1998 OPEL FRONTERA engine

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THIS MALUAL INCLUDES THE FOLLOWING SECTIONS:
6VD1 / 6VE1
SECTION No. CONTRNTS
6A ENGINE MECHANICAL
6B ENGINE COOLING
6C ENGINE FUEL
6D1 ENGINE ELECTRICAL
6D2 IGNITION SYSTEM
6D3 STARTING AND CHARGING SYSTEM
6E ENGINE DRIVEABILITY AND EMISSIONS
6F ENGINE EXHAUST
6G ENGINE LUBRICATION
6H ENGINE SPEED CONTROL SYSTEM
6J INDUCTION
HOME
6A
6B
6C
6D1
6D2
6D3
6E
6F
6G
6H
6J

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4JG2
4JX1 SECTION No. CONTRNTS
00 SERVICE INFORMATION
6A ENGINE MECHANICAL
6A2 4JG2-NA / 4JG2-TURBO ENGINE
6B ENGINE COOLING
6C FUEL SYSTEM
6D ENGINE ELECTRICAL
6E -
6F EXHAUST
6G -
SECTION No. CONTRNTS
6A ENGINE MECHANICAL
6B ENGINE COOLING
6C ENGINE FUEL
6D ENGINE ELECTRICAL
6E ENGINE DRIVEABILITY AND EMISSIONS
6F ENGINE EXHAUST
6G ENGINE LUBRICATION
6H ENGINE SPEED CONTROL
6J INDUCTION
HOME
00
6A
6A2
6B
6C
6D
6E
6F
6G
6A
6B
6C
6D
6E
6F
6G
6H
6J

D08RY00133
ECM
(J2-11)
0.5 L/P 0.5 L/P
I-25
I-25
3
I-25 2
I-25 6
I-25
5
4
1H-1614
0.3R/G0.85G/R 0.85G/R
ILLUMINATION
CONTROLLER TAIL RELAY(4)
ENGINE
WARMING
SW
1.25B 0.5B
C-74C-741 2THERMO SWH-919
0.5G/W 0.5G/W
0.5 L/P
0.5G/B
H-265
H-4216
H-52
0.5B
H-1615

D08RY00135
ECM
(J2-11)
0.5 L/P
I-25
I-25
3
I-25 2
I-25 6
I-25
5
4
1H-166
0.3R/G0.85G/R 0.85G/R
ILLUMINATION
CONTROLLER TAIL RELAY(4)
ENGINE
WARMING
SW
1.25B 0.5B
C-74C-741 2THERMO SWH-2417
0.5G/W 0.5G/W
0.5 L/P
0.5G/B
H-2516
H-4216
H-52
0.5B
H-1615

X-2124
13X-21
X-21 THERMO SW RELAY
0.5BR 0.5BR
0.5G/Y
QWS THER MO SW 0.5G/BX-21
B-2BODY-RH
B-19 BODY-LH
I-32 I-33I-32 I-32 I-33 I-33847111213
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

FULL AUTO display
INTAKE indication
(LED)
(switching between
fresh and interior air)
MODE indication
(LED) (Blow port)
AC display (LED)
FAN indication (LED)
FAN KNOB
AUTO SET
REC FRESH SWITCH
TEMP LEVER
(temperature control)
MODE SWITCH
(blow port selection)
AC SWITCH
IN CAR SENSOR
AMBIENT SENSOR
SUN SENSOR
DUCT SENSOR
MIX ACTUATOR
POTENTIOMETER
MODE ACTUATOR
POTENTIOMETER
AIR MIX DOOR
MODE DOOR
INTAKE ACTUATOR
RECINTAKE DOOR
FAN MOTORPOWER
TRANSISTOR
AUTOMATIC HEATER/AIR CONDITIONER CONTROL UNIT (with the built-in micro-computer)
MAX HI RELAY
PRESSURE
SWITCHAIR CONDITIONER
THERMO RELAY
COMPRESSOR
SWITCH MAGNET
CLUTCH
PCM
PRESSURE
SWITCHAIR CONDITIONER
THERMO RELAYMAGNET
CLUTCH
(4JX1engine)
MIX FRESH
F01RY00009

I-32
C-1C-3I-33
E-3E-19B-19C-25
A 2
B-361
H-14
C-19
25A
BLOWER
MOTOR
C-20
10A
A/C FL-1
80A
MAIN
Heater
Relay
1B-3610
H-13
0.3
B 0.85
W/G0.85
W/R
3.0
W
3.0
L/R
0.5
BR
1.25
B
B-19
BODY-LH3
B-36
4B-36
BATT.(+)
Blower
MotorIntake
Actuator STARTER
RELAY(1)
0.5
LG 0.5
BR0.5
BR
0.5
G/W
0.5
P/G0.5
P/G0.5
G/O
0.5
G/O
PCM
(C3-E15)
31 13
COMP-F/B 70.5
BR
0.5
BR/Y 0.3
G/B0.5
G/B0.5
BR/Y 0.5
BR
Triple
Pressure
Switch0.5
BR
A
A/C
Thermo Relay
Auto A/C Control Unit
3X-5
16
H-1617H-16
14
I-3218I-33
1X-5
13H-24
12
H-41
2 1
C-25
C-25
4X-5X-5 2
X-57
H-16
A/C
Compressor
Relay
Magnetic
clutch
1X-7
3X-74X-72
X-7
PCM
(C-1-B14)
E-39
1
H-67
H-41
5
H-41
Engine
Coolant
Temperature
Sensor
ENGINE COOLANT
TEMPERATURE GAUGE
0.5
Y/B
0.5
Y/B
0.5
Y/B
E-1911
1
H-61
H-24
I-334
B-36X-5X-7
H-14H-16
H-24
H-13
H-6H-41
6H-41
D08RY00182

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)