belt OPEL FRONTERA 1998 Workshop Manual

6G–11 ENGINE LUBRICATION
4. Install oil filter assembly and tighten bolts to the
specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
5. Install timing pulley on crankshaft.
Install timing belt.
Refer to installation procedure for Timing Belt in this
manual.
6. Install crankshaft pulley.
Refer to install procedure for Crankshaft Pulley in
this manual.
7. Install crankcase assembly.
Refer to installation procedure for Oil Pan and
Crankcase in this manual.
8. Refill engine oil until full level on engine oil dipstick.

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–14
ENGINE LUBRICATION
Main Data and Specification
General Specification
ItemSpecificationsItem6VD16VE1
Oil capacity5.3 liters
Torque Specifications
Crankcase, Oil pan, Timing belt tensioner, Timing
pulley, timing belt cover, Oil pump, Oil gallery, Oil
strainer Nꞏm (Kgꞏm/lb ft)
E06RW045

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
012RW110
3
2
1
012RW084
5
3
24
1
012RW110

6A – 34 ENGINE MECHANICAL
EXHAUST MANIFOLD
REMOVAL
1. Remove the hose from both turbocharger outlet and
intake manifold inlet side, then remove intercooler
assembly.
2. Loosen belt tensioner, remove A/C compressor
assembly.
3. Remove heat protector from turbocharger.
4.Remove water hoses and oil pipes from
turbocharger.
5. Remove turbocharger assembly from exhaust
manifold.
6. Remove exhaust manifold fixing nuts, then remove
exhaust manifold.
INSTALLATION
1. Install gasket on the exhaust manifold and tighten
to the specified torque.
Torque : 30 Nꞏm (3.1 kgꞏm/22 lb ft)
2. Install turbocharger on the exhaust manifold.
Torque : 27 Nꞏm (2.8 kgꞏm/20.2 lb ft)
3. Install water hoses and oil pipes.
4. Install heat protector to turbocharger.
Torque : 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
5. Install A/C compressor assembly and readjust belt
tensioner.
6. Install the intercooler assembly in the normal
position.
Connect both hoses to turbocharger and intake
manifold.
9875 63
21
4
025RW023
Legend
(1) Exhaust Manifold
(2) Gasket
(3) Turbocharger Assembly
(4) Water Hose(5) Water Hose
(6) Heat Protector
(7) Oil Pipe
(8) Oil Pipe
(9) Gasket

6A – 40 ENGINE MECHANICAL
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove air cleaner and air duct.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Remove PCV hose.
7. Remove EGR vacuum hose.
8. Disconnect harness connector around the cylinder
head.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out fan belt.
12. Remove heat protector and remove valve
assembly.
13. Remove water hose and oil pipe from turbocharger.
14. Remove turbocharger assembly.
15. Remove water hose between thermostat and
radiator.
16. Remove cylinder head noise insulator cover.
NOTE: Do not make damage to the harness.
17. Remove high pressure pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner and remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove water pipe between cylinder head and
water pump.
24. Remove fuel pipe between fuel pump and intake
manifold.
25. Remove fuel return pipe.
26. Remove intake manifold assembly.
27. Disconnect glow plug wiring and remove glow plug.
28. Remove cylinder head cover.
29. Drain oil from oil rail.
30. Disconnect injector harness connector.
31. Disconnect harness connector from oil pressure
sensor and oil temperature sensor on the oil rail.
32. Disconnect injector harness assembly.
33. Remove injector clamp.
34. Remove injector spacer.
35. Remove injector assembly.
36. Remove oil rail assembly.
37. Remove camshaft carrier.
38. Remove cylinder head assembly.
39. Remove cylinder gasket.
INSTALLATION
1. Install cylinder head gasket with top mark up.
NOTE: Determine cylinder head gasket grade by
measuring projection of piston head.2. Selection cylinder head gasket.
1) Measure the piston head projection by injector
gauge.
2) Measure the projection of piston head at the
nearest possible point to the cylinder bore.
3) Obtain the largest measurement from among all
cylinders.
4) Determine cylinder head gasket grade by
maximum value of measuring projection of
piston head.
Legend
(1) Top Mark
(2) Grade Mark
012RW073
2 1
011RW043

ENGINE MECHANICAL 6A – 41
Cylinder head gasket and piston projection mm
CAUTION:
The projection of each piston should be 0.333
mm or more and less than 0.483 mm.
Maximum difference in projection between
pistons should be less than 0.1 mm.
If the piston projection is without standard,
reassemble the engine all over again.
3. Install cylinder head assembly, tighten bolts by
angular tightening method.
To r q u e :
1st step; 49 Nꞏm (4.9 kgꞏm/35.4 lb ft)
2nd step; 60°
3rd step; 60°
4. Install camshaft carrier assembly.
Refer to “Camshaft” in this manual.
5. Install oil rail and injector assembly.
Refer to “Oil rail and injector” in this manual.
6. Install injector harness to connect harness
connector.
Note: Apply liquid gasket (TB 1207B or equivalent) to
the rubber seal of the camshaft end, injector harness
gasket area and No. 1 camshaft bracket. Refer to the
Cylinder head cover.
7. Install cylinder head cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
8. Install glow plug to tighten specified torque.
Torque: 15 Nꞏm (1.5 kgꞏm/11 lb ft) and connect
glow plug harness.
9. Install intake manifold.Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
10. Install fuel return pipe.
11. Install fuel pipe in between fuel pump and intake
manifold.
12. Install water pipe in between cylinder head and
water pump.
Tighten flange bolt to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
13. Install front plate.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
14. Install camshaft pulley, tighten with angular
tightening method.
1st step 40 Nꞏm (4.0 kgꞏm/29 lb ft)
2nd step 60°
NOTE: Apply engine oil to camshaft pulley bolt.
15. Align timing mark oil pump pulley and camshaft
pulley to front plate then put the timing belt and
tighten tensioner bolt.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) for M8
50 Nꞏm (5.1 kgꞏm/37 lb ft)
16. Install CMP sensor bracket.
17. Install timing belt cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
18. Fill with about 300 cc of engine oil from the high
pressure oil pipe installing port of oil rail using an oil
filler.
If assembled without filling the oil rail with oil, the
time for engine start will be longer.
19. Immediately install high pressure oil pipe to tighten
with specified torque.
Torque: 80 Nꞏm (8 kgꞏm/57.9 lb ft)
20. Install cylinder head noise insulator cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
Grade A Grade B Grade C
011RW042
Grade Piston projectionGasket
thickness
A more 0.333 to less 0.383 1.35
B more 0.383 to less 0.433 1.40
C more 0.433 to less 0.483 1.45

6A – 42 ENGINE MECHANICAL
Legend
(1) Cylinder Head Noise Insulator Cover
(2) Insulator
(3) Bolt
(4) Oil Seal
(5) Gasket
(6) Cylinder Head Cover
(7) Bolt
21. Install water hose between thermostat and radiator.
22. Install turbocharger assembly to exhaust manifold.
Torque: 27 Nꞏm (2.8 kgꞏm/20.2 lb ft)
23. Install water hose and oil pipe for turbocharger.
24. Install exhaust valve assembly and heat protector.
Torque: 27 Nꞏm (2.8 kgꞏm/20.2 lb ft) for valve
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft) for heat protector25. Install generator assembly.
Torque: 40 Nꞏm (4.0 kgꞏm/29 lb ft) for ACG bracket
Torque: 40 Nꞏm (4.0 kgꞏm/29 lb ft) between ACG and
bracket
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) between ACG
and adjuster plate
26.Fix the A/C compressor bracket and install A/C
compressor.
Torque: 47 Nꞏm (4.7 kgꞏm/34 lb ft) for A/C bracket
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) for belt tensioner
27. Reconnect harness connector around cylinder
head.
28. Connect EGR vacuum hose.
29. Install oil level gauge guide assembly.
Tighten nuts lower portion and tighten bolt.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
30. Install intercooler assembly.
Refer to “Intercooler” in this manual.
31. Install air duct between air cleaner and
turbocharger.
32. Fill engine coolant.
33. Reconnect battery.
036RW005
036RW006
1
2
3 7
4
5 6
010RW010

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
020RW028
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
014RW177

6A – 54 ENGINE MECHANICAL
14. Camshaft pulley
1) Align TDC mark with crankshaft pulley and gear
case cover.
2) Set camshaft stopper on the end of intake and
exhaust camshaft.
Camshaft Stopper: 5-8840-2592-0
3) Install key to camshaft and install camshaft
pulley.
4) Apply engine oil to camshaft pulley fixing bolt
and tighten bolt with angular tightening method.
First step: 40 Nꞏm (4.0 kgꞏm / 29 lb ft)
Second step: 60° to 90°
15. Timing belt
1) Install tensioner and tighten the bolt temporarily.
2) Align timing mark with camshaft pulley timing
mark and timing gear case timing mark.
3) Set No.1 cylinder TDC position.4) Install the timing belt in the following order
camshaft pulley, oil pump pulley, tensioner.
NOTE:
1) It is recommended for easy installation that the belt
be secured with a double clip after it is installed to
each pulley.
2) The “ISUZU” mark should be read from the front of
the engine when installing the timing belt.
5) Install the belt tensioner.
6) Conform not phase difference each pulley.
7) Tension the timing belt with two turns of the
crankshaft.
8) Tighten the tensioner bolt in order A to B to the
specified torque.
Torque: Bolt A 5 Nꞏm (0.5 kgꞏm/3.6 lb ft)
Bolt B 2 Nꞏm (0.2 kgꞏm/1.4 lb ft)
Legend
(1) Align Mark
(2) Camshaft Pulley
(3) Timing Belt
(4) Oil Pump Pulley
(5) Bolt B
(6) Tensioner Assy
(7) Tensioner Bolt A
(8) Tensioner Spring
16. CMP sensor bracket
1) Install CMP sensor bracket and tighten bolt to
the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
17. Timing belt cover
1) Install timing belt cover and tighten bolt to the
specified torque.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
2) Tighten CMP sensor to the specified torque.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
012RW036
012RW099
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3
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F06RW055