1999 OPEL FRONTERA Service and Repair Manual

WORKSHOP MANUAL US VERSION RIGHT HAND MODEL EXP UBS PubNo. RV99_02-01.E

WORKSHOP MANUAL 1999 Frontera (UE) 2000 Frontera (UE) 2001 Frontera (UE)

SECTION TABLE OF CONTENTS GENERAL INFORMATION 0A General Information 0B Maintenance and Lubrication WORKSHOP MANUAL HEATING, VENTILATION AND AIR CONDITIONING 1A HVAC System STEERING 2A Power-Assisted System FRONTERA (UE) SUSPENSION 3C Front Suspension 3D Rear Suspension 3E Wheel and Tire System DRIVELINE/AXLE 4A1 Differential (Front) 4A2 Differential (Rear) 4B Driveline Control System 4C Drive Shaft System 4D Transfer Case FOREWORD This manual includes special notes, important points, service data, precautions, etc. That are needed for the maintenance, adjustments, service, removal and installation of vehicle components. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. All rights are reserved to make changes at any time without notice. Arrangement of the material is shown in the table of contents on the right-hand side of this page. A black spot on the first page of each section can be seen on the edge of the book below each section title. These point to a more detailed table of contents preceding each section. BRAKE 5A Brake Control System 5B Anti-Lock Brake System 5C Power-Assisted Brake System 5D Parking Brake System HEC 6VD1 ENGINE 6A 6A Engine Mechanical 6B 6B Engine Cooling 6C 6C Engine Fuel 6D1 6D1 Engine Electrical 6D2 6D2 Ignition System 6D3 6D3 Starting and Charging System 6E1 6E2 Driveability and Emissions 6F 6F Engine Exhaust 6G 6G Engine Lubrication 6H 6H Engine Speed Control System 6J 6J Induction TRANSMISSION 7A Automatic Transmission 7A1 Transmission Control System 7B Manual Transmission 7C Clutch This manual applies to 1999 models. BODY AND ACCESSORIES 8A Lighting System 8B Wiper/Washer System 8C Entertainment 8D Wiring System 8E Meter and Gauge 8F Body Structure 8G Seats 8H Security and Locks 8I Sun Roof/Convertible Top 8J Exterior/Interior Trim RESTRAINTS 9A Seat Belt System 9J Supplemental Restraint System (Air Bag System) 9J1 Restraint Control System CONTROL SYSTEM 10A Cruise Control System

GENERAL INFORMATION 0A–1 GENERAL INFORMATION CONTENTS General Information ....................................... 0A - 1 Meintenance and Lubrication......................... 0B - 1 GENERAL INFORMATION CONTENTS General Repair Instruction ............................. 0A - 1 Illustration Arrows .......................................... 0A - 2 Identification................................................... 0A - 3 Lifting Instructions .......................................... 0A - 5 Standard Bolts Torque Specifications............ 0A - 8 Abbreviations Charts ..................................... 0A - 9 Service Parts Identification Plate ................... 0A - 11 General Repair Instruction 1. If a floor jack is used, the following precautions are recommended. Park vehicle on level ground, “block" front or rear wheels, set jack against the recommended lifting points (see “Lifting Instructions" in this section), raise vehicle and support with chassis stands and then perform the service operations. 2. Before performing service operations, disconnect ground cable from the battery to reduce the chance of cable damage and burning due to short circuiting. 3. Use a cover on body, seats and floor to protect them against damage and contamination. 4. Brake fluid and anti–freeze solution must be handled with reasonable care, as they can cause paint damage. 5. The use of proper tools and recommended essential and available tools, where specified, is important for efficient and reliable performance of service repairs. 6. Use genuine Isuzu parts. 7. Used cotter pins, plastic clips, gaskets, O–rings, oil seals, lock washers and self–locking nuts should be discarded and new ones should be installed, as normal function of the parts cannot be maintained if these parts are reused. 8. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nuts separate is very important, as they vary in hardness and design depending on position of installation. 9. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air, and make certain they are free from restrictions. 10. Lubricate rotating and sliding faces of the parts with oil or grease before installation. 11. When necessary, use a sealer on gaskets to prevent leakage. 12. Carefully observe all specifications for bolt and nut torques. 13. When removing or replacing parts that require refrigerant to be discharged from the air conditioning system, be sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle Refrigerant–134a. 14. When a service operation is completed, make a final check to be sure the service has been done properly and the problem has been corrected. 15. SUPPLEMENTAL RESTRAINT SYSTEM The vehicle is equipped with a Supplemental Restraint System (SRS) – Air Bags. This system is not to be serviced without consulting the appropriate service information. Consult Section 9J “SRS System" if work is to be done on the front of the vehicle such as bumper, sheet metal, seats, wiring, steering wheel or column. Also review SRS system information if any arc welding is to be done on the vehicle. The SRS system equipped vehicle can be identified by: 1. “AIR BAG" warning light on the instrument cluster. 2. A Code “J" for fifth digit of Vehicle Identification Number.

0A–2 GENERAL INFORMATION Illustration Arrows Arrows are designed for specific purposes to aid your understanding of technical illustrations. Arrow Type Application Front of vehicle Up Side Task Related View Detail View Angle Dimension (1:2) Sectioning (1:3) • Ambient/Clean air flow • Cool air flow • Gas other than ambient air • Hot air flow • Ambient air mixed with another gas • Can indicate temperature change Motion or direction Lubrication point oil or fluid Lubrication point grease Lubrication point jelly Arrow Type Application

GENERAL INFORMATION 0A–3 Identification Vehicle Identification Number (VIN) This is the legal identification of the vehicle. it is located on the left bottom of the windshield. It can be easily seen through the windshield from outside the vehicle. F00RX018 F00RX017

0A–4 GENERAL INFORMATION Engine Serial Number • 6VD1 Engine The gasoline engine serial number is stamped on the left rear lower area of the cylinder block above the starter. F06RW001 • X22SE Engine The gasoline engine serial number is stamped on the rear end raised area of the cylinder block left side. 035RW022 Transmission Serial Number Manual : Stamped on the left side of the transmission intermediate plate. 220RS025 Automatic : Stamped on the identification plate, located on the left side of the transmission above the mode switch. 240RW019

GENERAL INFORMATION 0A–5 Lifting Instructions Lifting Points and Supportable Point Locations 4 Door Model C00RX002

0A–6 GENERAL INFORMATION 2 Door Model C00RX001 Lifting Point: Front • When using a floor jack, lift on the Convex portion of the skid plate. 545RS001 Supportable Point: Front • Position the chassis stands at the bottom of the frame sidemember, behind the front wheel. 501RS003

GENERAL INFORMATION 0A–7 Lifting Point: Rear • Position the floor jack at the center of the rear axle case when lifting the vehicle. 420RS002 Supportable Point: Rear • Position the chassis stands at the bottom of the frame sidemember, just behind the trailing link bracket. 501RW002 Legend EndOFCallout Supportable Point: Rear • Position the chassis stands at the bottom of the rear axle case. 420RS001 (1) Trailing Link Bracket

1999 OPEL FRONTERA Service and Repair Manual

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