2000 OPEL FRONTERA 1998 Owner's Manual

6A – 40 ENGINE MECHANICAL
INSTALLATION
1. Install turbocharger assembly to exhaust manifold,
tighten to the specified torque.
Torque : 27 Nꞏm (2.8 kgꞏm/20.2 lb ft)
2. Install exhaust adaptor.
Torque : 27 Nꞏm (2.8 kgꞏm/20.2 lb ft)
3. Install heat protector.
4. Install water outlet pipe with gasket.
Torque : 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
5. Install turbocharger oil drain pipe.
Torque : 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)6. Install oil supply pipe to turbocharger.
1) Fill with 100 cc engine oil at the turbocharger oil
supply hole before installing the oil pipe.
2) Turn the turbocharger by hand to lubricate
turbocharger shaft.
3) Install oil supply pipe with new gasket to the
turbocharger and tighten oil supply pipe bolts to
the specified torque.
Torque : 22 Nꞏm (2.2 kgꞏm/15.9 lb ft) for M10
54 Nꞏm (5.5 kgꞏm/39.8 lb ft) for M14
7. Install water inlet pipe with new gasket, tighten to
the specified torque.
Torque : 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
8. Install intercooler assembly.
Refer to “Intercooler” in this manual.
9. Install air cleaner cover with air duct, connect both
side hoses.
10. Fill with engine coolant.
11. Install the battery and connect battery cables.
For Europe
025R200007
For Europe
025R200007
For Europe
025R200006

ENGINE MECHANICAL 6A – 43
CYLINDER HEAD GASKET
12
13
14
15
8
3
4
5 6
10
11 9
With
spacer type
Without
spacer type
1 7
2
011R200002
Legend
(1) Cylinder Head Noise Insulator Cover
(2) Insulator
(3) Bolt and Gasket
(4) Oil Seal
(5) Gasket
(6) Cylinder Head Cover
(7) Bolt, Stud and Rubber Mounting
(8) Injector Clamp(9) Oil Rail
(10) Injector Assembly
(11) Camshaft Carrier
(12) Cylinder Head Bolt
(13) Cylinder Head Assembly
(14) Cylinder Head Gasket
(15) Cylinder Block

6A – 46 ENGINE MECHANICAL
Legend
(1) Cylinder Head Noise Insulator Cover
(2) Insulator
(3) Bolt
(4) Oil Seal
(5) Gasket
(6) Cylinder Head Cover
(7) Bolt, Stud and Rubber Mounting
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.
For Europe
025R200007
For Europe
025R200006
1 7
2
3
4
5 6
010R200006

ENGINE MECHANICAL 6A – 47
CAMSHAFT
2 1
6With
spacer type
Without
spacer type
13 14
8
12
11
109
3
4
7
5
012R200004
Legend
(1) Nut and Washer
(2) Injector Clamp
(3) Nut
(4) Bolt
(5) Oil Rail Assembly
(6) Spacer (If equipped) and Bolt
(7) Injector Assembly(8) Camshaft
(9) Camshaft Carrier
(10) Plug
(11) Oil Seal
(12) Camshaft Bracket
(13) Gasket
(14) Gasket

ENGINE MECHANICAL 6A – 53
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear A
(4) Idle Gear A Shaft
(5) Align Mark
(6) Crankshaft Gear
(7) O-Ring
13. Idle gear C
1) Use the special tool on idle gear C, turning the
sub gear to align the teeth, then set lock pin.
2) Remove idle gear C fixing bolt then remove the
idle gear C with flange.
Camshaft Gear Tool : 5-8840-2591-0
Legend
(1) Lock pin
(2) Camshaft Gear ToolLegend
(1) Bolt
(2) Retainer
(3) Idle Gear C
(4) Idle Gear C Shaft
(5) Align Mark
(6) Align Mark
(7) Idle Gear A
(8) Balance Shaft Gear LH
(9) Timing Mark
14. Idle gear B
1) Loosen idle gear B fixing bolt to remove idle
gear B with flange.
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear B
(4) Idle Gear B Shaft
(5) Align Mark
3
6
5
4
3
2
1 7 1
7
014R200007
1
2
014RW181
12345 56
6 8
8 37
7
9
99
014RW175
35
5
4
3
2
1
014R200008

ENGINE MECHANICAL 6A – 55
3. Idle gear A
1) Insert idle gear A shaft to align alignment mark
between idle gear A shaft and timing gear case.
2) Apply engine oil to the shaft surface.
3) Install the idle gear A to align the timing mark
with the crankshaft gear.
4) Install the flange, tighten bolts to the specified
torque.
Torque: 25 Nꞏm (2.5 kgꞏm/18 lb ft)
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear A
(4) Idle Gear A Shaft
(5) Align Mark
(6) Crankshaft Gear
(7) O-Ring
NOTE: Conform not difference timing marks between
each others.
4. Idle gear C
1) Insert idle gear C shaft to align alignment mark
between idle gear C shaft and timing gear case.
2) Apply engine oil to the shaft surface.
3) Align timing mark on idle gear C with balance
shaft gear LH and idle gear A timing marks, then
insert idle gear C.
4) Set position of idle gear C flange with a dowel
pin, tighten bolt to the specified torque.
Torque: 25 Nꞏm (2.5 kgꞏm/18 lb ft)Legend
(1) Bolt
(2) Retainer
(3) Idle Gear C
(4) Idle Gear C Shaft
(5) Align Mark
(6) Align Mark
(7) Idle Gear A
(8) Balance Shaft Gear LH
(9) Timing Mark
5. Idle gear B
1) Insert idle gear B shaft to align alignment mark
between idle gear B shaft and timing gear case.
2) Apply engine oil to the shaft surface.
3) Align timing mark on idle gear B with balance
shaft gear RH and crankshaft gear timing marks,
then insert idle gear B.
4) Install flange and tighten the bolt to the specified
torque.
Torque: 51 Nꞏm (5.2 kgꞏm/38 lb ft)
3
6
5
4
3
2
1 7 1
7
014R200007
12345 56
6 8
8 37
7
9
99
014RW175

6A – 56 ENGINE MECHANICAL
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear B
(4) Idle Gear B Shaft
(5) Align Mark
6. High pressure oil pump
1) Install O-ring on the high pressure oil pump.
2) Install the high pressure oil pump to the timing
gear case, tighten the nut to the specified
torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
NOTE: Be sure to set O-ring completely.
Legend
(1) O-ring (large)
(2) High pressure oil pump
(3) Nut
(4) O-ring (small)7. High pressure oil pump
1) Install O-ring on the oil pump shaft with grease
and install the gear with the idle gear A timing
mark set at the oil pump gear timing mark.
2) Tighten center bolt to the specified torque.
Torque: 75 Nꞏm (7.6 kgꞏm / 55 lb ft)
NOTE: Be sure to align timing marks with each other.
Legend
(1) O-ring
(2) High Pressure Oil Pump Gear
(3) Center Bolt
(4) Timing Mark
8. Remove lock from idle gear.
1) Remove lock bolt from idle gear A and remove
lock pin from idle gear C.
9. Timing gear case assembly
1) Clean fixing surface of timing gear case.
2) Install the gasket on the idle gear rear side end.
3) Apply liquid gasket to the timing gear case fitting
surface.
NOTE: Be sure to apply liquid gasket evenly.
4) Install timing gear case and tighten bolts to the
specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
NOTE: Must install within 5 minutes after applying liquid
gasket.
35
5
4
3
2
1
014R200008
1
2
43
040RW007
4
GEAR:O/PUMP
IDLE GEAR A
1
2
3
040RW005

ENGINE MECHANICAL 6A – 69
OIL RAIL AND INJECTOR
REMOVAL
Prior to removal, be sure to confirm and record the
group code of the injector installed using Tech2.
1. Disconnect battery ground cable.
2. Remove air cleaner cover and air duct.
3. Remove intercooler.
Refer to “Intercooler” in this manual.
4. Remove PCV hose and pipe.
5. Remove cylinder head noise insulator cover.
6. Remove high pressure oil pipe.
CAUTION:
1) Sleeve nut should be loosened with cloth tied
around it to prevent oil from spurting due to the
remaining pressure.
2) The high pressure pipe should be disconnected
with a cloth tied around the intake manifold
glow plug to prevent oil from flowing out of the
oil rail.7. Loosen eye bolt of fuel pipe at fuel pump side.
NOTE: Cloth should be put around the loosened eye
bolt to prevent fuel from flowing out.
8. Remove fuel return hose at chassis side.
9. Remove PCV hose to cylinder head cover.
10. Remove cylinder head cover.
11. Drain the oil from oil rail assembly.
12. Record the identification marking of injector for
each cylinder which is indicated on the upper
portion of injector.
There are nine kinds of identification marking
available, one alphabet letter and one numeral
letter.
In case three kinds of markings are given, one
alphabet letter (sometimes printed) and one
numeral letter, top priority is given to the one
alphabet letter and one numeral letter.
1
6
27
3
5
4
With
spacer type
Without
spacer type
012R200005
Legend
(1) Injector Clamp
(2) Injector Assembly
(3) Oil Rail Assembly(4) Camshaft Bracket
(5) Camshaft
(6) O-Ring
(7) Drain Plug

ENGINE MECHANICAL 6A – 71
12. Immediately install high pressure oil pipe and
tighten to specified torque.
Torque: 80 Nꞏm (8.1 kgꞏm / 57.9 lb ft)
13. Install cylinder head noise insulator cover.
Refer to “Cylinder Head” in this manual.
14. Install intercooler assembly.
Refer to “Intercooler” in this manual.
15. Install air cleaner cover and air duct.
16. Use TECH2 to rewrite injector data to ECM.
For rewriting method refer to section “Data
Programming in Case of ECM Change” of 6E 4JX1
engine driveability and emissions in this manual.
NOTE:
1) On completion of servicing, bleed air from the
engine inside fuel passage by means of the priming
pump. (The priming pump should be operated more
times than in the case of conventional engines.)
2) As air is in the oil rail, it takes more time to start the
engine. Rough idling may occur while the air is
being bled completely after starting the engine, but
it does not indicate trouble.
The air will be bled and normal engine status will be
reached while the vehicle is driven for about 5 km
or engine is operated for about 5 minutes at 1500 to
2000 rpm.
3) The injector spare part will be provided for group
number B1, B2 and B3 only.

ENGINE MECHANICAL 6A – 99
OIL COOLER
For Europe1
2050R200001
Legend
(1) Oil Cooler Assembly
(2) Oil Filter Cartridge
OIL FILTER CARTRIDGE
REMOVAL
1. Place a receptacle beneath the oil filter to contain
the drained oil.
2. Remove the oil filter cartridge using filter wrench.
Filter wrench : 5-8840-0203-0
INSTALLATION
1, Lightly apply oil to the O-ring of oil filter cartridge.
2. Turn the new oil filter cartridge by hand until the
sealing face is fitted against the O-ring.
3. Use the filter wrench to turn the oil filter an
additional one and 1/8 turns.
4. Start the engine and check for oil leakage from oil
filter.