battery OPEL FRONTERA 1998 Workshop Manual

6F–7 ENGINE EXHAUST
Rear Exhaust pipe
Rear Exhaust pipe and Associated Parts
E06RW033
Legend
(1) Mounting Rubber(2) Rear Exhaust Pipe
(3) Rear Exhaust Pipe Fixing Nuts
Removal
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety
stands.
3. Remove rear exhaust pipe fixing nuts (3), then
disconnect rear exhaust pipe from exhaust silencer.
4. Remove mounting rubber (1).
5. Remove rear exhaust pipe (2).
Installation
1. Install the mounting rubber (1).
2. Install the exhaust pipe (2) and tighten two nuts (3) on
exhaust silencer to specified torque.
Nuts: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)

6G–7 ENGINE LUBRICATION
Oil Pan and Crankcase
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Lift vehicle by supporting the frame.
4. Remove front wheels.
5. Remove oil level dipstick from level gauge tube.
6. Remove stone guard.
7. Remove radiator under fan shroud.
8. Remove suspension cross member fixing bolts, 2 pcs
each per side and remove suspension cross member.
9. Remove pitman arm and relay lever assembly, using
the 5–8840–2005–0 remover, remove pitman arm
from the steering unit and remove four fixing bolts for
relay lever assembly.
10. Remove axle housing assembly four fixing bolts from
housing isolator side and mounting bolts from wheel
side. At this time support the axle with a garage jack
and remove axle housing assembly.
11. Remove oil pan fixing bolts.
12. Remove oil pan, using 5–8840–2153–0 sealer cutter,
remove oil pan.
013RS003
13. Remove crankcase fixing bolts.
14. Remove crankcase, using 5–8840–2153–0 sealer
cutter, remove crankcase.
NOTE: Do not deform or damage the flange of oil pan and
crankcase.
Replace the oil pan and/or crankcase if deformed or dam-
aged.
013RS003
Installation
1. Install crankcase.
1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB-1207C or equivalent) to mounting
surface of crankcase.
Sealant beat must be continuous.
The crankcase must be installed within 5
minutes after sealant application before the
sealant hardens.
013RW010

6G–10
ENGINE LUBRICATION
Oil Pump
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankcase assembly.
Refer to removal procedure for Oil Pan and
Crankcase in this manual.
4. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
5. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
6. Remove timing pulley from crankshaft.
7. Remove four fixing bolts from oil filter assembly.
8. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
9. Remove three bolts from oil pipe and O-ring.
10. Remove eight oil pump fixing bolts, then oil pump
assembly.
11. Remove sealant from mounting surface of oil pump
assembly, cylinder block and take care not to damage
mounting surfaces of oil pump and cylinder block.
Installation
1. Install oil pump assembly
Apply sealant (TB-1207B or equivalent) to the oil
pump mounting surfaces as shown in the
illustration.
The oil pump assembly must be installed within 5
minutes after sealant application before the sealant
hardens.
NOTE: Do not apply sealant to the oil ports.
051RW002
Use 5–8840–2287–0 installer when installing new
oil seal.
Apply engine oil to oil seal lip.
Install oil pump assembly to the cylinder block.
NOTE: Do not damage oil seal during installation of oil
pump assembly.
015RS001
Tighten fixing bolts to the specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
051RW001
2. Install oil pipe with O-ring, tighten fixing bolt to the
specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
3. Install oil strainer with O-ring, tighten fixing bolt to the
specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)

6G–12
ENGINE LUBRICATION
Oil Pump Oil Seal
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
4. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
5. Remove timing pulley from crankshaft.
6. Remove oil pump oil seal using a sealer puller.
NOTE: Take care not to damage sealing surfaces of oil
pump and crankshaft when removing oil seal.
Installation
1. Install oil pump oil seal, apply engine oil to oil seal lip,
then install oil seal using 5–8840–2287–0 installer.
015RS001
2. Install timing pulley to crankshaft.
3. Install timing belt.
Refer to installation procedure for Timing Belt in this
manual.
4. Install crankshaft pulley.
Refer to installation procedure for Crankshaft
Pulley in this manual.
5. Refill engine oil until full level.

6G–13 ENGINE LUBRICATION
Oil Filter
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove oil filter using 5-8840-0203-0 filter wrench.
Installation
1. Clean filter fitting surface and apply small amount of
engine oil to sealing surface.
2. Install oil filter cartridge by hand until it comes in
contact with sealing surface then rotate additional 2/3
turn to tighten using 5-8840-0203-0 filter wrench.
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Filter
(5) To Filter
3. Fill engine oil until full level on dipstick.
4. Reconnect battery ground cable.

6A – 28 ENGINE MECHANICAL
ENGINE ASSEMBLY
For General Export
For Europe
F06R200004
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 Assembly1) 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.

ENGINE MECHANICAL 6A – 29
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.
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.
To r q u e : 4 0 N ꞏm ( 4 k g ꞏm / 2 9 l b ꞏf t )
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
For E urope
F06R200005

6A – 30 ENGINE MECHANICAL
ENGINE MOUNT (RH)
REMOVAL
1. Disconnect battery ground cable
2. Hang the engine assembly.
3. Rubber engine mount.
1) Remove bolts from chassis frame bracket.
2) Remove nuts from rubber engine mount and
engine mounting bracket.
4. Remove bolt which is fixed between engine and
mounting bracket then remove the engine mounting
bracket.
INSTALLATION
Tighten the fixing bolts to the specified torque.
1. Engine mounting bracket to cylinder block.
Torque : 40 Nꞏm (4 kgꞏm/29 lb ft) (for M10)
127 Nꞏm (13 kgꞏm/94 lb ft) (for M14)
2. Rubber engine mount to chassis frame and engine
mounting bracket.
Torque :40 Nꞏm (4 kgꞏm/29 lb ft)
43
12
022RW018
Legend
(1) Rubber Engine Mount (LH)
(2) Engine Mounting Bracket (LH)
(3) Rubber Engine Mount (RH)
(4) Engine Mounting Bracket (RH)

ENGINE MECHANICAL 6A – 31
ENGINE MOUNT (LH)
REMOVAL
1. Disconnect battery ground cable
2. Hang the engine assembly.
3. Rubber engine mount.
1) Remove bolts from chassis frame bracket.
2) Remove nuts from rubber engine mount and
engine mounting bracket.
4. Remove bolt which is fixed between engine and
mounting bracket then remove the engine mounting
bracket.
INSTALLATION
Tighten the fixing bolts to the specified torque.
1. Engine mounting bracket to cylinder block.
Torque : 40 Nꞏm (4 kgꞏm/29 lb ft) (for M10)
127 Nꞏm (13 kgꞏm/94 lb ft) (for M14)
2. Rubber engine mount to chassis frame and engine
mounting bracket.
Torque :40 Nꞏm (4 kgꞏm/29 lb ft)
43
12
022RW018
Legend
(1) Rubber Engine Mount (LH)
(2) Engine Mounting Bracket (LH)
(3) Rubber Engine Mount (RH)
(4) Engine Mounting Bracket (RH)

6A – 32 ENGINE MECHANICAL
INTERCOOLER
REMOVAL
1. Disconnect the battery ground cable.
2. Remove air cleaner cover and air duct.
3. Remove intercooler cover.
4. Remove intercooler assembly.
1) Remove rubber hose from between intercooler
outlet and intake manifold inlet.
2) Remove rubber hose from between
turbocharger outlet and intercooler inlet.
3) Remove intercooler assembly fixing bolts from
the bracket, remove intercooler assembly.
INSTALLATION
1. Intercooler assembly
1) Connect outlet hose to intake manifold.
Torque : 4 Nꞏm (0.4 kgꞏm/3 lb ft)
2) Connect inlet hose from turbocharger to
intercooler.
Torque : 4 Nꞏm (0.4 kgꞏm/3 lb ft)
3) Install intercooler and tighten fixing bolts to the
specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
2. Install intercooler cover.
3. Install air cleaner cover and air duct.
4. Connect the battery ground cable.
For Europe
2
33
1
135R200003
Legend
(1) Air Cleaner Cover & Air Duct(2) Intercooler Cover
(3) Intercooler Assembly