timing belt OPEL FRONTERA 1998 Owner's Manual

6E–82
ENGINE DRIVEABILITY AND EMISSIONS
Engine Cranks But Will Not Run
StepNo Ye s Va l u e ( s ) Action
131. Remove any ignition coil and install a spark tester at
the spark plug end of the coil.
2. Observe the tester while the engine is cranking.
Was a crisp, blue spark observed? Only one or two
sparks followed by no result is considered the same as
“No Spark.”
—Go to Step 15Go to Step 14
14Replace the ignition coil, and return to Step 13 to test
the remaining coils.
Is the action complete?
—Verify repair—
15Repeat Step 13 for each coil. Remove only one coil at a
time, and reinstall each coil on its spark plug after
testing, but do not refasten coils with screws at this
time.
After all coils have passed the spark test, does the
engine start?
—
Refasten all
coils with
their screws
Go to Step 16
161. Remove the spark plugs from all cylinders.
2. Visually inspect the spark plug electrodes.
3. Replace any spark plugs with loose or missing
electrodes or cracked insulators.
Did your inspection reveal any spark plugs exhibiting
excessive fouling?
—
Correct the
fouling
condition
Go to Step 17
17Refer to Engine Mechanical Diagnosis to diagnose the
following conditions:
Faulty or incorrect camshaft drive belts
Leaking or sticky valves or rings
Excessive valve deposits
Loose or worn rocker arms
Weak valve springs
Incorrect valve timing
Leaking head gasket
Is the action complete?
—Verify repairGo to Step 19
18Observe the “Engine Speed” data display on the scan
tool while cranking the engine.
Is the engine RPM indicated? (If the scan tool is
normally powered from the cigarette lighter socket, and
if the scan tool display goes blank while cranking the
engine, it will be necessary to power the scan tool
directly from the vehicle battery.)
—Go to Step 19Go to Step 28
191. Disconnect the 7-pin gray connector at the rear of
the air filter beneath the point where the air duct
attaches to the MAF sensor.
2. Ignition “ON.”
3. Using a test light connected to ground, probe the
ignition terminal at the PCM (female) side of the
7-pin connector.
Is the test light “ON?”
—Go to Step 20Go to Step 26

6E–269 ENGINE DRIVEABILITY AND EMISSIONS
Lack of Power, Sluggish or Spongy Symptom
StepNo Ye s Va l u e ( s ) Action
111. Check the PCM grounds for the cleanliness,
tightness and proper locations. Refer to the PCM
wiring diagrams in
Electrical Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 12
121. Check the exhaust system for possible restriction:
Inspect the exhaust system for damaged or
collapsed pipes.
Inspect the muffler for heat distress or possible
internal failure.
Check for a possible plugged three-way
catalytic converter by checking the exhaust
system back pressure. Refer to
Restricted
Exhaust System Check
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 13
131. Check the torque converter clutch (TCC) for proper
operation. Refer to
4L30-E Transmission
Diagnosis
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 14
141. Check for an engine mechanical problem. Check
for low compression, incorrect or worn camshaft,
loose timing belt, etc. Refer to
Engine Mechanical.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 15
151. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Te c h 2 d a t a
Freeze Frame data/Failure Records buffer
All electrical connections within a suspected
circuit and/or system.
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repair
Contact
Te c h n i c a l
Assistance

6E–274
ENGINE DRIVEABILITY AND EMISSIONS
Rough, Unstable, or Incorrect Idle, Stalling Symptom
StepNo Ye s Va l u e ( s ) Action
171. Check ignition coils for cracks or carbon tracking.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 18
18Using Tech 2, monitor the throttle position (TP) angle
with the engine idling.
Is the TP angle at the specified value and steady?
0%Go to Step 19
Refer to DTC
P0123
for
further
diagnosis
191. Check the positive crankcase ventilation (PCV)
valve for proper operation. Refer to
Crankcase
Ventilation System
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 20
201. Check the transmission range switch circuit. Use
Tech 2 and be sure Tech 2 indicates that the vehicle
is in drive with the gear selector in drive or overdrive.
2. If a problem is found, diagnose and repair the
transmission range switch as necessary (refer to
4L30-E Automatic Transmission Diagnosis).
Was a problem found?
—Verify repairGo to Step 21
211. Check for the following engine mechanical items.
Refer to
Engine Mechanical for diagnosis
procedures:
EGR valve mounted backward. Compare with
a known-good vehicle.
Low compression
Sticking or leaking valves
Worn camshaft lobe(s)
Camshaft drive belt slipped or stripped
Incorrect valve timing
Worn rocker arms
Broken valve springs
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 22
221. Check for faulty motor mounts. Refer to Engine
Mechanical
for inspection of mounts.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 23
231. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Te c h 2 d a t a
Freeze Frame data/Failure Records buffer
All electrical connections within a suspected
circuit and/or system.
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repair
Contact
Te c h n i c a l
Assistance

6E–281 ENGINE DRIVEABILITY AND EMISSIONS
Backfire Symptom
StepNo Ye s Va l u e ( s ) Action
91. Check for the following engine mechanical
conditions.
Refer to
Engine Mechanical for diagnosis
procedures:
Low compression
Sticking or leaking valves
Worn camshaft lobe(s)
Camshaft drive belt slipped or stripped
Incorrect valve timing
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 10
101. Check the intake and exhaust manifold(s) for
casting flash. Refer to
Engine Mechanical.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 11
111. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Te c h 2 d a t a
Freeze Frame data/Failure Records butter
All electrical connections within a suspected
circuit and/or system.
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repair
Contact
Te c h n i c a l
Assistance

6E–284
ENGINE DRIVEABILITY AND EMISSIONS
Cuts Out, Misses Symptom
StepNo Ye s Va l u e ( s ) Action
171. Check ignition coils for cracks or carbon tracking.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 18
18Using Tech 2, monitor the TP angle with the engine
idling.
Is the TP angle at the specified value and steady?
0%Go to Step 19
Refer to DTC
P0123
for
further
diagnosis
191. Check the PCV valve for proper operation. Refer to
Crankcase Ventilation System.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 20
201. Check the transmission range switch circuit. Use
Tech 2 and be sure Tech 2 indicates that the vehicle
is in drive with the gear selector in drive or overdrive.
2. If a problem is found, diagnose and repair the
transmission range switch as necessary (refer to
4L30-E Automatic Transmission Diagnosis).
Was a problem found?
—Verify repairGo to Step 21
211. Check the following engine mechanical items.
Refer to
Engine Mechanical for diagnosis
procedures:
Low compression
Sticking or leaking valves
Worn camshaft lobe(s)
Camshaft drive belt slipped or stripped
Incorrect valve timing
Worn rocker arms
Broken valve springs
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 22
221. Check for faulty motor mounts. Refer to Engine
Mechanical
for inspection of mounts.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 23
231. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Te c h 2 d a t a
Freeze Frame data/Failure Records butter
All electrical connections within a suspected
circuit and/or system
3. If a problem is found, repair as necessary.
Was a problem found?
—Verify repair
Contact
Te c h n i c a l
Assistance

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–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 – 44 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 (If equipped.).
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 dial
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