engine OPEL FRONTERA 1998 Workshop Manual

ENGINE LUBRICATION 6G – 1
ENGINE LUBRICATION
CONTENTS
General Description . . . . . . . . . . . . . . . . . . 6G–2
Lubrication Chart . . . . . . . . . . . . . . . . . . 6G–2
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . 6G–3
Oil Pump Specification . . . . . . . . . . . . . . 6G–3
Oil Filter Specification . . . . . . . . . . . . . . . 6G–3
Sub Oil Filter Specification . . . . . . . . . . . 6G–4Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–5
Oil Cooler Assembly . . . . . . . . . . . . . . . . . . 6G–6
Oil Cooler Specification . . . . . . . . . . . . . . 6G–6
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–6
Sub Oil Filter . . . . . . . . . . . . . . . . . . . . . 6G–6

6G – 2 ENGINE LUBRICATION
GENERAL DESCRIPTION
LUBRICATION CHART
P
33
32
31
30
1
2
3
4
56
8
97
10
11
12
13
14 23 29
25
28
27262415
16
17 18
19 20 21 22
Legend
(1) Camshaft
(2) Balance Shaft
(3) Crankshaft
(4) Oil Cooler and Oil Filter Assembly
(5) Oil Filter Relief Valve 98 Kpa (1 kg/cm
2/14.2 Psi)
(6) Oil Cooler Relief Valve 245 Kpa (2.5 kg/cm2/
36 Psi)
(7) First Oil Pump
(8) Main Oil Relief Valve 588 Kpa (6 kg/cm
2/ 85 Psi)
(9) To Oil Pan
(10) To Oil Pan
(11) Injector
(12) Oil Rail(13) Sub Oil Filter Relief Valve 98 Kpa (1 kg/cm
2/
14.2 Psi)
(14) Sub Oil Filter
(15) Relief Valve 588 Kpa (6 kg/cm
2/ 85 Psi)
(16) Second Oil Pump
(17) Oil Pan
(18) To Oil Pan
(19) Balance Shaft
(20) Cooling Jet Relief Valve 245 Kpa (2.5 kg/cm
2/
36 Psi)
(21) Cooling Jet
(22) To Oil Pan
(23) Two Way Check Valve
(24) Nipple Filter
040RW018

ENGINE LUBRICATION 6G – 3
To meet a newly adopted electronically controlled fuel
injection system using engine oil two oil pumps have
been provided to increase circulating oil capacity.
The first oil pump serves mainly to lubricate the engine
parts, while the second mainly serves the fuel injectors
and partially cools the pistons.
The oil cooler is provided on the first oil pump side and
uses engine coolant.
OIL FLOW
Legend
(1) Oil Pump
(2) Regulator Valve
(3) Oil Cooler
(4) Oil Filter Relief Valve
(5) Full Flow Filter
(6) Oil Cooler Relief Valve
(7) Gallery
OIL PUMP SPECIFICATIONS
OIL FILTER SPECIFICATIONS
Legend
(1) Oil cooler assembly
(2) Oil filter assembly (25) Edge Filter
(26) Edge Filter
(27) High Pressure Oil Pump Assembly
(28) To Oil Pan
(29) Pressure Control Valve(30) To Oil Pan
(31) Turbocharger
(32) Oil Gallery
(33) Timing Gear Train
17 65 4
3
2
050RW010
1
2
050RW009

6G – 4 ENGINE LUBRICATION
SUB OIL FILTER SPECIFICATIONS
The sub oil filter requires no servicing until the
replacement interval is reached.
The element is designed to provide special filtering
efficiency until it becomes due for replacement.
It is recommended to check and replace the sub filter
when the engine is being overhauled or if it is broken
inside the engine.
442RW004

ENGINE LUBRICATION 6G – 5
OIL PUMP
REMOVAL
1. Remove battery ground cable.
2 Raise the vehicle and support with suitable safety
stand.
3. Drain engine oil.
4. Remove flywheel assembly.
5. Remove rear plate (For A/T) or flywheel housing
(For MT).
6. Remove first oil pump assembly from cylinder block
and second oil pump assembly from crank case.
INSPECTION AND REPAIR
1. Inspect flaws and/or wear on the teeth surface.
2. Inspect abnormal wear journal on the gear and in
the drive spline.
3. If problem is found during inspection, the worn parts
must be replaced.
INSTALLATION
1. Install first oil pump.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
2. Install second oil pump.
Torque: 20 Nꞏm (2ꞏ0 kg.m / 14.5 lb ft)
2
1
5
6
3
4
Legend
(1) Flywheel
(2) Rear Plate
(3) First Oil Pump(4) Second Oil Pump
(5) O-ring (For 1st oil pump)
(6) O-ring (For 2nd oil pump)
012RW097

6G – 6 ENGINE LUBRICATION
OIL COOLER ASSEMBLY
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove front exhaust pipe.
4. Remove heat protector.
5. Remove exhaust valve assembly.
6. Oil cooler assembly.
1) Remove water hose from water inlet and outlet
side.
2) Cloth should be put under the oil cooler to
prevent oil from flowing out.
3) Loosen fixing bolt then remove oil cooler
assembly.
Legend
(1) Oil cooler assembly
(2) Oil filter assembly
INSPECTION AND REPAIR
1. Inspect for corrosion, wear, and breaks on the oil
cooler core.
2. If a problem is found on the oil cooler core, the oil
cooler assembly must be replaced.
INSTALLATION
1. Oil cooler assembly
1) Tighten oil cooler fixing bolt to the specified
torque and install water hoses.
Torque: 29 Nꞏm (3.0 kgꞏm / 21.7 lb ft)
2. Install exhaust valve assembly to turbocharger
assembly and tighten to the specified torque.
Torque: 27 Nꞏm (2.7 kgꞏm / 19.5 lb ft)3. Install front exhaust pipe to the exhaust valve.
To r q u e :
67 Nꞏm (6.8 kgꞏ.m / 49.2 lb ft)
(At exhaust valve side)
43 Nꞏm (4.4 kgꞏm / 32 lb ft)
(At center exhaust pipe side)
4. Install heater protector.
5. Fill engine coolant.
6. Connect battery ground cable.
7. Start engine and carefully check for leakage of oil
and coolant.
OIL COOLER SPECIFICATIONS
OIL FILTER
REMOVAL
1. Put container under the oil filter to prevent oil from
the oil filter from flowing out.
2. Use filter wrench to remove oil filter.
Filter wrench: 5-8840-0203-0
INSTALLATION
1. Apply engine oil thinly to oil filter O-ring.
2. Tighten oil filter by hand until O-ring comes in
contact with the sealing surface.
3. Use filter wrench to tighten oil filter one turn and 1/8
turn.
4. Start engine and carefully check for oil leakage from
oil filter.
SUB OIL FILTER
The sub oil filter requires no servicing until the
replacement interval is reached.
The element is designed to provide special filtering
efficiency until it becomes due for replacement.
It is recommended to check and replace the sub oil filter
when the engine is being overhauled or if it is broken
inside the engine.
1
2
050RW009

ENGINE SPEED CONTROL 6H – 1
ENGINE SPEED CONTROL
CONTENTS
General Description . . . . . . . . . . . . . . . . . . 6H–2 Engine Speed Control . . . . . . . . . . . . . . . . . 6H–3

6H – 2 ENGINE SPEED CONTROL
GENERAL DESCRIPTION
3For A/T
1For M/T
2
1
101RW012
Engine control has been changed from the control
cable system to an electronically controlled TP (Throttle
Position) sensor.
The TP sensor is a potentiometer (Variable resistance)
type and installed to the accelerator pedal bracket.
A voltage of 5 V is always applied from the ECM
(Electronic Control Module) to the TP sensor so that the
operating angle of the accelerator pedal can be
detected from a change in voltage.
Further, this sensor is equipped with an accelerator
switch which sends signals to the ECM when the
accelerator pedal is stepped on.
This switch remains on and turns off only when the
accelerator pedal is stepped on.An A/T (Automatic Transmission) vehicle is equipped
with a throttle cable for A/T use. There is a return spring
provided on the throttle cable lever side. No change in
the throttle cable lever. An MT (Manual Transmission)
vehicle has no throttle cable, and therefore, a return
spring is provided on the accelerator pedal and a return
cable assembly having the sliding resistance of a cable
is used to give the pedal a feeling.
To meet the newly adopted electronic control system,
the idling control button has been dropped. Legend
(1) Accerator Position Sensor
(2) Return Cable
(3) A/T Throttle Cable

ENGINE SPEED CONTROL 6H – 3
REMOVAL
1. For vehicle with MT
1) Remove harness connector from accelerator
pedal sensor.
2) Remove accelerator pedal assembly from
chassis.
2. For vehicle with A/T
1) Remove A/T control cable from accelerator
pedal assembly.
2) Remove harness connector from accelerator
pedal sensor.
3) Remove accelerator pedal assembly from
chassis.
INSPECTION AND REPAIR
1. Check moving condition of accelerator pedal, if not
smooth working, apply oil to the pivot etc.
2. Check tightening condition of accelerator sensor, if
not completely tightened, it should be tightened
additionally.
INSTALLATION
The installation for both MT and A/T vehicles follows the
reverse manner of removal.
ENGINE SPEED CONTROL

6J – 4 INDUCTION
TURBOCHARGER
REMOVAL
2. Drain engine coolant.
3. Remove air cleaner cover and air duct.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove water pipe from water inlet of
turbocharger.
6. Remove oil pipe.
1) Remove fixing bolts from oil inlet of turbocharger
then remove oil pipe.
2) Plug open port of turbocharger to prevent
foreign materials from entering the turbocharger.
7. Remove oil drain pipe from turbocharger.
8. Remove water outlet pipe from turbocharger.
9. Remove heat protector.
10. Remove exhaust valve assembly.
11. Remove turbocharger fixing nuts from exhaust
manifold then remove turbocharger assembly.
9875 63
21
4
Legend
(1) Exhaust Manifold
(2) Gasket
(3) Turbocharger Assembly
(4) Water Hose(5) Water Hose
(6) Heat Protector
(7) Oil Pipe
(8) Oil Pipe
(9) Gasket
025RW023
036RW006