engine OPEL FRONTERA 1998 Workshop Manual

ENGINE EXHAUST 6F – 5
CENTER EXHAUST PIPE
REMOVAL
1. Battery negative cable.
2. Raise the vehicle and support with suitable safety
stands.
3. Remove mounting rubber.
4. Remove fixing nuts from silencer side.
5. Remove fixing nuts from front exhaust pipe.
6. Remove center exhaust pipe assembly.
INSTALLATION
1. Place center exhaust pipe in the original position
then tighten fixing nuts temporarily.
2. Install mounting rubber.
3. Tighten front exhaust pipe side nuts to the specified
torque.
Torque : 43 Nꞏm (4.4 kgꞏm/32 lb ft)
4. Tighten silencer side nuts to the specified torque.
Torque : 43 Nꞏm (4.4 kgꞏm/32 lb ft)
3
2 1
Legend
(1) Front Exhaust Pipe
(2) Center Exhaust Pipe
(3) Mounting Rubber
150RW071

6F – 6 ENGINE EXHAUST
EXHAUST SILENCER
REMOVAL
1. Battery negative cable.
2. Raise the vehicle and support with suitable safety
stands.
3. Remove mounting rubber from silencer.
4. Remove silencer mounting bracket.
5. Remove fixing nuts between center exhaust pipe
and silencer.
6. Remove fixing nuts from tail pipe flange.
7. Remove silencer assembly.
INSTALLATION
1. Place silencer assembly in the original installation
position, tighten both side (front and rear) nuts
temporarily.
2. Tighten silencer mounting bracket to the specified
torque.
Torque : 16 Nꞏm (1.6 kgꞏm/12 lb ft)
3. Tighten center exhaust pipe side nuts to the
specified torque.
Torque : 43 Nꞏm (4.4 kgꞏm/32 lb ft)
4. Tighten tail pipe side nuts to the specified torque.
Torque : 43 Nꞏm (4.4 kgꞏm/32 lb ft)
5. Install silencer mounting rubber.
6
3
4
2
1
5
Legend
(1) Mounting Rubber
(2) Post Silencer
(3) Silencer(4) Mounting Bracket
(5) Mounting Rubber
(6) Tail Pipe
150RW072

ENGINE EXHAUST 6F – 7
REAR EXHAUST PIPE
REMOVAL
1. Battery negative cable.
2. Raise the vehicle and support with suitable safety
stands.
3. Remove mounting rubber from post silencer.
4. Remove fixing nuts at silencer side.
5. Remove tail pipe together with post silencer.
6. Remove fixing nuts between tail pipe and post
silencer which separates them.
INSTALLATION
1. Install tail pipe and post silencer and tighten them to
the specified torque.
Torque : 43 Nꞏm (4.4 kgꞏm/32 lb ft)
2. Place tail pipe together with post silencer to original
position and tighten fixing nuts at silencer side.
Torque : 43 Nꞏm (4.4 kgꞏm/32 lb ft)
3. Install mounting rubber for post silencer.
4. Lower the vehicle.
5. Reconnect battery negative cable.
6
3
4
2
1
5
Legend
(1) Mounting Rubber
(2) Post Silencer
(3) Silencer(4) Mounting Bracket
(5) Mounting Rubber
(6) Tail Pipe
150RW072

ENGINE LUBRICATION 6G – 1
ENGINE LUBRICATION
CONTENTS
General Description . . . . . . . . . . . . . . . . . . 6G–2
Lubrication Chart . . . . . . . . . . . . . . . . . . 6G–2
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . 6G–3
Oil Pump Specification . . . . . . . . . . . . . . 6G–3
Oil Filter Specification . . . . . . . . . . . . . . . 6G–3
Sub Oil Filter Specification . . . . . . . . . . . 6G–4Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–5
Oil Cooler Assembly . . . . . . . . . . . . . . . . . . 6G–6
Oil Cooler Specification . . . . . . . . . . . . . . 6G–6
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–6
Sub Oil Filter . . . . . . . . . . . . . . . . . . . . . 6G–6

6G – 2 ENGINE LUBRICATION
GENERAL DESCRIPTION
LUBRICATION CHART
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
040RW018

ENGINE LUBRICATION 6G – 3
To meet a newly adopted electronically controlled fuel
injection system using engine oil two oil pumps have
been provided to increase circulating oil capacity.
The first oil pump serves mainly to lubricate the engine
parts, while the second mainly serves the fuel injectors
and partially cools the pistons.
The oil cooler is provided on the first oil pump side and
uses engine coolant.
OIL FLOW
Legend
(1) Oil Pump
(2) Regulator Valve
(3) Oil Cooler
(4) Oil Filter Relief Valve
(5) Full Flow Filter
(6) Oil Cooler Relief Valve
(7) Gallery
OIL PUMP SPECIFICATIONS

OIL FILTER SPECIFICATIONS
Legend
(1) Oil cooler assembly
(2) Oil filter assembly (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
17 65 4
3
2
050RW010
For Europe1
2
050R200001

6G – 4 ENGINE LUBRICATION
SUB OIL FILTER SPECIFICATIONS
The sub oil filter requires no servicing until the
replacement interval is reached.
The element is designed to provide special filtering
efficiency until it becomes due for replacement.
It is recommended to check and replace the sub filter
when the engine is being overhauled or if it is broken
inside the engine.
442RW004

ENGINE LUBRICATION 6G – 5
OIL PUMP
REMOVAL
1. Remove battery ground cable.
2 Raise the vehicle and support with suitable safety
stand.
3. Drain engine oil.
4. Remove flywheel assembly.
5. Remove rear plate (For A/T) or flywheel housing
(For MT).
6. Remove first oil pump assembly from cylinder block
and second oil pump assembly from crank case.
INSPECTION AND REPAIR
1. Inspect flaws and/or wear on the teeth surface.
2. Inspect abnormal wear journal on the gear and in
the drive spline.
3. If problem is found during inspection, the worn parts
must be replaced.
INSTALLATION
1. Install first oil pump.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
2. Install second oil pump.
Torque: 20 Nꞏm (2ꞏ0 kg.m / 14.5 lb ft)
2
1
5
6
3
4
Legend
(1) Flywheel
(2) Rear Plate
(3) First Oil Pump(4) Second Oil Pump
(5) O-ring (For 1st oil pump)
(6) O-ring (For 2nd oil pump)
012RW097

6G – 6 ENGINE LUBRICATION
OIL COOLER ASSEMBLY
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove front exhaust pipe.
4. Remove heat protector.
5. Remove exhaust valve assembly.
6. Oil cooler assembly.
1) Remove water hose from water inlet and outlet
side.
2) Cloth should be put under the oil cooler to
prevent oil from flowing out.
3) Loosen fixing bolt then remove oil cooler
assembly.
Legend
(1) Oil cooler assembly
(2) Oil filter assembly
INSPECTION AND REPAIR
1. Inspect for corrosion, wear, and breaks on the oil
cooler core.
2. If a problem is found on the oil cooler core, the oil
cooler assembly must be replaced.
INSTALLATION
1. Oil cooler assembly
1) Tighten oil cooler fixing bolt to the specified
torque and install water hoses.
Torque: 29 Nꞏm (3.0 kgꞏm / 21.7 lb ft)
2. Install exhaust valve assembly to turbocharger
assembly and tighten to the specified torque.
Torque: 27 Nꞏm (2.7 kgꞏm / 19.5 lb ft)3. Install front exhaust pipe to the exhaust valve.
Torque:
67 Nꞏm (6.8 kgꞏ.m / 49.2 lb ft)
(At exhaust valve side)
43 Nꞏm (4.4 kgꞏm / 32 lb ft)
(At center exhaust pipe side)
4. Install heater protector.
5. Fill engine coolant.
6. Connect battery ground cable.
7. Start engine and carefully check for leakage of oil
and coolant.
OIL COOLER SPECIFICATIONS
OIL FILTER
REMOVAL
1. Put container under the oil filter to prevent oil from
the oil filter from flowing out.
2. Use filter wrench to remove oil filter.
Filter wrench: 5-8840-0203-0
INSTALLATION
1. Apply engine oil thinly to oil filter O-ring.
2. Tighten oil filter by hand until O-ring comes in
contact with the sealing surface.
3. Use filter wrench to tighten oil filter one turn and 1/8
turn.
4. Start engine and carefully check for oil leakage from
oil filter.
SUB OIL FILTER
The sub oil filter requires no servicing until the
replacement interval is reached.
The element is designed to provide special filtering
efficiency until it becomes due for replacement.
It is recommended to check and replace the sub oil filter
when the engine is being overhauled or if it is broken
inside the engine.
For Europe1
2
050R200001

ENGINE SPEED CONTROL 6H – 1
ENGINE SPEED CONTROL
CONTENTS
General Description . . . . . . . . . . . . . . . . . . 6H–2 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . 6H–3