OPEL FRONTERA 1998 Workshop Manual

6C – 10 ENGINE FUEL
INJECTOR
2 1
6
13 14
8
12
11
109
3
4
7
5
Legend
(1) Nut and Washer
(2) Injector Clamp
(3) Nut
(4) Bolt
(5) Oil Rail Assembly
(6) Bolt
(7) Injector Assembly(8) Camshaft
(9) Camshaft Carrier
(10) End Plug
(11) Camshaft Oil Seal
(12) Camshaft Bracket
(13) Gasket
(14) O-Ring
012RW022-1

ENGINE FUEL 6C – 11
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 to prevent oil from spurting due to the
remaining pressure.
2) High oil pressure pipe should be disconnected
with 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.
NOTE: Do not drop O-ring
12. Record the grade code of injector for each cylinder
that is indicated on the upper portion of injector.
There are nine kinds of grade code available, one
alphabet letter and one numeral letter.
Grade codeLegend
(1) Part Number
(2) Category Number (Grade code)
(3) Serial Number
(4) Bar Code
13. Remove harness connector from each injector.
14. Loosen nuts and bolts for oil rail.
15. Remove injector fixing bolts.
16. Remove injector clamp.
17. Remove injector assembly.
INSTALLATION
1. Install oil rail, tighten temporarily
2. Install injector assembly.
NOTE:
1) Do not forget to install O-ring between injector and
oil rail.
2) Use new O-ring
3) Clean O-ring groove and fitting surface of parts.
4) Apply engine oil to O-ring.
3. Install injector fixing bolts, tighten temporarily.
4. Install injector clamp, tighten nut temporarily.
5. Tighten injector fixing bolts to the specified torque.
Torque: 6.5 Nꞏm (0.7 kgꞏm / 5.1 lb ft)
6. Tighten injector clamp nut to the specified torque
with special method.
Torque: 30 Nꞏm (3.1 kgꞏm / 22.4 lb ft) then loosen a
time again tighten as following torque.
Torque: 25 Nꞏm (2.4 kgꞏm / 17.4 lb ft)
7. Tighten oil rail to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
1
4
32
055RW00001
Category number
A– 1
A– 2
A– 3
B – 1
B – 2
B – 3
C – 1
C – 2
C – 3

6C – 12 ENGINE FUEL
8. Install injector harness assembly, reconnect
harness connecter to injector.
9. Record the identification marking of injector for
each cylinder that is indicated on the upper portion
of injector.
Legend
(1) Part Number
(2) Category Number (Grade code)
(3) Serial Number
(4) Bar Code
10. Install cylinder head assembly.
Refer to “Cylinder Head” in this manual.
11. Fill with about 300cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil filler.
If assembled without filling the oil rail with oil, the
time for engine starting will be longer.
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 section
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 engine start, 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.
Injector Grade code Programming
(Injector Change)
In case of an injector change, the injector grade code
(category number) must be programmed by Tech-2.
Programming Procedure
1. Connect the Tech-2 to the vehicle DLC.
2. Turn the starter switch to the “ON” position.
3. Select the “Diagnosis” from the Main menu.
4. Select the “Programming” from the Application
menu.
1
4
32
055RW00001
F0 : Diagnostic C ode
F1 : Data Display
F2 : Snapshot
F3 : Miscellaneous Test
F4 : ProgrammingA pplication Menu
035RW00002

ENGINE FUEL 6C – 13
5. Select “Programming Trim Date” from
Programming menu.
6. Select the injector change from Programming Trim
Date menu.
7. Select the cylinder number which changed injector.
8. Appoint and select the grade code (Category
number) of injector.9. Confirm the completion of injector programming.
Note; The injector grade code (category number) is
indicated on the new (service part) injector.
Injectorー1 Injectorー4
Injectorー3 Injectorー1
Programming Trim Data
Select cylinder Injectorー2 (W) 1998 (UE) Rodeo/Amigo,Wizard
Electronic System 3.0L L4 4JX1
035RW00003
Injectorー1
Programming Trim Data
Do you program trim data in
this cylinder？ (W) 1998 (UE) Rodeo/Amigo,Wizard
Electronic System 3.0L L4 4JX1
Yes No
035RW00004
Injectorー1
Programming Trim Data
Programming was succededCategory A1 (W) 1998 (UE) Rodeo/Amigo,Wizard
Electronic System 3.0L L4 4JX1
Confirmed
035RW00005

6C – 14 ENGINE FUEL
HIGH PRESSURE OIL PUMP
REMOVAL
1. Disconnect battery ground cable.
2. Remove air cleaner cover and air duct
3. Intercooler assembly
Refer to “Intercooler” in this manual.
4. Remove high pressure oil pipe
5. Timing belt cover
Disconnect CMP sensor cable.
Remove CMP sensor bracket.
6. Tensioner
7. Timing Belt
8. Remove high pressure oil pump timing pulley
9. Remove crankshaft damper pulley
10. Remove timing gear case cover
11. Remove idle gear A
Before removing idle gear A, set two bolts to the
sub gear of idle gear A and turn it to align the teeth
of idle gear A main gear.
Then lock them by bolts as shown in the illustration.Legend
(1) Idle gear A sub gear
(2) Idle gear A main gear
(3) Bar
(4) Lock bolt
1
2
43
Legend
(1) O-Ring
(2) High Pressure Oil Pump Assembly
(3) Nut
(4) O-Ring
040RW007
4 1
2
3
014RW177

ENGINE FUEL 6C – 15
12. Remove high pressure oil pump
13. Remove high pressure oil pump assembly
Legend
(1) O-ring
(2) High pressure oil pump
(3) Nut
(4) O-ring
1
2
43
040RW007
2
5 1
4
63
051RW020
Legend
(1) Reservoir
(2) Repair Kit
(3) Fuel Pump and Bolt(4) Bearing
(5) Oil Rail Pressure Control Valve
(6) High Pressure Oil Pump Body

6C – 16 ENGINE FUEL
INSPECTION AND REPAIR
The high pressure oil pump is made precisely,
therefore, disassembly is not recommended to repair,
only replace special parts.
Special parts
1. Reservoir
2. Fuel pump assembly
3. Bearing
4. Oil Rail Pressure Control Valve
5. High pressure oil pump
6. Repair kit
INSTALLATION
1. Set O-ring to high pressure oil pump assembly.
Install the pump assembly into the rear of timing
gear case.
Tighten nut to specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
Legend
(1) O-ring
(2) High Pressure Oil Pump Assembly
(3) Nuts
(4) O-ring
2. Tighten high pressure oil pump assembly bracket
together with two way valve bracket.
Torque: 27 Nꞏm (2.8 kgꞏm/20.2 lb ft)Legend
(1) High Pressure Oil Pump Assembly
(2) Nut
(3) Two Way Valve Bracket
(4) Bolt
3. Install the pump gear to align timing mark with idle
gear A.
Tighten high pressure pump gear fixing bolt to the
specified torque.
Apply engine oil to thread and seat of bolt.
Torque: 75 Nꞏm (7.6 kgꞏm/55 lb ft)
Legend
(1) O-ring
(2) Pump Gear
(3) Bolt
(4) Timing Mark
1
2
43
040RW007
2
3
4 1
040RW006
4
GEAR:O/PUMP
IDLE GEAR A
1
2
3
040RW005

ENGINE FUEL 6C – 17
4. Remove lock bolt of idle gear A.
5. Install timing gear case cover.
Refer to “Timing gear” in this manual.
6. Install front plate.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
7. Install timing pulley of high pressure oil pump.
Torque: 10 Nꞏm (1.0 kgꞏm/7.2 lb ft)
8. Install timing belt and tighten timing belt tensioner
assembly.
Refer to “Cylinder head” in this manual.
Legend
(1) Align Mark
(2) Camshaft Pulley
(3) Timing Belt
(4) High Pressure Oil Pump Pulley
(5) Bolt
(6) Tensioner Assembly
(7) Tensioner Bolt
(8) Tensioner Spring
9. Install CMP sensor bracket.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
10. Connect CMP sensor cable.
11. Install timing belt cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
12. Fill with about 300 cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil filler.
If assembled without filling the oil rail with oil, the
time for engine starting will be longer.
13. Immediately install high pressure oil pipe and
tighten to specified torque.
NOTE:
1) Use new O-ring.
2) Clean O-ring groove and fitting surface of parts.
3) Apply engine oil to O-ring.
Torque: 80 Nꞏm (8.1 kgꞏm/57.9 lb ft)14. Install the crankshaft damper pulley with specified
torque.
Torque: 220 Nꞏm (22 kgꞏm/159 lb ft)
15. Install the intercooler assembly.
Refer to “Intercooler” in this manual.
16. Install air cleaner cover and air duct.
1
2
3
8
67
4 5
F06RW055

6C – 18 ENGINE FUEL
HIGH PRESSURE OIL PIPE INSTALLATION
1. Install the nipple filter
1) Wash thread of the nipple filter, remove engine
oil and foreign material and air blow it.
2) Install nipple filter to high pressure oil pump inlet
port, tighten to the specified torque.
Torque : 90 Nꞏm (9.2 kgꞏm/66.5 lb ft)
2. Install the edge filter.
1) Wash thread, O-ring groove and fitting surface
of edge filter, remove engine oil and foreign
materials.
2) Install edge filter to high pressure oil pump,
tighten edge filter to the specified torque.
Torque : 90 Nꞏm (9.2 kgꞏm/66.5 lb ft)
3. Install upper bracket to two way valve, tighten them
temporarily.
4. Install pipe A to two way valve, tighten pipe A
temporarily with union nut D.
5. Install two way valve assembly to cylinder block,
tighgten with union nut C temporarily.6. Install pipe B to two way valve, tighten union nut E
and union nut F temporarily.
7. Tighten upper bracket to specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
8. Tighten union nut in the following order, union nut
C, D, F, and E to the specified torque.
Torque : 80 Nꞏm (8.1 kgꞏm/57.9 lb ft)
9. Tighten lower bracket to the specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
NOTE:
1) Wash inside pipe, inside union nut and O-ring seal
surface to remove engine oil and foreign materials.
2) It is recommended to check and replace the edge
filter when overhauling the engine, or if it is broken
inside the engine.
1
2
3
5
6
8 9
7
104
Legend
(1) Union Nut F
(2) Pipe B
(3) Union Nut E
(4) Upper Bracket
(5) Union Nut D(6) Pipe A
(7) Union Nut C
(8) Lower Bracket
(9) To Oil Rail
(10) To High Pressure Oil Pump through Edge Filter
040RW015

ENGINE FUEL 6C – 19
Nipple Filter and Edge Filter Installation
The nipple filter is provided at the front of the inlet port
side. The edge filter is provided at the rear of the outlet
port on the high pressure oil pump assembly.
1. Install the nipple filter
1) Wash threads and filter to remove engine oil and
foreign materials before installing the nipple
filter.
2) Install the nipple filter to the inlet port of high
pressure oil pump, tighten to the specified
torque.
Torque : 90 Nꞏm (9.2 kgꞏm/66.5 lb ft)
(Tighten dry condition)
2. Install the edge filter.
1) Wash threads and O-ring groove and part fitting
surface to remove engine oil and foreign
materials before installing the nipple filter.
2) Install edge filter to outlet port of high pressure
oil pump, tighten to the specified torque.
Torque : 90 Nꞏm (9.2 kgꞏm/66.5 lb ft)
(Tighten dry condition)
NOTE: It is recommended to check and replace the
edge filter when overhauling the engine, or if it is broken
inside the engine.