cooling OPEL FRONTERA 1998 Workshop Manual

ENGINE MECHANICAL 6A – 3
SERVICE INFORMATION
MAIN DATA AND SPECIFICATION
Engine type Diesel, four cycle water cooled inline
Camshaft type DOHC
Number of cylinders 4
Bore x stroke (mm) 95.4 x 104.9
Total piston displacement (cc) 2999
Compression ratio (to 1) 19.0
Engine weight (dry) N (kg/lb) 2492 (254/560) (A/T)
2649 (270/593) (M/T)
Engine idling speed (Reference) RPM 720
Compression pressure kpa (kg/cm
2/psi)-rpm 3000 (31/440)-200
Firing order 1–3–4–2
VALVE SYSTEM
Intake valves open at: B.T.D.C. 3°
close at: A.B.D.C. 57.6°
Exhaust valves open at: B.B.D.C. 56.5°
close at: A.T.D.C. 5°
Valve clearance at cold mm (in)
intake: 0.15 (0.006)
exhaust: 0.25 (0.01)
Oil filter Full flow and bypass combined type
Oil capacity (Original factory fill or rebuilt engine) 9.0 liters (7.9 US quarts)
Oil capacity (Service change)
with filter change 6.0 liters (6.3 US quarts)
without filter change 5.0 liters (5.3 US quarts)
Oil cooler Water cooled type
Inter cooler Air cooled type
Turbocharger method
Control method Wastegate control
Lubrication Pressurized control
Cooling method Coolant cooled

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
2psi) 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 1.2
Coolant total capacity lit (Imp.qt./US qt.) 9.3 (8.2/9.8)
Model HITACHI S14-0
Rating
Voltage V 12
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 – 8 ENGINE MECHANICAL
Parts Items Service standard Service limit Remarks
Cylinder
Block—
95.421 – 95.450
(3.7567 – 3.7579)0.20 (0.0079) Warpage
(Upper surface of the cylinder block)
Cylinder bore diameter
Parts Items Service standard Service limit Remarks
Thermostat
Radiator cap83 – 87°C
(181 – 189°F)
More than 9.5 (0.374)
at 100°C (212°F)
88.2 – 117.6 kPa
(12.8 –17.0 psi) Valve opening temperature
Valve full open temperature and lift
Valve opening pressure
Engine Coolingmm (in) mm (in)

6A – 10 ENGINE MECHANICAL
8. Check the engine oil level and replenish to the
specified level if required.
9. Start the engine and check for oil leakage from the
main oil filter.
FUEL SYSTEM
Fuel filter
Replacement Procedure
1. Loosen the used fuel filter by turning it
counterclockwise with the filter wrench.
Filter Wrench : 5-8840-0203-0
2. Clean the filter cover fitting faces.
This will allow the new fuel filter to seat properly.
3. Apply a light coat of engine oil to the O-ring.
4. Turn the fuel filter until the sealing face comes in
contact with the O-ring.
5. Turn the fuel filter with a filter wrench 2/3 of a turn
until sealed.
Filter Wrench: 5-8840-0203-0Legend
(1) Priming pump
6. Operate the priming pump until the air is discharged
completely from fuel system.
NOTE: The use of an Isuzu genuine fuel filter is
strongly recommended.
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator
reserve tank as necessary.
If the coolant level falls below the “‘MIN” line, carefully
check the cooling system for leakage. Then add
enough coolant to bring the level up to the “MAX” line.
NOTE: Do not overfill the reserve tank.
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ENGINE MECHANICAL 6A – 11
Remove the radiator filler cap only when absolutely
necessary.
Always check the coolant level when the engine is cold.
Always refer to the chart at the left to determine the
correct cooling water to antifreeze solution mixing ratio.
Cooling System Inspection
Install a radiator filler cap tester to the radiator. Apply
testing pressure to the cooling system to check for
leakage.
The testing pressure must not exceed the specified
pressure.
Testing Pressure: 196 kPa (2 kg/cm
2/28.45 psi)
Radiator Cap Inspection
The radiator filler cap is designed to maintain coolant
pressure in the cooling system at 103 kPa (1.05
kg/cm
2/15 psi).
Check the radiator filler cap with a radiator filler cap
tester.The radiator filler cap must be replaced if it fails to hold
the specified pressure during the test procedure.
Radiator Filler Cap Pressure Valve: 88.2 – 117.6 kPa
(0.899 – 1.199 kg/cm
2/12.8 – 17.1 psi)
Negative Valve (Reference): 1.0 – 3.9 kPa
(0.01 – 0.04 kg/cm
2/0.14 – 0.57 psi)
Thermostat Operating Test
1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature:
83 – 87°C (181 – 189°F)
4. Check the thermostat full opening temperature.
Thermostat Full Opening Temperature:
100°C (212°F)
Valve Lift at Fully Open Position: 9.5 mm (0.374
in)0
-10
-20
-30
-40
-50
-60
10 20 30
Mixing ratio (%)
Freezing point (
C)
40 50 60
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6A – 12 ENGINE MECHANICAL
Drive Belt Adjustment
Check the drive belt tension
Depress the drive belt mid-portion with a 98 N (10 kg/
22 lb) force.
Drive Belt Deflection: 10 mm (0.39 in)
Check the drive belt for cracking and other damage.
Legend
(1) Crankshaft pulley
(2) Generator pulley
(3) Cooling fan pulley
(4) A/C compressor pulley
(5) Belt tensioner pulley
Cooling Fan Pulley Drive Belt
Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98 N (10 kg/
22 lb) force.Legend
(1) Crankshaft pulley
(2) Generator pulley
(3) Cooling fan pulley
Compressor Pulley Drive Belt
Move the tensioner pulley as required to adjust the
compressor drive belt tension.
Depress the drive belt mid-portion with a 98 N (10 kg/
22 lb) force.
Legend
(1) Crankshaft pulley
(2) Generator pulley
(3) Cooling fan pulley
(4) A/C compressor pulley
(5) Belt tensioner pulley
5
3
24
1
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2
1
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3
24
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6A – 26 ENGINE MECHANICAL
ENGINE ASSEMBLY
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REMOVAL
1. Remove battery.
2. Drain engine coolant
3. Disconnect window washer hose and remove
engine hood.
4. Radiator Hose
1) Disconnect upper and lower hoses from engine
side.
5. Fan Shroud
1) Disengage clips and remove upper and lower
fan shrouds.
6. Cooling Fan Assembly
1) Remove cooling fan assembly fixing nuts,
cooling fan assembly.
7. Radiator Assembly
1) Remove bracket and radiator assembly.
8. Air Cleaner Cover & Air Duct
9. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
10. Engine Ground Cable
1) Disconnect ground cable from A/C compressor
bracket.
11. AC Generator Harness
1) Disconnect B terminal and harness connector
from AC generator.12. A/C Compressor Assembly
1) Disconnect magnetic clutch harness connector.
2) Remove A/C compressor fixing bolt (rear under
side of compressor).
3) Remove fixing bolts (upper and front lower side
of compressor) and set A/C compressor
assembly with pipe lines on battery carrier.
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.

ENGINE MECHANICAL 6A – 27
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.
Torque: 40 Nꞏm (4 kgꞏm/29 lbꞏft)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
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6A – 48 ENGINE MECHANICAL
TIMING GEAR
REMOVAL
1. Loosen fixing bolt for generator and remove
generator assembly.
2. Remove fixing nuts, then remove cooling fan
assembly and fan pulley.
3. Remove crankshaft damper pulley.
4. Belt cover
1) Disconnect harness connector of CMP
(camshaft position) sensor.
2) Remove CMP sensor.
3) Remove belt cover.
5. Loosen belt tensioner to remove timing belt.
6. Remove camshaft pulley.
7. Remove high pressure oil pump pulley.
8. Remove front plate.
9. Remove vacuum pump.
10. Remove power steering pump.
11. Remove gear cover assembly.
12. Idle gear A.
1) Set two bolts to sub gear of idle gear A and turn
it to align the tooth of idle gear A then lock them
by bolt as show in the illustration.
2) Remove idle gear A fixing bolts.
3) Remove idle gear A.Legend
(1) Sub-Gear
(2) Main Gear
(3) Bar
(4) Locking Bolt
2
3
4
5 8
7
6 91
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Legend
(1) Idle Gear A
(2) High Pressure Oil Pump Gear
(3) Vacuum Pump Gear
(4) Power Steering Pump Gear(5) Balance Gear LH
(6) Idle Gear C
(7) Crankshaft Gear
(8) Balance Gear RH
(9) Idle Gear B
4 1
2
3
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ENGINE MECHANICAL 6A – 55
18. Crankshaft damper pulley
1) Insert damper pulley with the crankshaft key
groove set on the key.
2) Tighten damper pulley bolt to the specified
torque.
Torque: 220 Nꞏm (22 kgꞏm / 159 lb ft)19. Cooling fan Assembly
1) Install the cooling fan assembly to the fan pulley,
tighten the nuts to the specified torque.
Torque: 8 Nꞏm (0.8 kgꞏm / 5.8 lb ft)
20. AC generator drive belt.
1) Temporarily tighten generator fixing bolts and
belt tensioner adjustment plate.
2) Tension the generator drive belt then tighten the
generator fixing bolt.
Torque: 40 Nꞏm (4.0 kgꞏm / 29 lb ft)
3) Tighten the belt tensioner adjustment plate bolt.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
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