fuel pressure OPEL FRONTERA 1998 Workshop Manual

ENGINE MECHANICAL 6A – 45
Cylinder head gasket and piston projection mm
CAUTION:
The projection of each piston should be 0.333
mm or more and less than 0.483 mm.
Maximum difference in projection between
pistons should be less than 0.1 mm.
If the piston projection is without standard,
reassemble the engine all over again.
3. Install cylinder head assembly, tighten bolts by
angular tightening method.
To r q u e :
1st step; 49 Nꞏm (4.9 kgꞏm/35.4 lb ft)
2nd step; 60°
3rd step; 60°
CAUTION: The cylinder head bolts cannot be
reused.
4. Install camshaft carrier assembly.
Refer to “Camshaft” in this manual.
5. Install oil rail and injector assembly.
Refer to “Oil rail and injector” in this manual.
6. Install injector harness to connect harness
connector.
Note: Apply liquid gasket (TB 1207B or equivalent) to
the rubber seal of the camshaft end, injector harness
gasket area and No. 1 camshaft bracket. Refer to the
Cylinder head cover.
7. Install cylinder head cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
8. Install glow plug to tighten specified torque.
Torque: 15 Nꞏm (1.5 kgꞏm/11 lb ft) and connectglow plug harness.
9. Install intake manifold.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
10. Install fuel return pipe.
11. Install fuel pipe in between fuel pump and intake
manifold.
12. Install water pipe in between cylinder head and
water pump.
Tighten flange bolt to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
13. Install front plate.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
14. Install camshaft pulley, tighten with angular
tightening method.
1st step 40 Nꞏm (4.0 kgꞏm/29 lb ft)
2nd step 60°
NOTE: Apply engine oil to camshaft pulley bolt.
15. Align timing mark oil pump pulley and camshaft
pulley to front plate then put the timing belt and
tighten tensioner bolt.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) for M8
50 Nꞏm (5.1 kgꞏm/37 lb ft)
16. Install CMP sensor bracket.
17. Install timing belt cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
18. Fill with about 300 cc of engine oil from the high
pressure oil pipe installing port of oil rail using an oil
filler.
If assembled without filling the oil rail with oil, the
time for engine start will be longer.
19. Immediately install high pressure oil pipe to tighten
with specified torque.
Torque: 80 Nꞏm (8 kgꞏm/57.9 lb ft)
20. Install cylinder head noise insulator cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
Grade A Grade B Grade C
011RW042
Grade Piston projectionGasket
thickness
A more 0.333 to less 0.383 1.35
B more 0.383 to less 0.433 1.40
C more 0.433 to less 0.483 1.45

6A – 60 ENGINE MECHANICAL
VALVE STEM SEAL, VALVE SPRING AND ADJUSTER
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove the air duct from between air cleaner and
turbocharger.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Disconnect PCV hose.
7. Disconnect EGR vacuum hose.
8. Disconnect harness connectors around the cylinder
head such as the injector, CMP sensor, MAP
sensor, EGR sensor, EVRV, IAT sensor, A/C
compressor, TP stepping motor, TP sensor and fuel
temperature sensor etc.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out drivebelt.
12. Remove heat protector, remove exhaust valve
assembly.
13. Remove water cooling hose and lubrication pipe for
turbocharger.
14. Remove turbocharger assembly.
15. Remove hose between thermostat and radiator.
16. Remove noise insulator cover of cylinder head.
NOTE: Do not damage injector harness.
17. Remove high pressure oil pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner then remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove engine coolant pipe between cylinder
head and water pump.
1
2
3
4
5
6
9
10
7
8
011RW031
Legend
(1) Adjuster
(2) Tappet
(3) Split Collar
(4) Spring Seat Upper
(5) Valve Spring(6) Spring Seat Lower
(7) Valve Stem Seal
(8) Valve Guide
(9) Valve Seat
(10) Valve

ENGINE MECHANICAL 6A – 61
24. Remove fuel pipe between fuel pump and intake
manifold.
25. Remove fuel return pipe from rear of cylinder head.
26. Remove intake manifold assembly.
27. Disconnect glow plug harness and remove glow
plug.
28. Remove cylinder head cover.
29. Remove injector harness connector.
30. Disconnect harness connector from oil pressure
sensor and oil temperature sensor on the oil rail.
31. Remove injector harness assembly.
32. Remove injector clamp.
33. Remove injector is fixed bolts.
34. Remove injector assembly.
35. Remove oil rail.
36. Remove camshaft carrier assembly with camshaft.
37. Remove cylinder head assembly.
38. Disassemble valve spring according to the following
method.
1) Use valve spring compressor then remove split
collars.
2) Valve spring compressor: 5-8840-2441-0
NOTE: Put removed valve spring in order of cylinder
number.
39. Valve stem seal.
1) Use a screwdriver or pliers to remove valve
stem seal.
NOTE: Do not reuse removed valve stem seal.
INSPECTION AND REPAIR
Make the necessary adjustments, repairs and part
replacements if excessive wear or damage is
discovered during inspection.
Va l v e s p r i n g
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is
evident.
1. Free height
1) Measure the free height of the springs. The
springs must be replaced if the height is below
the specified limit.
Standard: 45.85 mm (1.8051in)
Limit: 43.9 mm (1.7283 in)
2. Squareness
1) Measure the valve spring squareness with a
steel square.
2) Replace the valve springs if the measured value
exceeds the specified limit.
Limit: 1.6 mm (0.063 in)
014rw042
014rs004
014rs005

6A – 66 ENGINE MECHANICAL
INSTALLATION
1. Valve stem seal
1) Use the special tool to install the stem seal to the
valve guide.
Stem Seal Installer: 5-8840-2033-0
2. Valve spring.
1) Install the lower valve seat spring, valve spring,
then the upper valve spring seat.
2) Use valve spring compressor to compress the
spring then install the split collar.
Valve spring compressor: 5-8840-2441-0
NOTE: Make sure the split collar installs completely.
3. Install cylinder head assembly.
Refer to “Cylinder Head” in this manual.
4. Install the camshaft carrier with camshaft.
Refer to “Camshaft” in this manual.
5. Install oil rail assembly.
Refer to “Oil rail and injector” in this manual.
6. Install injector assembly.
Refer to “Oil rail and injector” in this manual.
7. Install the injector harness assembly.
Refer to “Injector” in this manual.
8. Reconnect harness connecter to oil pressure
sensor and oil temperature sensor on the oil rail.
9. Reconnect Injector harness connecter to injector.
Refer to “Injector” in this manual.
10. Install cylinder head cover with gasket.
Refer to “Cylinder Head Cover” in this manual.
11. Install glow plug with specified torque.
Torque: 15 Nꞏm (1.5 kgꞏm / 10.8 lb ft)
12. Install the intake manifold assembly.
Refer to “Intake Manifold” in this manual.
13. Install the fuel pipe.14. Install the water pipe between the cylinder head
and water pump.
Torque: 20 Nꞏm (2.0 kꞏm / 14.5 lb ft)
15. Install the front plate.
16. Install the camshaft pulley.
Refer to “Timing Gear” in this manual.
17. Install timing belt and set the tensioner.
Refer to “Timing Belt” in this manual.
18. Install CMP sensor bracket.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
19. Install timing belt cover.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
20. Fill the oil rail with engine oil then immediately
install the high pressure oil pipe with the specified
torque.
Torque: 80 Nꞏm (8.1 kgꞏm / 57.9 lb ft)
21. Install the noise insulator cover.
22. Reconnect hose between thermostat and radiator.
23. Install turbocharger assembly.
Refer to “Turbocharger” in this manual.
24. Install water hose and oil pipe for turbocharger.
Refer to “Turbocharger” in this manual.
25. Install the valve assembly and install heat protector.
26. Install generator and set the fan belts.
27. Install A/C compressor bracket, compressor
assembly and set drive belt.
28. Reconnect harness connector around cylinder
head.
29. Reconnect vacuum hose to EGR valve.
30. Reconnect PCV hose.
31. Install oil level gauge guide assembly.
32. Install intercooler assembly.
Refer to “Intercooler” in this manual.
33. Install the air duct assembly.
34. Fill engine coolant.
35. Connect battery ground cable.
014RW042

ENGINE MECHANICAL 6A – 69
OIL RAIL AND INJECTOR
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 it to prevent oil from spurting due to the
remaining pressure.
2) The high pressure pipe should be disconnected
with a 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.
12. Record the identification marking of injector for
each cylinder which is indicated on the upper
portion of injector.
There are nine kinds of identification marking
available, one alphabet letter and one numeral
letter.
In case three kinds of markings are given, one
alphabet letter (sometimes printed) and one
numeral letter, top priority is given to the one
alphabet letter and one numeral letter.
1
6
27
3
5
4
With
spacer type
Without
spacer type
012R200005
Legend
(1) Injector Clamp
(2) Injector Assembly
(3) Oil Rail Assembly(4) Camshaft Bracket
(5) Camshaft
(6) O-Ring
(7) Drain Plug

ENGINE MECHANICAL 6A – 71
12. Immediately install high pressure oil pipe and
tighten to specified torque.
Torque: 80 Nꞏm (8.1 kgꞏm / 57.9 lb ft)
13. Install cylinder head noise insulator cover.
Refer to “Cylinder Head” in this manual.
14. Install intercooler assembly.
Refer to “Intercooler” in this manual.
15. Install air cleaner cover and air duct.
16. Use TECH2 to rewrite injector data to ECM.
For rewriting method refer to section “Data
Programming in Case of ECM Change” of 6E 4JX1
engine driveability and emissions in this manual.
NOTE:
1) On completion of servicing, bleed air from the
engine inside fuel passage by means of the priming
pump. (The priming pump should be operated more
times than in the case of conventional engines.)
2) As air is in the oil rail, it takes more time to start the
engine. Rough idling may occur while the air is
being bled completely after starting the engine, but
it does not indicate trouble.
The air will be bled and normal engine status will be
reached while the vehicle is driven for about 5 km
or engine is operated for about 5 minutes at 1500 to
2000 rpm.
3) The injector spare part will be provided for group
number B1, B2 and B3 only.

ENGINE FUEL 6C – 1
ENGINE FUEL
CONTENTS
GENERAL DESCRIPTION
General Description . . . . . . . . . . . . . . . . . . 6C–1
On-Vehicle Service . . . . . . . . . . . . . . . . . . 6C–7
Fuel Filter Assembly . . . . . . . . . . . . . . . . 6C–7
Fuel Filter Cartridge . . . . . . . . . . . . . . . . 6C–7
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–9
Fuel Pump Pipe . . . . . . . . . . . . . . . . . . . 6C–13High Pressure Oil Pump . . . . . . . . . . . . . 6C–15
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . 6C–20
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . 6C–21
Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . 6C–21
To realize the compatibility between low exhaust
emission and high engine output, an HEUI
(Hydraulically actuated Electronically controlled Unit
Injector) system, has been introduced. This system is
comprised of a hydraulic system, fuel system, and
electronic control system, using a high-pressure oil
pump in place of the conventional fuel injection pump.
The oil pressurized by means of this pump and by
signals from the ECM (Electronic Control Module)
actuates the fuel injector provided for each cylinder.
Inside of the fuel injector, fuel pressure is increased due
to the high-pressure oil. The ECM detects the driving
state of the vehicle, forms, signals sent by engine and
other part sensors, which determines the optimum fuel
injection amount and timing, thus controlling the fuel
injectors. Thus high engine output, good fuel economy,
and low exhaust emission are realized.When working on the fuel system, there are several
things to keep in mind:
1) Any time the fuel system is being worked on,
disconnect the negative battery cable except for
those tests where battery voltage is required.
2) Always keep a dry chemical (Class B) fire
extinguisher near the work area.
3) Replace all pipes with the same pipe and fittings
that were removed.
Clean and inspect “O” rings. Replace where
required.
4) Always relieve the line pressure before servicing
any fuel system components.
5) Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
6) After maintenance work, push priming pump and
send enough fuel to the fuel system before starting
the engine.
NOTE: In comparison with the conventional engine,
the capacity of fuel passage in the 4JX1 engine is
larger. It takes the priming pump more time to fill the
engine with fuel.

6C – 2 ENGINE FUEL
FUEL FLOW
1
14 Except above region
89
10111
2
2
4
12
5 6
7
3
13
14 For Europe, Nicaragua,
Argentina, Philippin
11
4
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(4) Fuel Supply Pipe
(5) Fuel Filter with Priming Pump
(6) Fuel Pump
(7) High Pressure Oil Pump(8) Cylinder Head
(9) Injector
(10) Orifice
(11) Fuel Return Pipe
(12) Fuel Tank Pressure Release Hose
(13) Intake Air Duct
(14) Fuel Tank Pressure Control Valve
040R200001

ENGINE FUEL 6C – 3
FUEL PUMP
1
2
3 4
Legend
(1) High Pressure Oil Pump
(2) To Injector(3) From Fuel Tank
(4) Fuel Pump
140RW041

6C – 4 ENGINE FUEL
HIGH PRESSURE OIL PUMP, OIL FLOW
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
(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
040RW018