engine oil OPEL FRONTERA 1998 Workshop Manual

6A – 2 ENGINE MECHANICAL
GENERAL DESCRIPTION
Cylinder Head Gasket
The cylinder head gasket is laminated steel sheets.
Three grades of the gasket according to the measured
piston head projection from the cylinder block are
provided to give the engine a minimum compression
ratio fluctuation.
Tightening Method for
Special Bolt
The cylinder head fixing bolts, flywheel bolts and
connecting rod cap fixing bolts are tightened by the
angular Tightening Method.
Piston
Auto-thermatic pistons having steel struts with a 0.4
mm offset from the piston pin center line, are applied to
reduce thermal expansion and resulting engine noise
when the engine is cold.
Bearings
The crankshaft bearings and connecting rod bearings
are of aluminum having a high bearing surface.
These bearings are especially sensitive to foreign
material such as metal scraps. So, it is very important
that the oil ports and other related surfaces are kept
clean and free of foreign material.
Crankshaft bearings are selected for optimum bearing
and journal clearance which reduces vebration and
noise.
For General Export
For Europe
F06R200004

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
For Europe : 18.5
Engine weight (dry) N (kg/lb) 2492 (254/560) (A/T)
For Europe : 2422 (247/545) (A/T)
2649 (270/593) (M/T)
For Europe : 2697 (275/606) (M/T)
Engine idling speed (Reference) RPM 720
Compression pressure kpa (kg/cm
2/psi)-rpm 3040 (31/441)-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
Crankshaft
As tufftriding (Nitrizing treatment) is applied to increase
crankshaft strength, crankpins and journals should not
be reground.
Piston Cooling
An oiling jet device for piston cooling is provided in the
lubricating oil circuit from the cylinder block oil gallery
via a check valve.
Take care not to damage any oiling jet when removing
and installing piston and connecting assembly.
Fuel Injection System
The injection system is oil rail type.
Quick On Start 4 System
QOS4 preheating system which features a quick-on
glow plug with thermometer control of the glowing time
and the afterglow time function, is applied.

6A – 6 ENGINE MECHANICAL
SERVICE STANDARD
Enginemm (in)
Parts Items Service standard Service limit Remarks
Cylinder Head
Va l v e S p r i n g
Va l v e a n d
Valve guide
Camshaft0.075 (0.0030) or less
95.0 (3.740)
45.7 (1.8)
—
241 (54.2)
6.959 – 6.977
(0.27 – 0.272)
6.692 – 6.970
(0.271 – 0.272)
0.023 – 0.056
(0.0009 – 0.0022)
0.03 – 0.063
(0.0011 – 0.0024)
8.0 (0.312)
1.1 (0.0433)
1.2 (0.0472)
1.2 (0.0472)
45°
2.1 (0.0827)
2.1 (0.0827)
0.08 (0.00314)
46.67 (1.8374)
46.77 (1.8413)
29.939 – 29.960
(1.167 – 1.168)
0.02 (0.0008) or less
0.40 – 0.082
(0.0016 – 0.0032)0.50 (0.0197)
—
44.8 (1.765)
1.6 (0.063)
210 (47.22)
6.92 (0.270)
6.90 (0.269)
0.19 (0.0074)
0.20 (0.0079)
—
1.6 (0.0630)
1.1 (0.0433)
1.1 (0.0433)
—
2.6 (0.1024)
2.6 (0.1024)
2.0 (0.00797)
46.57 (1.8335)
46.67 (1.8374)
29.84 (1.1748)
0.10 (0.0039)
0.12 (0.0047)Cannot be
reground Cylinder head lower surface for flatness
Cylinder head height
Free height
Squareness
Spring tension (when assembled) N(lb)
Diameter of Valve stem IN
EX
Valve and valve guide clearance IN
EX
Valve guide upper end height
(Measured from the Cylinder head upper
face)
Valve guide margin
Valve thickness IN
EX
Valve seat contact surface angle
Valve seat contact width IN
EX
End play
Cam lobe height IN
EX
Journal diameter
Runout
Camshaft oil clearance

ENGINE MECHANICAL 6A – 7
Parts Items Service standard Service limit Remarks
Tappet
Crankshaft
Piston,
Piston pin,
Piston ring
and
Connecting
rod32.977 – 32.990
(1.2983 – 1.2988)
0.01 – 0.039
(0.0004 – 0.0015)
0.04 – 0.20
(0.0016 – 0.0079)
0.037 – 0.068
(0.0015 – 0.0027)
0.05 (0.0020) or less
69.917 – 69.932
(2.7526 – 2.7532)
52.915 – 52.930
(2.0933 – 2.0839)
95.32 – 95.349
(3.7527 – 3.7539)
0.11 – 0.92
(0.0043 – 0.0362)
0.25 – 0.40
(0.0098 – 0.0157)
0.20 – 0.35
(0.0079 – 0.0138)
0.10 – 0.30
(0.0039 – 0.0118)
0.05 – 0.09
(0.0020 – 0.0035)
0.03 – 0.07
(0.00118 – 0.00276)
30.995 – 31.000
(1.203 – 1.205)
0.008 – 0.020
(0.0003 – 0.00079)
0.005 – 0.018
(0.0002 – 0.0007)
0.08 (0.031) or less
0.05 (0.0020) or less
0.230 (0.0091)
0.022 – 0.042
(0.0009 – 0.0017)32.950 (1.2972)
0.10 (0.0039)
0.30 (0.00118)
0.11 (0.0043)
0.08 (0.0031)
69.91 (2.7524)
52.90 (2.0827)
—
—
1.5 (0.0590)
1.5 (0.0590)
1.5 (0.0590)
0.15 (0.0059)
0.15 (0.0059)
30.97 (1.2078)
0.05 (0.0020)
0.04 (0.0016)
0.20 (0.00787)
0.15 (0.0059)
0.35 (0.0138)
0.0060
(0.0024)Uneven
wear limit
0.05 (0.002)
Uneven
wear limit
0.08 (0.0031)
Per 100
(3.94)
Per 100
(3.94) Outside diameter
Oil clearance
Thrust clearance
Main bearing oil clearance
Crankshaft runout
Main journal diameter
Crank pin diameter
Piston diameter
Piston clearance
Piston ring gap 1st
2nd
Oil
Piston ring clearance 1st/2nd
Oil
Piston pin diameter
Piston pin clearance
(Between connecting rod and piston pin)
Piston pin clearance
(Between piston and piston pin)
Connecting rod alignment Bend
Twist
Connecting rod thrust clearance
Oil clearance
(Between crank pin and Connecting rod)
mm (in)

ENGINE MECHANICAL 6A – 9
SERVICING
Servicing refers to general maintenance procedures to
be performed by qualified service personnel.
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the rear left hand
side of the cylinder body.
AIR CLEANER
Oil Wetted (Viscous) Type Paper Element.
The air cleaner has an oil wetted paper element. No
servicing is required until the replacement interval is
reached.
Never attempt to clean the element, no matter how dirty
it may appear. The element is designed to provide
normal filtering efficiency until it becomes due for
replacement.
Refer to the Item “Service and Maintenance” in the
Owner’s and Driver’s Manual for general service
information.
LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
1. Loosen the drain plug to drain the engine oil.
2. Wait a few minutes and then retighten the drain
plug.
3. Loosen the used oil filter (2) by turning it counter-
clockwise with the filter wrench.
4. Clean the oil filer gasket fitting face.
This will allow the new oil filter to seat properly.
5. Apply a light coat of engine oil to the O-ring.
6. Turn the new oil filter until the filter O-ring is fitted
against the sealing face.
7. Use the filter wrench to turn the filter additional one
and 1/4 turns.
Filter Wrench: 5-5540-0203-0
012RW115
012RW062
For Europe1
2
050R200001

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.
012RW112
012RW078
1
012RW111
012RW080

6A – 14 ENGINE MECHANICAL
TIGHTENING TORQUE
Timing Gear Case, Timing Gear
Nꞏm (kgꞏm/lbꞏft)
75(7.6/55)
Apply engine oil to
thread and seat 8(0.8/6)
20(2.0/14.5)
51(5.2/38)
25(2.5/18)
020RW00001

ENGINE MECHANICAL 6A – 15
Cylinder Head, Flywheel, Crank Case, Oil Pan
Nꞏm (kgꞏm/lbꞏft)
012RW121
1st
49N•m(5.0kg•m/36 Ib ft)
167(17.0/123)
8(0.8/5.8)
20(2.0/14.5)
20(2.0/14.5)
30(3.1/22)
25(2.5/18)
2nd
60
1st
59N•m(6kg•m/43 Ib ft)
2nd
60-90
1st
29N•m(3.0kg•m/22 Ib ft)
2nd
45-60
3rd
60
19(1.9/14)

ENGINE MECHANICAL 6A – 19
Injector
Nꞏm (kgꞏm/lbꞏft)
E06R200022
With
spacer type
Without
spacer type
20Nꞏm(2.0kgꞏm/14 Ib ft)
7Nꞏm(0.7kgꞏm/61 Ib in)
Recheck tightening torque
after tighten the oil rail
Apply engine oil on the
thread of stud bolts
20Nꞏm(2.0kgꞏm/14 Ib ft)
Tighten 30Nꞏm(3.1kgꞏm/22 Ib ft)
Then loosen it again tighten with
24Nꞏm(2.4kgꞏm/17 Ib ft)
Apply engine oil
both side

6A – 20 ENGINE MECHANICAL
High Pressure Oil Pipe
Nꞏm (kgꞏm/lbꞏft)
80(8.1/57.9)
80(8.1/57.9)
80(8.1/57.9)
80(8.1/57.9)
052R200002