oil pump OPEL FRONTERA 1998 User Guide

6A–11
ENGINE MECHANICAL
Condition CorrectionPossible cause
Engine overheatingLevel of Engine Coolant too lowReplenish
Fan clutch defectiveReplace
Incorrect fan installedReplace
Thermostat defectiveReplace
Engine Coolant pump defectiveCorrect or replace
Radiator cloggedClean or replace
Radiator filler cap defectiveReplace
Level of oil in engine crankcase too
low or wrong engine oilChange or replenish
Resistance in exhaust system
increasedClean exhaust system or replace
defective parts
Throttle Position Sensor adjustment
incorrectReplace with Throttle Valve ASM
Throttle Position Sensor circuit open
or shortedCorrect or replace
Cylinder head gasket damagedReplace
Engine overcoolingThermostat defectiveReplace (Use a thermostat set to
open at 82
C (180F))
Engine lacks compression————Refer to Hard Start
OthersTire inflation pressure abnormalAdjust to recommended pressures
Brake dragAdjust
Clutch slippingAdjust or replace
Level of oil in engine crankcase too
highCorrect level of engine oil
Exhaust Gas Recirculation Valve
defectiveReplace
Engine Noisy
Abnormal engine noise often consists of various noises
originating in rotating parts, sliding parts and othermoving parts of the engine. It is, therefore, advisable to
locate the source of noise systematically.
Condition
Possible causeCorrection
Noise from crank journals or from
crank bearings
(Faulty crank journals and crankOil clearance increased due to worn
crank journals or crank bearingsReplace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing
yj
bearings usually make dull noise that
becomes more evident when
accelerating)Crankshaft out of roundReplace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing
Crank bearing seizedCrank bearing seized. Replace crank
bearings and crankshaft or regrind
crankshaft and install the undersize
bearing
Troubleshooting Procedure
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with defectivebearing by listening for abnormal noise that stops when
spark plug is shorted out.

6A–16
ENGINE MECHANICAL
Lubrication Problems
ConditionPossible causeCorrection
Oil pressure too lowWrong oil in useReplace with correct engine oil
Relief valve stickingReplace
Oil pump not operating properlyCorrect or replace
Oil pump strainer cloggedClean or replace strainer
Oil pump wornReplace
Oil pressure gauge defectiveCorrect or replace
Crankshaft bearing or connecting
rod bearing wornReplace
Oil contaminationWrong oil in useReplace with correct engine oil
Oil filter cloggedReplace oil filter
Cylinder head gasket damageReplace gasket
Burned gases leakingReplace piston and piston rings or
cylinder body assembly
Oil not reaching valve systemOil passage in cylinder head or
cylinder body cloggedClean or correct
Engine Oil Pressure Check
1. Check for dirt, gasoline or water in the engine oil.
a. Check the viscosity of the oil.
b. Change the oil if the viscosity is outside the
specified standard.
c. Refer to the “Maintenance and Lubrication” section
of this manual.
2. Check the engine oil level.
The level should fall somewhere between the “ADD”
and the “FULL” marks on the oil level dipstick.
If the oil level does not reach the “ADD” mark on the
oil level dipstick, engine oil must be added.3. Remove the oil pressure unit.
4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach normal
operating temperature (About 80
C).
6. Measure the oil pressure.
Oil pressure should be:
392–550 kPa (56.9–80.4 psi) at 3000 rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure unit.
10. Start the engine and check for leaks.

6A–19
ENGINE MECHANICAL
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 power steering oil pump pulley.
13. Remove fan pulley and bracket assembly.
14. Remove idle pulley assembly.
15. Remove auto tensioner assembly.
16. Remove crankshaft pulley using 5–8840–0133–0
crankshaft holder.
17. Remove timing belt covers from the right bank side to
the left bank side in order.
18. Remove ignition coil assemblies for the left side bank.
060RW018
Legend
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies
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 to prevent
premature hardening of sealant.
014RW144
Tighten bolts to the specified torque.
Torque : 9 Nꞏm (0.9 Kgꞏm/78 lb in)
010RW008
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 covers from left bank side to right
bank side, 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 (17.0 Kgꞏm/123 lb ft)

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–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–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–41
ENGINE MECHANICAL
3. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
050RW002
Legend
(1) Oil Pump
(2) Oil Strainer
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
4. Remove three fixing bolts, oil pipe with O-ring.
5. Remove eight fixing bolts, oil gallery.
6. Remove piston with connecting rod assembly, before
removing the bearing cap, remove carbon on the top
of cylinder bore and push piston with connecting rod
out from the top of cylinder bore.
Installation
1. Install piston with connecting rod assembly.
Apply engine oil to cylinder bore, connecting rod
bearing and crank pin.
When installing the piston, its front mark must face
the engine front side.
The bearing cap number must be the same as
connecting rod number.
Apply engine oil to the thread and seating surface of
each nut.
Tighten nuts to the specified torque.
Torque : 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
After tightening the nuts, make sure that the
crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back faces
and connecting rod bearing fitting surfaces.
015RW003
Legend
(1) Piston Front Mark
(2) Piston Grade
(3) Connecting Rod Front Mark
2. Install oil gallery and tighten the bolts in two steps, in
the order shown in illustration.
To r q u e :
1st step : 29 Nꞏm (3.0 Kgꞏm/21 lb ft)
2nd step : 55
–65
051RS009
3. Install oil pipe with O-ring.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
4. Install oil strainer assembly with O-ring.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
5. Install crankcase with Oil Pan.
Refer to installation procedure for Oil Pan and
Crankcase in this manual.
6. Install cylinder head assembly.
Refer to installation procedure for Cylinder Head in
this manual.