OPEL FRONTERA 1998 Workshop Manual

6B – 12 ENGINE COOLING
Torque:
For A.C. Generator fixing bolt
40 Nꞏm (4.1 kgꞏm/29.7 lb ft)
For Adjusting plate fixing bolt
24 Nꞏm (2.4 kgꞏm/17.4 lb ft)
For Adjusting plate lock bolt
19 Nꞏm (1.9 kgꞏm/13.7 lb ft)
2) Adjust the A/C compressor drive belt by tightening
the belt tensioner bolt.
Legend
(1) Crankshaft Pulley
(2) A.C. Generator Pulley
(3) Cooling Fan Pulley
(4) A/C Compressor Pulley
(5) Belt Tensioner Pulley
5
3
24
1
012RW110

ENGINE FUEL 6C – 1
ENGINE FUEL
CONTENTS
GENERAL DESCRIPTION
General Description . . . . . . . . . . . . . . . . . . 6C–1
On-Vehicle Service . . . . . . . . . . . . . . . . . . 6C–8
Fuel Filter Assembly . . . . . . . . . . . . . . . . 6C–8
Fuel Filter Cartridge . . . . . . . . . . . . . . . . 6C–8
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–10High Pressure Oil Pump . . . . . . . . . . . . . 6C–14
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . 6C–20
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . 6C–21
Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . 6C–21
To realize the compatibility between low exhaust
emission and high engine output, an HEUI
(Hydraulically actuated Electronically controlled Unit
Injector) system, has been introduced. This system is
comprised of a hydraulic system, fuel system, and
electronic control system, using a high-pressure oil
pump in place of the conventional fuel injection pump.
The oil pressurized by means of this pump and by
signals from the ECM (Electronic Control Module)
actuates the fuel injector provided for each cylinder.
Inside of the fuel injector, fuel pressure is increased due
to the high-pressure oil. The ECM detects the driving
state of the vehicle, forms, signals sent by engine and
other part sensors, which determines the optimum fuel
injection amount and timing, thus controlling the fuel
injectors. Thus high engine output, good fuel economy,
and low exhaust emission are realized.When working on the fuel system, there are several
things to keep in mind:
1) Any time the fuel system is being worked on,
disconnect the negative battery cable except for
those tests where battery voltage is required.
2)Always keep a dry chemical (Class B) fire
extinguisher near the work area.
3) Replace all pipes with the same pipe and fittings
that were removed.
Clean and inspect “O” rings. Replace where
required.
4) Always relieve the line pressure before servicing
any fuel system components.
5) Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
6) After maintenance work, push priming pump and
send enough fuel to the fuel system before starting
the engine.
NOTE: In comparison with the conventional engine,
the capacity of fuel passage in the 4JX1 engine is
larger. It takes the priming pump more time to fill the
engine with fuel.

6C – 2 ENGINE FUEL
FUEL FLOW
For EC
89
1011141
2
4
12
5 6
7
3
13
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(4) Fuel Supply Pipe
(5) Fuel Filter with Priming Pump
(6) Fuel Pump
(7) High Pressure Oil Pump(8) Cylinder Head
(9) Injector
(10) Orifice
(11) Fuel Return Pipe
(12) Fuel Tank Pressure Release Hose
(13) Intake Air Duct
(14) Fuel Tank Pressure Control Valve
040RX001

ENGINE FUEL 6C – 3
For except EC
78
9101
2
3
4 5
6
11
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Fuel Supply Pipe
(4) Fuel Filter with Priming Pump
(5) Fuel Pump(6) High Pressure Oil Pump
(7) Cylinder Head
(8) Injector
(9) Orifice
(10) Fuel Return Pipe
(11) Fuel Tank Pressure Control Valve
040RX002

6C – 4 ENGINE FUEL
FUEL PUMP
1
2
3 4
Legend
(1) High Pressure Oil Pump
(2) To Injector(3) From Fuel Tank
(4) Fuel Pump
140RW041

ENGINE FUEL 6C – 5
HIGH PRESSURE OIL PUMP, OIL FLOW
P
33
32
31
30
1
2
3
4
56
8
97
10
11
12
13
14 23 29
25
28
27262415
16
17 18
19 20 21 22
Legend
(1) Camshaft
(2) Balance Shaft
(3) Crankshaft
(4) Oil Cooler and Oil Filter Assembly
(5) Oil Filter Relief Valve 98 Kpa (1 kg/cm
2/14.2 Psi)
(6) Oil Cooler Relief Valve 245 Kpa (2.5 kg/cm2/
36 Psi)
(7) First Oil Pump
(8) Main Oil Relief Valve 588 Kpa (6 kg/cm
2/ 85 Psi)
(9) To Oil Pan
(10) To Oil Pan
(11) Injector
(12) Oil Rail
(13) Sub Oil Filter Relief Valve 98 Kpa (1 kg/cm
2/
14.2 Psi)
(14) Sub Oil Filter
(15) Relief Valve 588 Kpa (6 kg/cm
2/ 85 Psi)
(16) Second Oil Pump(17) Oil Pan
(18) To Oil Pan
(19) Balance Shaft
(20) Cooling Jet Relief Valve 245 Kpa (2.5 kg/cm
2/
36 Psi)
(21) Cooling Jet
(22) To Oil Pan
(23) Two Way Check Valve
(24) Nipple Filter
(25) Edge Filter
(26) Edge Filter
(27) High Pressure Oil Pump Assembly
(28) To Oil Pan
(29) Pressure Control Valve
(30) To Oil Pan
(31) Turbocharger
(32) Oil Gallery
(33) Timing Gear Train
040RW018

6C – 6 ENGINE FUEL
FUEL FILTER
Legend
(1) Priming Pump
(2) Fuel Filter Cartridge
A cartridge type fuel filter is used along with the piston
type fuel pump on the high pressure oil pump.
The fuel filter removes foreign material from the fuel
before it reaches the fuel pump.
A diaphragm type priming pump is installed at the top of
the fuel filter. It is used during the air bleeding
procedures.
INJECTOR ASSEMBLY
Legend
(1) Oil Passage
(2) Fuel Passage
1. Construction of Fuel Injector
The fuel injector is comprised of the solenoid
section, hydraulic line, and fuel line. Fuel injection is
controlled by the continuity time signal and
continuity start timing signal sent by the ECM
(Electronic Control Module) to the solenoid.
2. Working of Fuel Injector
1) The ECM detects the working of the engine from
its input signals, such as engine speed
accelerator throttle opening, and engine coolant
temperature, sending the optimal signals to the
solenoid.
1
2
041RW017
1
2
055RW018

ENGINE FUEL 6C – 7
2) With the current carried to the solenoid, a
poppet valve is opened by means of an
armature to let high-pressure engine oil into the
injector.
3) Under the oil pressure, the piston and plunger
are depressed to compress the fuel. The
pressure of the compressed fuel is increased
over the pressure of high-pressure engine oil by
the ratio (about 7 : 1) of piston top to plunger
bottom.
4) The injection nozzle end needle is lifted under
the increased pressure of the fuel for fuel
injection.
5) With current stopped from the ECM, the poppet
valve is closed which holds up the high-pressure
engine oil and lets the oil used to compress fuel
out of the injector through its drain hole.

6C – 8 ENGINE FUEL
ON-VEHICLE SERVICE
FUEL FILTER ASSEMBLY
REMOVAL
1. Disconnect battery ground cable.
2. Fuel Filler cap
3. Fuel Hose
1) Disconnect fuel hose from filter body.
Plug the hose ends to prevent fuel spillage.
4. Remove the Bolt on Fuel Filter Bracket
5. Remove Fuel Filter Assembly
INSTALLATION
1. Install the fuel filter assembly
2. Tighten the Fuel Filter Bracket Fixing Bolt
3. Fuel Hose
1) Connect hoses to filter body.
4. Fuel Filler Cap
1) Connect the battery ground cable.
2) Feed fuel to the fuel pump by priming, and bleed
the air from fuel system.
FUEL FILTER CARTRIDGE
DISASSEMBLY
1. Drain fuel completely from the fuel filter.
2. Protect the filter body with cloth and lightly grip with
a vise.
3. Remove the cartridge using a filter wrench.
Filter wrench: 5-8840-0203-0
1
Legend
(1) Priming Pump
012RW111
012RW112

ENGINE FUEL 6C – 9
REASSEMBLY
1. Clean the cartridge mounting surface of the filter
body so that the cartridge can be secured.
Apply engine oil thinly to new cartridge O-ring.
2. To facilitate bleeding, fill the new cartridge with light
oil.
3. Tighten the cartridge until O-ring comes in contact
with the seal, taking care not to spill the light oil.
4. Retighten 1/3 – 2/3 using a filter wrench.
Filter wrench: 5-8840-0203-0
Bleeding
1. Loosen air bleeding plug.
2. Operate priming pump to bleed the air in the fuel
line.
3. Operate the priming pump until the fuel is overflow
from air bleeding plug.
4. Tighten the air bleeding plug.
5. Start the engine, and if it is not started in 10
seconds or less, repeat the bleeding steps.
6. Make sure of no fuel leakage, and tighten the
priming pump.
Legend
(1) Priming Pump
NOTE: In comparison with the conventional engine,
the capacity of fuel passage in the 4JX1 engine is
larger. It takes the priming pump more time to fill the
engine with fuel.
012RW078
1
012RW111