OPEL FRONTERA 1998 Workshop Manual

6A–25
ENGINE MECHANICAL
3. Tighten adjusting nut and lock nut temporarily.
4. Loosen adjusting nut by three turns and tighten
lock nut.
Then manually operating the throttle valve, make
sure that the valve lever returns up to the stopper
screw.
If it does not reach the stopper screw, repeat from
step 1.
035RW004
Legend
(1) Clearance
(2) Lock Nut
(3) Adjusting Nut
10. Install air cleaner duct assembly.
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element.
(5) Mass Air Flow Sensor

6A–26
ENGINE MECHANICAL
Exhaust Manifold LH
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
3. Remove exhaust front pipe three stud nuts from
exhaust side and two nuts from rear end of exhaust
front pipe.
150RW062
Legend
(1) Exhaust Front Pipe LH
4. Remove heat protector two fixing bolts then the heat
protector.5. Remove a bolt on engine LH side for air conditioner
(A/C) compressor bracket and loosen two bolts for
A/C compressor then move A/C compressor to front
side.
6. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.
Installation
1. Install exhaust manifold and tighten exhaust manifold
fixing nuts to the specified torque with new nuts.
Torque: 57 Nꞏm (5.8 Kgꞏm/42 lb ft)
2. Install heat protector.
3. Install exhaust front pipe and tighten three stud nuts
and two nuts to the specified torque.
To r q u e :
Stud nuts: 67 Nꞏm (6.8 Kgꞏm/49 lb ft)
Nuts: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
150RW062
Legend
(1) Exhaust Front Pipe LH
4. Set A/C compressor to normal position and tighten
two bolts and a bolt to the specified torque.
Torque : 40 Nꞏm (4.1 Kgꞏm/30 lb ft)
5. Install air cleaner duct assembly.

6A–27
ENGINE MECHANICAL
Exhaust Manifold RH
Removal
1. Disconnect battery ground cable.
2. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
3. Remove exhaust front pipe three stud nuts and two
nuts then disconnect exhaust front pipe.
150RW061
Legend
(1) Exhaust Front Pipe RH
(2) O
2 Sensor (for IGM)
4. Remove heat protector two fixing bolts then the heat
protector.
5. Remove exhaust gas recirculation (EGR) pipe fixing
bolt and nut from exhaust manifold, remove a nut
from EGR valve and a bolt from rear side of cylinder
head for bracket of EGR pipe then remove the EGR
pipe.
056RW001
Legend
(1) Exhaust Gas Recirculation (EGR) Valve
(2) EGR Pipe
6. Remove exhaust manifold eight fixing nuts then the
exhaust manifold.
Installation
1. Install exhaust manifold and tighten bolts to the
specified torque.
Torque : 57 Nꞏm (5.8 Kgꞏm/42 lb ft)
2. Install the EGR pipe, tighten bolt and nut on exhaust
manifold to specified torque.
Torque : 28 Nꞏm (2.9 Kgꞏm/21 lb ft)
Tighten nut to EGR valve to the specified torque.
Torque : 44 Nꞏm (4.5 Kgꞏm/33 lb ft)
Tighten the bolt for EGR pipe bracket to specified
torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
3. Install heat protector
4. Install exhaust front pipe and tighten three stud nuts
and two nuts to the specified torque.
To r q u e :
Stud nuts: 67 Nꞏm (6.8 Kgꞏm/49 lb ft)
Nuts: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
5. Install the torsion bar and readjust the vehicle height.
Refer to installation and vehicle height adjustment
procedure for Front Suspension.

6A–28
ENGINE MECHANICAL
Crankshaft Pulley
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
3. Remove radiator upper fan shroud from radiator.
4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Serpentine Belt
5. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
6. Remove crankshaft pulley assembly using J-8614-01
crankshaft holder, hold crankshaft pulley then
remove center bolt and pulley.
Installation
1. Install crankshaft pulley using J-8614-01 crankshaft
holder, hold the crankshaft pulley and tighten center
bolt to the specified torque.
Torque : 167 Nꞏm (17.0 Kgꞏm/123 lb ft)
2. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in) for fan and
clutch assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.

6A–29
ENGINE MECHANICAL
Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench
then remove drive belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt
5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10. Remove crankshaft pulley assembly using
5–8840–0133–0 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
13. Remove pusher.CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.
014RW011
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its core
could be damaged. The belt should not be bent at
a radius less than 30 mm.
2. Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during installation.
4. Store timing belt in a cool and dark place. Never
expose the belt direct sunlight or heat.

6A–30
ENGINE MECHANICAL
Installation
NOTE: For correct belt installation, the letter on the belt
must be able to be read as viewed from the front of the
vehicle.
014RY00042
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley
014RY00043
Legend
(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt
(9) Alignment Mark (notch) on Crankshaft Timing
Pulley.
(10) Alignment Mark (groove) on Crankshaft Timing
Pulley.
014RW006
Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
1. Install timing belt.
1. Align the mark (notch) of crankshaft timing pulley
(2) with mark on oil pump (1).
Align the mark (groove) on the crankshaft timing
pulley (3) with alignment mark (white dots line) on
the timing belt (4).
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.
014RW003
Legend
(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt

6A–31
ENGINE MECHANICAL
2. Align the alignment mark on the RH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover RH (3).
3. Align the alignment mark (white line) on the timing
belt (1) with alignment mark on the RH bank
camshaft drive gear pulley (2) (on the left side as
viewed from the front of the vehicle) and put the
timing belt on the camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
014RW00004
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.
4. Align the alignment mark on the LH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover LH (3).
5. Align the alignment mark (white line) on the timing
belt (1) with the alignment mark on the LH bank
camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench to
turn the camshaft drive gear pulley, then set the
timing mark between timing belt and camshaft
drive gear pulley and put the timing belt on the
camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
NOTE: It is recommended for easy installation that the
belt be secured with a double clip or equivalent clip after
it is installed the timing belt to each pulley.
014RW00005
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.
6. Install crankshaft pulley temporarily and tighten
center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give some
belt slack between the crankshaft timing pulley
and the RH bank camshaft drive gear pulley.
2. Install pusher and tighten bolt to the specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
1. Install the pusher while pushing the tension pulley
to the belt.
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).
014RW011

6A–32
ENGINE MECHANICAL
Legend
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin
3. Remove double clips or equivalent clips, from
timing belt pulleys.
Turn the crankshaft pulley clockwise by two turns.
3. Install timing belt cover.
Remove crankshaft pulley that was installed in step
1 item 5.
Tighten bolts to the specified torque.
Torque: 19 Nꞏm (1.9 Kgꞏm/14 lb ft)
020RW004
Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower
020RW003
Legend
(1) Timing Belt Cover
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body
4. Install crankshaft pulley using 5–8840–0133–0, hold
the crankshaft pulley and tighten center bolt to the
specified torque.
Torque : 167 Nꞏm (17.0 Kgꞏm/123 lb ft)
5. Install fan pulley bracket and tighten fixing bolts to the
specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
6. Install power steering pump assembly and tighten to
the specified torque.
To r q u e :
M8 bolt : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
M10 bolt : 46 Nꞏm (4.7 Kgꞏm/34 lb ft)
7. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in) for fan and
clutch assembly.
8. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Auto Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt
9. Install radiator upper fan shroud.
10. Install air cleaner assembly.

6A–33
ENGINE MECHANICAL
Camshaft
Removal
1. Disconnect battery ground cable.
2. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
3. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
4. Remove cylinder head cover LH.
Refer to removal procedure for Cylinder Head
Cover LH in this manual.
5. Remove cylinder head cover RH.
Refer to removal procedure for Cylinder Head
Cover RH in this manual.
6. Remove twenty fixing bolts from inlet and exhaust
camshaft bracket on one side bank, then camshaft
brackets.
014RW027
7. Remove camshaft assembly.
8. Remove fixing bolt for camshaft drive gear pulley.
9. Remove three fixing bolts from camshaft drive gear
retainer, then camshaft drive gear assembly.
014RW026
Legend
(1) Right Bank
(2) Left Bank
(3) Timing Mark on Retainer
Installation
1. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
2. Tighten bolt for camshaft drive gear assembly pulley
to the specified torque.
Torque : 98 Nꞏm (10.0 Kgꞏm/72 lb ft)
3. Tighten sub gear setting bolt.
1. Use the 5–8840–2443–0 gear spring lever to turn
sub gear to right direction until it aligns with the M5
bolt hole between camshaft driven gear and sub
gear.
2. Tighten the M5 bolt to a suitable torque to prevent
the sub gear from moving.

6A–34
ENGINE MECHANICAL
014RW041
4. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the specified
torque.
1. Apply engine oil to camshaft journal and bearing
surface of camshaft bracket.
2 . A l i g n t i m i n g m a r k o n i n t a k e c a m s h a f t ( o n e d o t f o r
right bank, two dot for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).
014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
(LI: Left bank intake, RI: Right bank intake)
(LE: Left bank exhaust, RE: Right bank
exhaust)
014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin