torque OPEL FRONTERA 1998 Workshop Manual

6G–10
ENGINE LUBRICATION
Oil Pump
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankcase assembly.
Refer to removal procedure for Oil Pan and
Crankcase in this manual.
4. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
5. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
6. Remove timing pulley from crankshaft.
7. Remove four fixing bolts from oil filter assembly.
8. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
9. Remove three bolts from oil pipe and O-ring.
10. Remove eight oil pump fixing bolts, then oil pump
assembly.
11. Remove sealant from mounting surface of oil pump
assembly, cylinder block and take care not to damage
mounting surfaces of oil pump and cylinder block.
Installation
1. Install oil pump assembly
Apply sealant (TB-1207B or equivalent) to the oil
pump mounting surfaces as shown in the
illustration.
The oil pump assembly must be installed within 5
minutes after sealant application before the sealant
hardens.
NOTE: Do not apply sealant to the oil ports.
051RW002
Use 5–8840–2287–0 installer when installing new
oil seal.
Apply engine oil to oil seal lip.
Install oil pump assembly to the cylinder block.
NOTE: Do not damage oil seal during installation of oil
pump assembly.
015RS001
Tighten fixing bolts to the specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
051RW001
2. Install oil pipe with O-ring, tighten fixing bolt to the
specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
3. Install oil strainer with O-ring, tighten fixing bolt to the
specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)

6G–11 ENGINE LUBRICATION
4. Install oil filter assembly and tighten bolts to the
specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
5. Install timing pulley on crankshaft.
Install timing belt.
Refer to installation procedure for Timing Belt in this
manual.
6. Install crankshaft pulley.
Refer to install procedure for Crankshaft Pulley in
this manual.
7. Install crankcase assembly.
Refer to installation procedure for Oil Pan and
Crankcase in this manual.
8. Refill engine oil until full level on engine oil dipstick.

6G–14
ENGINE LUBRICATION
Main Data and Specification
General Specification
ItemSpecificationsItem6VD16VE1
Oil capacity5.3 liters
Torque Specifications
Crankcase, Oil pan, Timing belt tensioner, Timing
pulley, timing belt cover, Oil pump, Oil gallery, Oil
strainer Nꞏm (Kgꞏm/lb ft)
E06RW045

6H–1 ENGINE SPEED CONTROL SYSTEM
ENGINE
ENGINE SPEED CONTROL SYSTEM
CONTENTS
Service Precaution 6H–1. . . . . . . . . . . . . . . . . . . . . .
Accelerator Pedal Control Cable 6H–2. . . . . . . . . .
Removal 6H–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6H–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6H–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 6H–2. . . . . . . . . . . . . . . . . . . . . . . . . . . Accelerator Pedal 6H–3. . . . . . . . . . . . . . . . . . . . . . .
Accelerator Pedal and Associated Parts 6H–3. .
Removal 6H–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6H–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 6H–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

INDUCTION6J–1
ENGINE
INDUCTION
CONTENTS
Service Precaution 6J–1. . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Element 6J–2. . . . . . . . . . . . . . . . . . . . .
Removal 6J–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6J–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6J–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

ENGINE MECHANICAL 6A – 1
ENGINE
ENGINE MECHANICAL
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . 6A–2
Service Information . . . . . . . . . . . . . . . . . . . . 6A–3
Service Standard . . . . . . . . . . . . . . . . . . . . . . 6A–6
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–9
Tightening Torque . . . . . . . . . . . . . . . . . . . . . 6A–14
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 6A–25
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . 6A–28
Engine Mount (RH) . . . . . . . . . . . . . . . . . . . . 6A–30
Engine Mount (LH). . . . . . . . . . . . . . . . . . . . . 6A–31
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–32
Cylinder Head Cover . . . . . . . . . . . . . . . . . . . 6A–33
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 6A–35
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . 6A–36
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . 6A–38Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 6A–41
Cylinder Head Gasket . . . . . . . . . . . . . . . . . . 6A–43
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–47
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–52
Valve Stem Seal, Valve Spring and Adjuster . . 6A–60
Valve Clearance Adjustment. . . . . . . . . . . . . . 6A–67
Oil Rail and Injector . . . . . . . . . . . . . . . . . . . . 6A–69
Crank Case . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–72
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–74
Piston and Connecting Rod . . . . . . . . . . . . . . 6A–84
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . 6A–92
Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . 6A–98
Oil Filter Cartridge . . . . . . . . . . . . . . . . . . . . . 6A–99
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–99

6A – 4 ENGINE MECHANICAL
Engine Cooling
Starting System
Cooling system Coolant forced circulation
Radiator (2 tube in row) Tube type corrugated
Heat radiation capacity J/h (kcal/h) 318 x 10
6(76000)
Heat radiation area m
2(ft2) 15.63 (1.454)
Front area m
2(ft2) 0.309 (2.029)
Dry weight N (kg/lb) 83 (8.5/18.7)
Radiator cap
Valve opening pressure kPa (kg/cm
2/ psi) 93.3 – 122.7 (0.95 – 1.25/13.5 – 17.8)
Coolant capacity lit (Imp.qt./US qt.) M/T 2.5 (2.2/2.6) A/T 2.4 (2.1/2.5)
Coolant pump Centrifugal impeller type
Pulley ratio (to 1) 1.2
Coolant total capacity lit (Imp.qt./US qt.) 9.3 (8.2/9.8)
Model HITACHI S14-0
Rating
Vo l t a ge V 1 2
Output kW 2.8
Time sec 30
Number of teeth of pinion 9
Rotating direction (as viewed from pinion) Clockwise
Weight (approx.) N(kg/lb) 49 (5.0/11)
No-load characteristics
Voltage/current V/A 11/160 or less
Speed rpm 4000 or more
Load characteristics
Voltage/current V/A 8.76/300
Torque Nꞏm(kgꞏm/lbꞏft) 7.4 (0.75/5.4) or more
Speed rpm 1700 or more
Locking characteristics
Voltage/current V/A 2.5/1100 or less
Torque Nꞏm(kgꞏm/lbꞏft) 18.6 (1.9/14) or more

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 – 19
Injector
Nꞏm (kgꞏm/lbꞏft)
E06R200022
With
spacer type
Without
spacer type
20Nꞏm(2.0kgꞏm/14 Ib ft)
7Nꞏm(0.7kgꞏm/61 Ib in)
Recheck tightening torque
after tighten the oil rail
Apply engine oil on the
thread of stud bolts
20Nꞏm(2.0kgꞏm/14 Ib ft)
Tighten 30Nꞏm(3.1kgꞏm/22 Ib ft)
Then loosen it again tighten with
24Nꞏm(2.4kgꞏm/17 Ib ft)
Apply engine oil
both side

ENGINE MECHANICAL 6A – 29
13 Vacuum Hose
1) Disconnect vacuum hose from vacuum pump.
14. Starter Harness
1) Disconnect B terminal and put cable harness
close to chassis side.
2) Disconnect S terminal connector.
15. Engine Harness
1) Disconnect engine harness close to engine side.
16. Fuel Pipe
1) Remove fuel pipe from fuel pump and take care
not to spill fuel and let dust enter.
17. Engine Ground Cable
1) Disconnect ground cable from left rear side of
timing gear case.
18. Vacuum Hose: Vacuum Tank
Disconnect vacuum hose from vacuum pump side.
19. Glow Plug Harness
20. Transmission Assembly
1) Set transmission support tool under the
transmission.
2) Remove transmission rear mount.
3) Remove transmission fixing bolt from rear of
engine assembly except two bolts.
4) Carefully hang up engine assembly with a hoist.
5) Remove remaining two transmission fixing bolts.
6) Remove transmission assembly.
7) Remove heater hose.
8) Disconnect wire harness connector for shift on
the fly.
9) Remove vacuum hose.
21. Prepare Engine Stand
22. Engine Assembly
1) Remove engine mount fixing bolts.
2) Carefully hang up the engine assembly.
3) Take out the engine assembly making sure not
to damage the brake oil pipe and other pipe etc.
INSTALLATION
1. Engine assembly
1) Install engine in mounting position by using
hoist.
2. Transmission Assembly
1) Refer to transmission installation steps in
section 7.
3. Engine Mounting
1) After all fixing bolts (left: two bolts, rights: two
bolts) were inserted in every hole, tighten fixing
bolts to the specified torque.
Torque: 40 Nꞏm (4 kgꞏm/29 lbꞏft)
4. Glow Plug Harness
5. Vacuum Hose
1) Connect Vacuum Hose to Vacuum Pump
6. Engine Ground Cable
7. Fuel Pipe
1) Install fuel pipe to fuel pump.
8. Engine Harness
9. Starter Harness
10. A/C Compressor Assembly
1) Tighten temporarily the fixing bolts (upper and
front lower sides of compressor.)2) Tighten fixing bolt (rear under side of
compressor) to the specified torque.
3) Tighten fixing bolts (front upper and lower sides
of compressor) to the specified torque.
To r q u e : 4 0 N ꞏm ( 4 k g ꞏm / 2 9 l b ꞏf t )
Legend
(1) Tensioner
(2) Bolt
(3) Bracket
(4) A/C compressor
(5) Bolt
11. A.C Generator Harness
12. Engine Ground Cable
1) Tighten ground cable to A/C compressor
bracket.
13. Air Cleaner cover & Duct
14. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
15. Radiator Assembly
1) Install rubber cushion in under left and right part
of radiator and position radiator.
2) Fix radiator with bracket.
16. Cooling Fan Assembly
1) Install cooling fan assembly and tighten fixing
bolts to the specified torque.
Torque: 8 Nꞏm (0.8 kgꞏm/5.8 lb ft)
17. Fan Shroud
18. Radiator Hose
1) Connect upper and lower hose to engine side.
2) Pour coolant into radiator.
19. Install battery.
20. Connect window washer hose and install engine
hood.
1
2
3
4
5
For E urope
F06R200005