torque OPEL FRONTERA 1998 Workshop Manual

6F – 4 ENGINE EXHAUST
REMOVAL
1. Battery negative cable.
2. Raise the vehicle and support with suitable safety
stands.
3. Remove front exhaust pipe fixing nuts from engine
side.
4. Remove fixing nuts between front exhaust pipe and
center exhaust pipe, remove front exhaust pipe.
5. Disconnect center exhaust pipe and silencer,
remove center exhaust pipe.
6. Remove fixing nuts from connection part of tail pipe,
remove mounting rubber and remove silencer
bracket, silencer.
7. Remove mounting rubber for tail pipe, remove tail
pipe.
INSTALLATION
1. Install front exhaust pipe and tighten it temporarily.
2. Tighten fixing nuts of front exhaust pipe to the
specified torque. (for engine side)
Torque: 67 Nꞏm (6.8 kgꞏm/50 lb ft)
3. Tighten fixing nuts of front exhaust pipe to the
specified torque. (for center pipe side)
Torque: 43 Nꞏm (4.4 kgꞏm/32 lb ft)
4. Install silencer and tighten silencer bracket nuts to
the specified torque.
Torque: 16 Nꞏm (1.6 kgꞏm/12 lb ft)
5. Install tail pipe and tighten it.
Torque: 43 Nꞏm (4.4 kgꞏm/32 lb ft)
6. Install mounting rubbers.

ENGINE EXHAUST 6F – 5
CENTER EXHAUST PIPE
REMOVAL
1. Battery negative cable.
2. Raise the vehicle and support with suitable safety
stands.
3. Remove mounting rubber.
4. Remove fixing nuts from silencer side.
5. Remove fixing nuts from front exhaust pipe.
6. Remove center exhaust pipe assembly.
INSTALLATION
1. Place center exhaust pipe in the original position
then tighten fixing nuts temporarily.
2. Install mounting rubber.
3. Tighten front exhaust pipe side nuts to the specified
torque.
Torque : 43 Nꞏm (4.4 kgꞏm/32 lb ft)
4. Tighten silencer side nuts to the specified torque.
Torque : 43 Nꞏm (4.4 kgꞏm/32 lb ft)
3
2 1
Legend
(1) Front Exhaust Pipe
(2) Center Exhaust Pipe
(3) Mounting Rubber
150RW071

6F – 6 ENGINE EXHAUST
EXHAUST SILENCER
REMOVAL
1. Battery negative cable.
2. Raise the vehicle and support with suitable safety
stands.
3. Remove mounting rubber from silencer.
4. Remove silencer mounting bracket.
5. Remove fixing nuts between center exhaust pipe
and silencer.
6. Remove fixing nuts from tail pipe flange.
7. Remove silencer assembly.
INSTALLATION
1. Place silencer assembly in the original installation
position, tighten both side (front and rear) nuts
temporarily.
2. Tighten silencer mounting bracket to the specified
torque.
Torque : 16 Nꞏm (1.6 kgꞏm/12 lb ft)
3. Tighten center exhaust pipe side nuts to the
specified torque.
Torque : 43 Nꞏm (4.4 kgꞏm/32 lb ft)
4. Tighten tail pipe side nuts to the specified torque.
Torque : 43 Nꞏm (4.4 kgꞏm/32 lb ft)
5. Install silencer mounting rubber.
6
3
4
2
1
5
Legend
(1) Mounting Rubber
(2) Post Silencer
(3) Silencer(4) Mounting Bracket
(5) Mounting Rubber
(6) Tail Pipe
150RW072

ENGINE EXHAUST 6F – 7
REAR EXHAUST PIPE
REMOVAL
1. Battery negative cable.
2. Raise the vehicle and support with suitable safety
stands.
3. Remove mounting rubber from post silencer.
4. Remove fixing nuts at silencer side.
5. Remove tail pipe together with post silencer.
6. Remove fixing nuts between tail pipe and post
silencer which separates them.
INSTALLATION
1. Install tail pipe and post silencer and tighten them to
the specified torque.
Torque : 43 Nꞏm (4.4 kgꞏm/32 lb ft)
2. Place tail pipe together with post silencer to original
position and tighten fixing nuts at silencer side.
Torque : 43 Nꞏm (4.4 kgꞏm/32 lb ft)
3. Install mounting rubber for post silencer.
4. Lower the vehicle.
5. Reconnect battery negative cable.
6
3
4
2
1
5
Legend
(1) Mounting Rubber
(2) Post Silencer
(3) Silencer(4) Mounting Bracket
(5) Mounting Rubber
(6) Tail Pipe
150RW072

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.
Torque:
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.
For Europe1
2
050R200001

INDUCTION 6J – 7
Legend
(1) Pressure gauge
(2) Waste gate control rod
4) Check for cracks or breaks on the hose, if a
problem is found, the hose must be replaced.
CAUTION: Do not apply more than 120 Kpa (900
mmHg / 18.7 PSi) to waste gate actuator.
INSTALLATION
1. Install turbocharger assembly to exhaust manifold,
tighten to the specified torque.
Torque: 27 Nꞏm (2.7 kgꞏm / 19.5 lb ft)2. Install exhaust valve assembly to outlet of
turbocharger, tighten bolts to the specified torque.
Torque: 27 Nꞏm (2.7 kgꞏm / 19.5 lb ft)
3. Install heat protector.
4. Water inlet pipe.
1) Tighten water inlet pipe with new gasket.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
5. Oil drain pipe.
1) Tighten oil drain pipe with new gasket.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
6. Oil inlet pipe.
1) Apply about 100 cc engine oil to turbocharger
housing before installing the oil pipe.
2) Turn the turbine shaft by hand to lubricate the
bearing.
3) Install the oil inlet pipe with a new gasket, tighten
bolt to the specified torque.
Torque: 22 Nꞏm (2.2 kgꞏm / 15.9 lb ft) For M10
Torque: 54 Nꞏm (5.5 kgꞏm / 39.8 lb ft) For M14
2
1
036RW011
For Europe
025R200007
For Europe
025R200006

6J – 8 INDUCTION
7. Water inlet pipe.
1) Install water inlet pipe with a new gasket, tighten
bolts to the specified torque.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
8. Install intercooler assembly.
Refer to “Intercooler” in this manual.
9. Install air cleaner cover with air duct.
10. Fill engine coolant to full level.
11. Install battery and connect battery cable.
For Europe
025R200007

INDUCTION 6J – 9
INTERCOOLER
REMOVAL
1. Disconnect battery ground cable.
2. Remove air cleaner cover with air duct.
3. Remove intercooler cover.
4. Intercooler assembly.
1) Remove rubber hose from intercooler outlet
side.
2) Remove rubber hose from intercooler inlet side.
3) Remove four fixing bolts and remove intercooler
assembly.
INSPECTION AND REPAIR
1. Visual check for clogs in the fins.
2. Check for brokens on the tube.
3. If any problem on the intercooler is observed during
inspection, clean or replace the intercooler.
INSTALLATION
1. Intercooler assembly.
1) Connect outlet hose to intake manifold.
Tighten hose clamp to the specified torque.
Torque: 4 Nꞏm (0.4 kgꞏm / 3 lb ft)
2) Connect inlet hose to the turbocharger outlet
side.
Tighten hose clamp to the specified torque.
Torque: 4 Nꞏm (0.4 kgꞏm / 3 lb ft)
3) Install intercooler assembly, tighten fixing bolts
to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
2. Install intercooler cover.
3. Install air cleaner cover and air duct.
4. Connect battery ground cable.
For Europe
2
33
1
Legend
(1) Air Cleaner Cover and Air Duct
(2) Intercooler Cover
(3) Intercooler Assembly
135R200003

6J – 10 INDUCTION
REMOVAL
1. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
2. Remove harness connector from motor and ITP
sensor.
3. Loosen the two fixing nuts and remove the throttle
valve assembly.
Legend
(1) Motor
(2) Intake Throttle Valve
(3) ITP sensor
INSPECTION AND REPAIR
1. Check for catching somwhere on the throttle valve.
2. If some problem is discovered during inspection on
the throttle valve, the throttle valve must replace.
INSTALLATION
1. Put gasket on the intake manifold and install throttle
valve.
2. Tighten nuts to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
3. Reconnect harness connector to motor and
ITPsensor.
4. Install intercooler assembly.
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025RW032
I N TA K E T H R O T T L E VA LV E