OPEL FRONTERA 1998 Workshop Manual

6A – 18 ENGINE MECHANICAL
Injector
Nꞏm (kgꞏm/lbꞏft)
011RX003
20Nꞏm(2.0kgꞏm/14.5 Ib ft)
6.5Nꞏm(0.7kgꞏm/5.0 Ib ft)
Recheck tightening torque
after tighten the oil rail
Apply engine oil on the
thread of stud bolts
20Nꞏm(2.0kgꞏm/14.5 Ib ft)
Tighten 30Nꞏm(3.1kgꞏm/22 Ib ft)
Then loosen it again tighten with
25Nꞏm(2.4kgꞏm/17 Ib ft)
Apply engine oil
both side

ENGINE MECHANICAL 6A – 19
High Pressure Oil Pipe
Nꞏm (kgꞏm/lbꞏft)
80(8.1/57.9)
80(8.1/57.9)
80(8.1/57.9)
80(8.1/57.9)
040RW016

6A – 20 ENGINE MECHANICAL
Air Duct and Intercooler
Nꞏm (kgꞏm/lbꞏft)
4.0(0.4/3)4.0(0.4/3)
3.0(0.3/2.2) 20(2.0/14.5)
036RW013

ENGINE MECHANICAL 6A – 21
Engine Mount Bracket
Nꞏm (kgꞏm/lbꞏft)
50(5.1/37)
50(5.1/37)127(13/94)
127(13/94)
40(4/29)
40(4/29)
40(4/29)
022RW019

6A – 22 ENGINE MECHANICAL
Exhaust System
Nꞏm (kgꞏm/lbꞏft)
150RW073
43(4.4/32)
43(4.4/32)
16(1.6/12)
43(4.4/32)
67(6.8/50)
43(4.4/32)

901RT034
Illustration Tool No. Tool Name
ENGINE MECHANICAL 6A – 23
SPECIAL TOOLS
5-8840-0203-0 Filter Wrench
5-8840-2441-0 Valve Spring Compressor
5-8840-2033-0 Stem Seal Installer
5-8840-9018-0 Piston Ring Compressor
5-8840-0075-0 Turbocharger Pressure Gauge
9-8523-1212-0 Valve Guide Replacer
F06RV038
901RT037
901LX017
901RX00001
1
2
901RW182

6A – 24 ENGINE MECHANICAL
Illustration Tool No. Tool Name
SPECIAL TOOLS
5-8840-2590-0 Valve Clearance Adjusting Tool
5-8840-2592-0 Camshaft Stopper
5-8840-2591-0 Camshaft Gear Tool
5-8840-2675-0
5-8531-7002-0Compression Gauge
Adapter: Compression Gauge
5-8840-2153-0 Seal Cutter
kg /cm20 10
7060 20 5030 40
F06RW056
F06RV037
901LX057
901LX056 F06RW057
901RT042

ENGINE MECHANICAL 6A – 25
Illustration Tool No. Tool Name
SPECIAL TOOLS
5-8840-0266-0 Angle Gauge
5-8840-2360-0 Rear Oil Seal Remover
5-8840-2359-0 Rear Oil Seal Installer
5-8840-2061-0
Front Oil Seal Installer
901LX030
901LX040
901LX025
901LX039901RV061
9-8522-0021-0 Crankshaft Gear Installer

6A – 26 ENGINE MECHANICAL
ENGINE ASSEMBLY
F06RW048
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 Assembly
1) 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.
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.

ENGINE MECHANICAL 6A – 27
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.
Torque: 40 Nꞏm (4 kgꞏm/29 lbꞏft)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
F06RW054