drain bolt OPEL FRONTERA 1998 Owners Manual

ENGINE COOLING 6B – 7
THERMOSTAT
REMOVAL
1. Disconnect battery ground cable.
2. Drain coolant from the radiator and engine.
3. Thermostat housing
1) Remove mounting bolt and remove thermostat
housing together with radiator hose.
4. Gasket
5. Thermostat
INSPECTION
Make necessary repair and parts replacement if
excessive wear or damage is found during inspection.
Submerge the thermostat assembly in the water.
Place wooden blocks on the bottom of the water
container.
Do not heat the thermostat directly.
Gradually increase the water temperature. Stir the
water so that the entire water is the same temperature.
1) Make sure that valve begins to open at the
specified temperature.
Valve Opening Temperature: 85°C (185°F)
2) Make sure that valve opens fully at the specified
temperature.
Valve Full Open Temperature: 100°C (212°F)
1
2
3
4
Legend
(1) Bolt
(2) Thermostat Housing
(3) Thermostat
(4) Intake Manifold
035RW002
031RS003

6C – 8 ENGINE FUEL
ON-VEHICLE SERVICE
FUEL FILTER ASSEMBLY
REMOVAL
1. Disconnect battery ground cable.
2. Fuel Filler cap
3. Fuel Hose
1) Disconnect fuel hose from filter body.
Plug the hose ends to prevent fuel spillage.
4. Remove the Bolt on Fuel Filter Bracket
5. Remove Fuel Filter Assembly
INSTALLATION
1. Install the fuel filter assembly
2. Tighten the Fuel Filter Bracket Fixing Bolt
3. Fuel Hose
1) Connect hoses to filter body.
4. Fuel Filler Cap
1) Connect the battery ground cable.
2) Feed fuel to the fuel pump by priming, and bleed
the air from fuel system.
FUEL FILTER CARTRIDGE
DISASSEMBLY
1. Drain fuel completely from the fuel filter.
2. Protect the filter body with cloth and lightly grip with
a vise.
3. Remove the cartridge using a filter wrench.
Filter wrench: 5-8840-0203-0
1
Legend
(1) Priming Pump
012RW111
012RW112

ENGINE FUEL 6C – 11
REMOVAL
Prior to removal, be sure to confirm and record the
group code of the injector installed using Tech2.
1. Disconnect battery ground cable.
2. Remove air cleaner cover and air duct.
3. Remove intercooler.
Refer to “Intercooler” in this manual.
4. Remove PCV hose and pipe.
5. Remove cylinder head noise insulator cover.
6. Remove high pressure oil pipe.
CAUTION:
1) Sleeve nut should be loosened with cloth tied
around to prevent oil from spurting due to the
remaining pressure.
2) High oil pressure pipe should be disconnected
with cloth tied around the intake manifold glow
plug to prevent oil from flowing out of the oil
rail.
7. Loosen eye bolt of fuel pipe at fuel pump side.
NOTE: Cloth should be put around the loosened eye
bolt to prevent fuel from flowing out.
8. Remove fuel return hose at chassis side.
9. Remove PCV hose to cylinder head cover.
10. Remove cylinder head cover.
11. Drain the oil from oil rail assembly.
NOTE: Do not drop O-ring
12. Record the grade code of injector for each cylinder
that is indicated on the upper portion of injector.
There are nine kinds of grade code available, one
alphabet letter and one numeral letter.
Grade codeLegend
(1) Part Number
(2) Category Number (Grade code)
(3) Serial Number
(4) Bar Code
13. Remove harness connector from each injector.
14. Loosen nuts and bolts for oil rail.
15. Remove injector fixing bolts.
16. Remove injector clamp.
17. Remove injector assembly.
INSTALLATION
1. Install oil rail, tighten temporarily
2. Install injector assembly.
NOTE:
1) Do not forget to install O-ring between injector and
oil rail.
2) Use new O-ring
3) Clean O-ring groove and fitting surface of parts.
4) Apply engine oil to O-ring.
3. Install injector fixing bolts, tighten temporarily.
4. Install injector clamp, tighten nut temporarily.
5. Tighten injector fixing bolts to the specified torque.
Torque: 6.5 Nꞏm (0.7 kgꞏm / 5.1 lb ft)
6. Tighten injector clamp nut to the specified torque
with special method.
Torque: 30 Nꞏm (3.1 kgꞏm / 22.4 lb ft) then loosen a
time again tighten as following torque.
Torque: 25 Nꞏm (2.4 kgꞏm / 17.4 lb ft)
7. Tighten oil rail to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
1
4
32
055RW00001
Category number
A– 1
A– 2
A– 3
B – 1
B – 2
B – 3
C – 1
C – 2
C – 3

6C – 20 ENGINE FUEL
FUEL TANK
REMOVAL
1. Disconnect battery ground cable.
2. Remove fuel filler cap.
3. Drain fuel.
After drain the fuel tighten the drain plug with
specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14 lb ft)
4. Remove fuel filler hose and let air pull off hose.
5. Remove breather hose.
6. Remove fuel feed hose and fuel return hose.
7. Disconnect harness connector from fuel gauge unit.
8. Remove under cover.
9. Remove fuel tank assembly.
INSTALLATION
1. Fuel tank assembly.
1) Place a flange on right side of tank on the
bracket.
2) Install a flange to left side of the bracket from the
bottom, and tighten bolts to the specified torque.
Torque : 36 Nꞏm (3.7 kgꞏm/26.8 lb ft)
2. Install fuel hose and fuel return hose.
3. Install the breather hose.
4. Reconnect harness connector to fuel gauge unit.
5. Install under cover.
6. Install fuel filler hose and let air pull off hose.
7. Fill fuel tank with fuel and tighten filler cap.
8. Reconnect battery ground cable.
1
2
6
7
4
5
3
Legend
(1) Fuel Tank Assembly
(2) Gauge Unit
(3) Under Cover(4) Fuel Filler Hose
(5) Fuel Filler Cap
(6) Breather Hose
(7) Control Valve (Except EC)
140RX023

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

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

6J – 6 INDUCTION
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
036RW005
036RW006

6J – 10 INDUCTION
INTAKE MANIFOLD
REMOVAL
1. Drain engine coolant and remove water hose from
thermostat housing
2. Remove intercooler assembly.
3. Remove bracket fixing bolt of oil level gauge guide
tube.
4. Remove PCV hose.
5. Remove hoses from EGR valve, EGR vacuum
sensor and outlet of heater unit.
6. Disconnect harness connector from MAP sensor,
EGR vacuum sensor, ETC sensor, Water
temperature unit, IAT sensor and EVRV.
7. Remove high pressure oil pipe.
8. Remove two way check valve.
9. Remove fuel pipe.
10. Remove fixing bolts and nuts of intake manifold,
remove intake manifold assembly.
Legend
(1) Intake manifold
(2) Fixing portion of throttle valve
(3) EGR passage
(4) EGR valve
2
3
4
1
Legend
(1) Intake Manifold
(2) Throttle Valve Assembly
(3) EGR Valve
(4) Gasket
025RW022
3124
025RW031

7A–22
AUTOMATIC TRANSMISSION (4L30–E)
Chart 16: Possible Causes Of
Transmission Fluid Leaks
Before attempting to correct an oil leak, the actual source
of the leak must be determined. In many cases, the
source of the leak may be difficult to determine due to
“wind flow” around the engine and transmission.
The suspected area should be wiped clean before in-
specting for the source of the leak.Oil leaks around the engine and transmission are gener-
ally carried toward the rear of the vehicle by the air
stream. In determining the source of an leak, the following
two checks should be made:
1. With the engine running, check for external line
pressure leaks.
2. With the engine off, check for oil leaks due to the
raised oil level caused by drainback of converter oil
into the transmission.
Possible Causes Of Fluid Leaks Due To Sealing Malfunction
240RX008
Legend
(1) Electrical Connector (Main Case) Seal
(2) Transmission Vent (Breather)
(3) Speed Sensor O–Ring
(4) Extension (Adapter) Lip Seal
(5) Extension (Adapter) to Main Case Gasket
(6) Overfill and Oil Drain Screws Gasket
(7) Oil Pan Gasket (Main Case)
(8) Selector Shaft Seal(9) Oil Cooler Connectors (2)
(10) Oil Pan Gasket (Adapter Case)
(11) Converter housing attaching bolts not correctly
torqued
(12) Converter Housing Lip Seal
(13) Line Pressure Tap Plug
(14) Electrical Connector (Adapter Case) Seal
(15) Adapter Case Seal Rings (2)

7A–39 AUTOMATIC TRANSMISSION (4L30–E)
Solenoid (Main Case Valve Body)
Removal
1. Raise the vehicle and support it on jack stands.
2. Disconnect battery ground cable.
3. Remove transfer and exhaust protectors.
4. Drain fluid.
5. Remove exhaust pipe and disconnect oxygen sensor
connector.
6. Support transfer case with a jack and remove third
crossmember.
7. Remove sixteen 10 mm screws, main case oil pan,
magnet, and gasket.
8. Remove three 13 mm screws, oil filter.
9. Disconnect wiring harness from band control
solenoid and shift solenoids. Pull only on connectors,
not on wiring harness.
10. Remove spring pin for shift solenoid A, shift solenoid
B, and band control solenoid respectively, using
suitable pliers taking care not to damage solenoids.
210RW010
244RW003
11. Remove shift solenoid A, shift solenoid B, band
control solenoid, and gaskets from main case valve
body. Do not pull on wiring harness. Remove
solenoids by grasping the metal tip.
Installation
1. Install shift solenoid A, shift solenoid B, band control
solenoid with new gaskets to main case valve body
respectively.
2. Carefully install spring pin with hammer to avoid
damage to valve body, etc.
243RW004
3. Connect wiring harness to solenoids.
4. Install oil filter with a new gasket and the three 13 mm
screws. Tighten the screws to the specified torque.
To r q u e : 2 0 N
m (2.0 kgꞏm/15 lb ft)
5. Install magnet, main case oil pan with new gasket,
sixteen 10 mm screws. Tighten the screws to the
specified torque.
To r q u e : 11 N
m (1.1 kgꞏm/96 lb in)
6. Install third crossmember and rear mount nuts.
Tighten the nuts and bolts to the specified torque.
Third crossmember bolt: 76 N
m
(7.8 kgꞏm/56 lb ft)
Rear mount nut: 50 N
m (5.1 kgꞏm/37 lb ft)
7. Install exhaust pipe and connect oxygen sensor
connector. Tighten the bolts to the specified torque.
Exhaust pipe flange bolt torque:
43 N
m(4.4kgꞏm/32lbft)
8. Install the transfer and exhaust protectors. Tighten
the bolts to the specified torque.
Torque: 37 N
m (3.8 kgꞏm/27 lb ft)
9. Fill transmission through the overfill screw hole of oil
pan, using ATF DEXRON
–III. Refer to Changing
Transmission Fluid in this section.
10. Connect the battery ground cable.