engine OPEL FRONTERA 1998 Workshop Manual

6A – 12 ENGINE MECHANICAL
Drive Belt Adjustment
Check the drive belt tension
Depress the drive belt mid-portion with a 98 N (10 kg/
22 lb) force.
Drive Belt Deflection: 10 mm (0.39 in)
Check the drive belt for cracking and other damage.
Legend
(1) Crankshaft pulley
(2) Generator pulley
(3) Cooling fan pulley
(4) A/C compressor pulley
(5) Belt tensioner pulley
Cooling Fan Pulley Drive Belt
Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98 N (10 kg/
22 lb) force.Legend
(1) Crankshaft pulley
(2) Generator pulley
(3) Cooling fan pulley
Compressor Pulley Drive Belt
Move the tensioner pulley as required to adjust the
compressor drive belt tension.
Depress the drive belt mid-portion with a 98 N (10 kg/
22 lb) force.
Legend
(1) Crankshaft pulley
(2) Generator pulley
(3) Cooling fan pulley
(4) A/C compressor pulley
(5) Belt tensioner pulley
5
3
24
1
012RW110
3
2
1
012RW084
5
3
24
1
012RW110

ENGINE MECHANICAL 6A – 13
VALVE CLEARANCE ADJUSTMENT
1. Install 2.80 mm valve adjuster (shim) first when
reassembling the engine.
Thickness mark faces down.
2. Measure the valve clearance after installing cam
carrier assy with camshafts.
3. Change the adjuster using a special tool when the
clearance is out of tolerance.
Valve Clearance Adjusting Tool: 5-8840-2590-0
VALVE CLEARANCE (When cold condition)
Inlet 0.15 ± 0.05 mm
Exh 0.25 ± 0.05 mm
COMPRESSION PRESSURE
MEASUREMENT
1. Start the engine and allow it to idle until the coolant
temperature reaches 70 – 80°C (158 – 176°F).
2. Remove the following parts.
Glow plugs
Fuel cut solenoid connector
QOS (Quick-On Start System) fuse in the fuse
box.
3. Set the adapter and compression gauge to the No.
1 cylinder glow plug hole.
Compression Gauge
(with Adapter): 5-8840-2008-0
4. Turn the engine over with the starter motor and take
the compression gauge reading.
Compression Pressure at 200 rpm
Standard: 3038 kPa (31 kg/cm
2/441 psi)
Limit: 2157 kPa (22 kg/cm
2/313 psi)
5. Repeat the procedure (Steps 3 and 4) for the
remaining cylinders.
QUICK-ON START 4 SYSTEM
Quick-On Start System Inspection Procedure
1. Disconnect the ECT-sensor connection around the
thermostat outlet pipe.
2. Turn the starter switch to the “ON” position.
If the Quick-On Start 4 System is operating
properly, the glow relay will make a clicking sound
within seven seconds after the starter switch is
turned on.
3. Measure the glow plug terminal voltage with a
circuit tester immediately after turning the starter
switch to the “ON” position.
Glow Plug Terminal Voltage: 8 – 9V
NOTE: Electrical power to the quick-on start system will
be cut after the starter has remained in the “ON”
position for twenty seconds.
Turn the starter switch to the “OFF” position and back
to the “ON” position.
This will reset the Quick-On Start 4 System.
014RW150

6A – 14 ENGINE MECHANICAL
TIGHTENING TORQUE
Timing Gear Case, Timing Gear
Nꞏm (kgꞏm/lbꞏft)
75(7.6/55)
Apply engine oil to
thread and seat 8(0.8/6)
20(2.0/14.5)
51(5.2/38)
25(2.5/18)
020RW00001

ENGINE MECHANICAL 6A – 15
Cylinder Head, Flywheel, Crank Case, Oil Pan
Nꞏm (kgꞏm/lbꞏft)
012RW121
1st
49N•m(5.0kg•m/36 Ib ft)
167(17.0/123)
8(0.8/5.8)
20(2.0/14.5)
20(2.0/14.5)
30(3.1/22)
25(2.5/18)
2nd
60
1st
59N•m(6kg•m/43 Ib ft)
2nd
60-90
1st
29N•m(3.0kg•m/22 Ib ft)
2nd
45-60
3rd
60
19(1.9/14)

6A – 16 ENGINE MECHANICAL
Timing Pulley
Nꞏm (kgꞏm/lbꞏft)
020RW024
20(2.0/14.5)
40(4/29) 60
-90
1st 2nd
10(1.0/7.2)
20(2.0/14.5)
50(5.1/37)
20(2.0/14.5)
9(0.9/6.5)
9(0.9/6.5)

ENGINE MECHANICAL 6A – 17
Engine Electricals
Nꞏm (kgꞏm/lbꞏft)
025RW026
20(2.0/14.5)
13(1.3/9.4)
9(0.9/6.5)
30(3.1/22) 19(1.9/14)
4(0.4/3.0)
20(2.0/14.5)

6A – 18 ENGINE MECHANICAL
Injector
Nꞏm (kgꞏm/lbꞏft)
011RX003
20Nꞏm(2.0kgꞏm/14.5 Ib ft)
6.5Nꞏm(0.7kgꞏm/5.0 Ib ft)
Recheck tightening torque
after tighten the oil rail
Apply engine oil on the
thread of stud bolts
20Nꞏm(2.0kgꞏm/14.5 Ib ft)
Tighten 30Nꞏm(3.1kgꞏm/22 Ib ft)
Then loosen it again tighten with
25Nꞏm(2.4kgꞏm/17 Ib ft)
Apply engine oil
both side

ENGINE MECHANICAL 6A – 19
High Pressure Oil Pipe
Nꞏm (kgꞏm/lbꞏft)
80(8.1/57.9)
80(8.1/57.9)
80(8.1/57.9)
80(8.1/57.9)
040RW016

6A – 20 ENGINE MECHANICAL
Air Duct and Intercooler
Nꞏm (kgꞏm/lbꞏft)
4.0(0.4/3)4.0(0.4/3)
3.0(0.3/2.2) 20(2.0/14.5)
036RW013

ENGINE MECHANICAL 6A – 21
Engine Mount Bracket
Nꞏm (kgꞏm/lbꞏft)
50(5.1/37)
50(5.1/37)127(13/94)
127(13/94)
40(4/29)
40(4/29)
40(4/29)
022RW019