will be necessary to recover
the refrigerant. Other than clutch repair procedures, the
same holds true for any disassembly of the compressor.
A clean workbench covered with a sheet of clean
paper, and a place (clean trays, etc) for all parts being
removed and replaced is important, as is the use of
proper clean service tools.
CAUTION: Any attempt to use makeshift or
inadequate service tools or equipment may result
in damage and/or improper compressor operation.
All parts required for servicing the internal compressor
are protected by a preservative process and packaged
in a manner which will eliminate the necessity of
cleaning, washing or flushing of the parts. The parts
can be used in the internal assembly just as they are
removed from the service package. Seals and
protective packaging should be left intact until just
prior to installation.
If the compressor rear head, front head or cylinder and
shaft assembly is to be serviced or replaced, the oil in
the compressor must be drained, measured, recorded
and replaced.
Legend
(1) Suction Port
(2) Discharge Port
(3) Mounting Boss
(4) Mounting Boss
(5) Pressure Relief Valve
(6) Mounting Boss
Seal Leak Detection
A shaft seal should not be changed because of small
amounts of oil found on an adjacent surface but only
after actual refrigerant leakage is found using an
approved leak detector.
CAUTION: Handling and care of seal protector is
important. If seal protector is nicked or the bottom
flared, the new seal may be damaged during
installation.
Removal
1. Recover the refrigerant using Refrigerant Recovery
System.
2. Loosen and reposition compressor in mounting
brackets, if necessary.
3. Remove clutch plate and hub assembly from
compressor as described previously.
4. Remove the shaft seal retainer ring, using snap ring
pliers.
5. Thoroughly clean inside of compressor neck area
surrounding the shaft, the exposed portion of the
seal, the retainer ring groove and the shaft itself.
Any dirt or foreign material getting into compressor
may cause damage.
6. Fully engage the knurled tangs of Seal Remover-
Installer J-23128-A into the recessed portion of the
Seal (1) by turning the handle clockwise. Remove
the Seal from the compressor with a rotary-pulling
motion.
Discard the seal. The handle must be hand-
tightened securely. Do not use a wrench or pliers.
1
2
3
456
871RW006
J-23128-A1
901RW008

7. Remove and discard the seal seat O-ring (2) from the
compressor neck using O-ring remover J-9553-01.
8. Recheck the shaft and inside of the compressor
neck for dirt or foreign material and be sure these
areas are perfectly clean before installing new parts.
Cleaning
Thoroughly clean O-ring seal groove in front head.
CAUTION: Seals should not be re-used. Always use
a new specification service seal on rebuild. Be sure
that the seal to be installed is not scratched or
damaged in anyway. Make sure that the seal seat
and seal are free of lint and dirt that could damage
the seal surface or prevent sealing.
Installation
1. Dip the new seal seat O-ring (1) in clean 525
viscosity refrigerant oil and assemble onto O-ring
installer J-33011.2. Insert the O-ring installer J-33011 into the
compressor neck until the installer "bottoms". Lower
the moveable slide of the O-ring installer to release
the O-ring into the seal O-ring lower groove (The
compressor neck top groove is for the shaft seal
retainer ring.) Rotate the installer to seat the O-ring
and remove the installer.
3. Dip the new seal in clean 525 viscosity refrigerant oil
and assemble seal to Seal Installer J-23128-A, by
turning handle clockwise. The stamped steel case
side of the lip seal must be engaged with knurled
tangs of installer so that flared-out side of lip seal is
facing and installed towards the compressor. Install
seal protector J-34614, in the seal lip and place over
the compressor shaft, and push the seal in place with
a rotary motion or place the seal protector J-34614
over end of compressor shaft, and slide the new seal
onto the shaft with a rotary motion until it stops. Take
care not to dislodge the O-ring. Be sure the seal (2)
makes good contact with the O-ring. Disengage the
installer from the seal and remove the installer
J-23128-A and the seal protector J-34614.
CAUTION: Handling and care of seal protector is
important. If seal protector is nicked or the bottom
flared, the new seal may be damaged during
installation.
4. Install the new seal retainer ring with its flat side
against the Seal, using Snap-Ring Pliers. Use the
sleeve from O-ring installer J-33011 to press in on
the seal retainer ring so that it snaps into its groove.
5. To leak test, install compressor leak test fixture
J-39893 on rear head of compressor and connect
gage charging lines and Refrigerant Recovery
System. Pressurize suction and high-side of
compressor with R-134a Refrigerant. Temporarily
install (M9
1.25 thread on shaft) nut and, with the
compressor in horizontal position, rotate the
compressor shaft in normal direction of rotation
several times by hand. Leak test the seal area and
correct and leak found. Recover the refrigerant.
Remove shaft nut.
2 J-9553-01
901RW009
1
J-33011
901RW010
J-34614
2
J-23128-A
901RW011

4A1–1 DIFFERENTIAL (FRONT)
DRIVELINE/AXLE
CONTENTS
Differential (Front) 4A1. . . . . . . . . . . . . . . . . . . . . . .
Differential (Rear/220mm) 4A2A. . . . . . . . . . . . . . . .
Differential (Rear/244mm) 4A2B. . . . . . . . . . . . . . . .
Driveline Control System (Shift on the Fly) 4B1. . Driveline Control System (TOD) 4B2. . . . . . . . . . .
Driveshaft System 4C. . . . . . . . . . . . . . . . . . . . . . .
Transfer Case (Standard Type) 4D1. . . . . . . . . . .
Transfer Case (TOD) 4D2. . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL (FRONT)
CONTENTS
Service Precaution 4A1–1. . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 4A1–2. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal 4A1–3. . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal and Associated Parts 4A1–3
Removal 4A1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A1–4. . . . . . . . . . . . . . . . . .
Installation 4A1–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle Assembly 4A1–5. . . . . . . . . . . . . . .
Front Drive Axle Assembly and
Associated Parts 4A1–5. . . . . . . . . . . . . . . . . . . . . .
Removal 4A1–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A1–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A1–9. . . . . . . . . . . . . . . . . . . .
Disassembled View 4A1–9. . . . . . . . . . . . . . . . . . . .
Disassembly 4A1–10. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A1–12. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A1–21. . . . . . . . . . . . . . .
Disassembled View 4A1–21. . . . . . . . . . . . . . . . . . . .
Disassembly 4A1–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A1–22. . . . . . . . . . . . . . . . . .
Reassembly 4A1–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A1–25. . . . . . . . . . .
Special Tools 4A1–28. . . . . . . . . . . . . . . . . . . . . . . . . .
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 REFORMING 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 specification. Following these
instructions can help you avoid damage to parts and
systems.

DIFFERENTIAL (FRONT) 4A1–6
3. Remove the drain bolt to drain differential oil.
NOTE:
a. During the work, be sure that the diff case is
supported by the jack.
412RS003
b. Remove the brake caliper fixing bolt and hang the
caliper. Refer to Front Disc Brake Caliper Assembly
in Brake section.
c. Remove the antilock brake system speed sensor (if
equipped). Refer to Front Wheel Speed Sensor in
Brakes section.
4. Remove the hub assembly (Disc, back plate and
knuckle), refer to Front Hub and Disc in this section.
5. Disconnect the knuckle and the suspension arm.
Refer to Suspension section.
6. Remove steering link and arm assembly, refer to
Steering Linkage in Steering section.
7. Remove suspension crossmember.
8. Remove propeller shaft, refer to Front Propeller Shaft
in this section.
9. Remove protector (Shift on the fly model).
10. Remove the hose clip.
11. Disconnect breather hose from front drive axle tube.
(and disconnect housing : Shift on the fly model).
12. Disconnect vacuum hose from actuator (Shift on the
fly model).13. Disconnect shift switch connector (Shift on the fly
model).
412RS031
14. Remove VSV assembly (1) (Shift on the fly model).
NOTE: Be sure not to remove hose and connector from
VSV asm.
412RW002