belt OPEL FRONTERA 1998 User Guide

6A–20
ENGINE MECHANICAL
5. Install auto tensioner assembly and tighten the fixing
bolts to the specified torque.
Torque :
Shorter Bolt : 20 Nꞏm (2.0 Kgꞏm/14 lb ft)
Longer Bolt : 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
6. Install idle pulley and bracket assembly and tighten
the fixing bolt to the specified torque.
Torque : 52 Nꞏm (5.3 Kgꞏm/38 lb ft)
7. Install fan pulley and bracket assembly and tighten
the fixing bolts and nut to the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
8. Install power steering oil pump pulley and tighten the
fixing bolt to the specified torque.
Torque : 78 Nꞏm (8.0 Kgꞏm/58 lb ft)
9. Install drive belt by pushing down the auto tensioner
using spanner as shown in the removal step of drive
belt.
10. Install cooling fan and clutch assembly and tighten
the fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/87 lb in)
11. Install upper fan guide and clip both side and tighten
the fixing bolts to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
12. Install engine harness and tighten the fixing bolts of
the retaining clip and bracket to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
13. Connect radiator upper and lower hoses and clip
them securely.
14. Connect vacuum hoses of those which were
disconnected in the removal step.
15. Connect wiring connectors and bonding cable of
those which were disconnected in the removal step.
16. Install air cleaner element and air cleaner duct
assembly, and clip the both end securely.
17. Connect MAF sensor connector, IAT sensor
connector and PCV hose.
18. Install engine cover mating with the dowels.

6A–21
ENGINE MECHANICAL
Cylinder Head Cover RH
Removal
1. Disconnect battery ground cable.
2. Remove battery from the vehicle.
3. Drain engine coolant from faucet bottom of radiator.
4. Remove engine cover from the dowels on the
common chamber.
F06RW018
5. Remove air cleaner duct assembly (3) and air cleaner
element (4).
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.
6. Disconnect following wiring connectors and bonding
cable:
Exhaust Gas Recirculation (EGR) valve
Fuel injectors for right bank
Ignition coils for right bank
Bonding cable
Othres as necessitated
7. Disconnect radiator upper and lower hoses.
8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
F06RW019
Legend
(1) Crankshaft Pulley
(2) Generator
(3) Auto Tensioner
(4) Idle Pulley
(5) Cooling Fan Pulley
(6) Power Steering Oil Pump
(7) Drive Belt
(8) Air Conditioner Compressor
12. Remove fan pulley and bracket assembly.
13. Remove idle pulley assembly.
14. Remove auto tensioner assembly.
15. Remove crankshaft pulley using 5–8840–0133–0
crankshaft holder.

6A–22
ENGINE MECHANICAL
16. Remove timing belt covers for right bank side.
17. Reomve timing belt covers for right bank side.
060RW001
Legend
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies
18. Remove ignition coil assemblies for the right side
bank.
19. Remove cylinder head cover assembly.
Installation
1. Install cylinder head cover.
Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area of
camshaft bracket on front and rear sides.
The cylinder head cover must be installed within 5
minutes after sealant application before the sealant
hardens.
014RW143
Tighten bolts in turn to the specified torque.
Torque : 8.8 Nꞏm (0.9 Kgꞏm/78 lb in)
010RW007
2. Install ignition coil assemblies and tighten the fixing
bolts to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35 lb in)
3. Install timing belt cover and tighten the fixing bolts and
nut to the specified torque.
Torque : 19 Nꞏm (1.9 Kgꞏm/14 lb ft)
4. Install crankshaft pulley and tighten the fixing bolt
using 5–8840–0133–0 crankshaft holder to the
specified torque.
Torque : 167 Nꞏm (17 Kgꞏm/123 lb ft)
5. Install auto tensioner assembly and tighten the fixing
bolts to the specified torque.
Torque :
Shorter Bolt : 20 Nꞏm (2.0 Kgꞏm/14.8 lb ft)
Longer Bolt : 39 Nꞏm (4.0 Kgꞏm/28.8 lb ft)

6A–23
ENGINE MECHANICAL
6. Install idle pulley assembly and tighten the fixing bolt
to the specified torque.
Torque : 52 Nꞏm (5.3 Kgꞏm/38.4 lb ft)
7. Install fan pulley and bracket assembly and tighten
the fixing bolts and nut to the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16.2 lb ft)
8. Install drive belt by pushing down the auto tensioner
using spanner as shown in the removal step of drive
belt.
9. Install cooling fan clutch assembly and tighten the
fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in)
10. Install upper fan guide and clip both side and tighten
the fixing bolts to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35.4 lb in)
11. Install engine harness and tighten the fixing bolts of
the retaining clip and brackets to the specified torque.
Torque : 4 Nꞏm (0.4 Kgꞏm/35.4 lb in)
12. Connect radiator upper and lower hoses and clip
them securely.
13. Connect wiring connectors and bonding cable of
those which were disconnected in the removal step.
14. Install air cleaner element and air cleaner duct
assembly, and the clip both end securely.
15. Connect MAF sensor connector, IAT sensor
connector and PCV hose.
16. Install engine cover mating with the dowels.

6A–28
ENGINE MECHANICAL
Crankshaft Pulley
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
3. Remove radiator upper fan shroud from radiator.
4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Serpentine Belt
5. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
6. Remove crankshaft pulley assembly using J-8614-01
crankshaft holder, hold crankshaft pulley then
remove center bolt and pulley.
Installation
1. Install crankshaft pulley using J-8614-01 crankshaft
holder, hold the crankshaft pulley and tighten center
bolt to the specified torque.
Torque : 167 Nꞏm (17.0 Kgꞏm/123 lb ft)
2. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in) for fan and
clutch assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.

6A–29
ENGINE MECHANICAL
Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench
then remove drive belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt
5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10. Remove crankshaft pulley assembly using
5–8840–0133–0 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
13. Remove pusher.CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.
014RW011
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its core
could be damaged. The belt should not be bent at
a radius less than 30 mm.
2. Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during installation.
4. Store timing belt in a cool and dark place. Never
expose the belt direct sunlight or heat.

6A–30
ENGINE MECHANICAL
Installation
NOTE: For correct belt installation, the letter on the belt
must be able to be read as viewed from the front of the
vehicle.
014RY00042
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley
014RY00043
Legend
(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt
(9) Alignment Mark (notch) on Crankshaft Timing
Pulley.
(10) Alignment Mark (groove) on Crankshaft Timing
Pulley.
014RW006
Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
1. Install timing belt.
1. Align the mark (notch) of crankshaft timing pulley
(2) with mark on oil pump (1).
Align the mark (groove) on the crankshaft timing
pulley (3) with alignment mark (white dots line) on
the timing belt (4).
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.
014RW003
Legend
(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt

6A–31
ENGINE MECHANICAL
2. Align the alignment mark on the RH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover RH (3).
3. Align the alignment mark (white line) on the timing
belt (1) with alignment mark on the RH bank
camshaft drive gear pulley (2) (on the left side as
viewed from the front of the vehicle) and put the
timing belt on the camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
014RW00004
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.
4. Align the alignment mark on the LH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover LH (3).
5. Align the alignment mark (white line) on the timing
belt (1) with the alignment mark on the LH bank
camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench to
turn the camshaft drive gear pulley, then set the
timing mark between timing belt and camshaft
drive gear pulley and put the timing belt on the
camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
NOTE: It is recommended for easy installation that the
belt be secured with a double clip or equivalent clip after
it is installed the timing belt to each pulley.
014RW00005
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.
6. Install crankshaft pulley temporarily and tighten
center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give some
belt slack between the crankshaft timing pulley
and the RH bank camshaft drive gear pulley.
2. Install pusher and tighten bolt to the specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
1. Install the pusher while pushing the tension pulley
to the belt.
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).
014RW011

6A–32
ENGINE MECHANICAL
Legend
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin
3. Remove double clips or equivalent clips, from
timing belt pulleys.
Turn the crankshaft pulley clockwise by two turns.
3. Install timing belt cover.
Remove crankshaft pulley that was installed in step
1 item 5.
Tighten bolts to the specified torque.
Torque: 19 Nꞏm (1.9 Kgꞏm/14 lb ft)
020RW004
Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower
020RW003
Legend
(1) Timing Belt Cover
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body
4. Install crankshaft pulley using 5–8840–0133–0, hold
the crankshaft pulley and tighten center bolt to the
specified torque.
Torque : 167 Nꞏm (17.0 Kgꞏm/123 lb ft)
5. Install fan pulley bracket and tighten fixing bolts to the
specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
6. Install power steering pump assembly and tighten to
the specified torque.
To r q u e :
M8 bolt : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
M10 bolt : 46 Nꞏm (4.7 Kgꞏm/34 lb ft)
7. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in) for fan and
clutch assembly.
8. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Auto Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt
9. Install radiator upper fan shroud.
10. Install air cleaner assembly.

6A–33
ENGINE MECHANICAL
Camshaft
Removal
1. Disconnect battery ground cable.
2. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
3. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
4. Remove cylinder head cover LH.
Refer to removal procedure for Cylinder Head
Cover LH in this manual.
5. Remove cylinder head cover RH.
Refer to removal procedure for Cylinder Head
Cover RH in this manual.
6. Remove twenty fixing bolts from inlet and exhaust
camshaft bracket on one side bank, then camshaft
brackets.
014RW027
7. Remove camshaft assembly.
8. Remove fixing bolt for camshaft drive gear pulley.
9. Remove three fixing bolts from camshaft drive gear
retainer, then camshaft drive gear assembly.
014RW026
Legend
(1) Right Bank
(2) Left Bank
(3) Timing Mark on Retainer
Installation
1. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
2. Tighten bolt for camshaft drive gear assembly pulley
to the specified torque.
Torque : 98 Nꞏm (10.0 Kgꞏm/72 lb ft)
3. Tighten sub gear setting bolt.
1. Use the 5–8840–2443–0 gear spring lever to turn
sub gear to right direction until it aligns with the M5
bolt hole between camshaft driven gear and sub
gear.
2. Tighten the M5 bolt to a suitable torque to prevent
the sub gear from moving.