oil temperature OPEL FRONTERA 1998 Workshop Manual

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–48
Check flowTrouble codePhenomenonStandard
1026The electromagnetic coil GND is
short-circuited.Resistance: 1.0 to 5.0 ohm (at ordi-
nary temperature)
D04RW060

4D2–28
TRANSFER CASE (TOD)
Tension of Lock-up Fork Spring
If the measurement exceeds the limit, replace the
spring. (When compressed to 41.4 mm)
Standard : 27.1-33.8 N {2.76-3.45 kg/6.08-7.61 Ib}
Allowable limit : 24.5 N {2.5 kg/5.5 Ib}
014RW048
Tension of Detent Spring Assembly
If the measurement exceeds the limit, replace the
spring. N {kg} (When compressed by 3 mm from the
free length)
Standard : 139 N -203 {14.2-20.7 kg/31.3-45.6 Ib}
Allowable limit : 130 N {13.3 kg/29.3 Ib}
261RW041
Oil Pump
Remove foreign materials from the strainer. If the
strainer is damaged, replace it.
If the area into which the shaft is inserted is
excessively worn or damaged, replace the pump.
Multi Plate Disk Clutch
If the burned, mirror-surfaced clutch facing, or
scraping is observed on the clutch plates, clutch
housing, armature plate, and insulator washer,
replace the part or parts.
266RW003
Coil Assembly
Check the resistance of the coil with a tester. If
defects are observed, replace the assembly.
* (ordinary temperature)
Standard : 1.4
2.0
Allowable limit : 1.05.0
261RW031

6A–5
ENGINE MECHANICAL
4. Engine Lacks Compression
Condition
Possible causeCorrection
Engine lacks compressionSpark plug loosely fitted or spark
plug gasket defectiveTighten to specified torque or replace
gasket
Valve timing incorrectAdjust
Cylinder head gasket defectiveReplace gasket
Valve incorrectly seatedLap valve
Valve stem seizedReplace valve and valve guide
Valve spring weakened or brokenReplace
Cylinder or piston rings wornOverhaul engine
Piston ring seizedOverhaul engine.
Engine Compression Test Procedure
1. Start and run the engine until the engine reaches
normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and fuse
box.
6. Engage the starter and check that the cranking speed
is approximately 300 rpm.7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the starter
engaged until the compression gage needle reaches
the maximum level. Note the reading.
9. Repeat the test with each cylinder.
If the compression pressure obtained falls below the
limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)

6A–7
ENGINE MECHANICAL
Condition CorrectionPossible cause
OthersEngine lacks compressionRefer to “Hard Start”
Valve incorrectly seatedLap valve
Air Cleaner Filter cloggedReplace filter element
Valve timing incorrectReadjust
Idle air control valve brokenReplace
Fast idle solenoid defectiveReplace
Positive Crankcase Ventilation valve
defective or cloggedReplace
Rough Engine Running
ConditionPossible causeCorrection
Engine misfires periodicallyIgnition coil layer shortedReplace
Spark plugs foulingClean or install hotter type plug
Spark plug(s) insulator nose leakingReplace
Fuel injector(s) defectiveReplace
Powertrain control module faultyReplace
Engine knocks periodicallySpark plugs running too hotInstall colder type spark plugs
Powertrain control module faultyReplace
Engine lacks powerSpark plugs fouledClean
Fuel injectors defectiveReplace
Mass Airflow Sensor or Intake
Airflow Sensor circuit defectiveCorrect or replace
Manifold Absolute Pressure (MAP)
Sensor or Manifold Absolute
Pressure Sensor circuit defectiveCorrect or replace
Engine Coolant Temperature Sensor
or Engine Coolant Temperature
Sensor circuit defectiveCorrect or replace
Powertrain Control Module faultyReplace
Intake Air Temperature Sensor or
Intake Air Temperature Sensor
circuit defectiveCorrect or replace
Throttle Position Sensor or Throttle
Position Sensor circuit defectiveCorrect or replace
Knock Sensor or Knock Sensor
circuits defectiveCorrect or replace
Knock Sensor Module or Knock
Sensor Module circuits defectiveCorrect or replace

6A–10
ENGINE MECHANICAL
Engine Lacks Power
ConditionPossible causeCorrection
Trouble in fuel systemFuel Pressure Control Valve not
working normallyReplace
Fuel injector cloggedClean or replace
Fuel pipe cloggedClean
Fuel filter clogged or fouledReplace
Fuel pump drive circuit not working
normallyCorrect or replace
Fuel tank not sufficiently breathing
due to clogged Evaporative
Emission Control System circuitClean or replace
Water in fuel systemClean
Inferior quality fuel in fuel systemUse fuel of specified octane rating
Powertrain Control Module supplied
poor voltageCorrect circuit
Throttle Position Sensor cable
broken or poor connectionsCorrect or replace
Throttle Position Sensor defectiveReplace
Mass Airflow Sensor not working
normallyReplace
Manifold Absolute Pressure Sensor
not working normallyReplace
Intake Air Temperature Sensor not
working normallyReplace
Engine Coolant Temperature Sensor
circuit open or shortedCorrect or replace
Engine Coolant Temperature Sensor
defectiveReplace
Powertrain Control Module defectiveReplace
Trouble in intake or exhaust systemAir Cleaner Filter cloggedReplace filter element
Air duct kinked or flattenedCorrect or replace
Ignition failure————Refer to Hard Start Troubleshooting
Guide
Heat range of spark plug inadequateInstall spark plugs of adequate heat
range
Ignition coil defectiveReplace

6A–16
ENGINE MECHANICAL
Lubrication Problems
ConditionPossible causeCorrection
Oil pressure too lowWrong oil in useReplace with correct engine oil
Relief valve stickingReplace
Oil pump not operating properlyCorrect or replace
Oil pump strainer cloggedClean or replace strainer
Oil pump wornReplace
Oil pressure gauge defectiveCorrect or replace
Crankshaft bearing or connecting
rod bearing wornReplace
Oil contaminationWrong oil in useReplace with correct engine oil
Oil filter cloggedReplace oil filter
Cylinder head gasket damageReplace gasket
Burned gases leakingReplace piston and piston rings or
cylinder body assembly
Oil not reaching valve systemOil passage in cylinder head or
cylinder body cloggedClean or correct
Engine Oil Pressure Check
1. Check for dirt, gasoline or water in the engine oil.
a. Check the viscosity of the oil.
b. Change the oil if the viscosity is outside the
specified standard.
c. Refer to the “Maintenance and Lubrication” section
of this manual.
2. Check the engine oil level.
The level should fall somewhere between the “ADD”
and the “FULL” marks on the oil level dipstick.
If the oil level does not reach the “ADD” mark on the
oil level dipstick, engine oil must be added.3. Remove the oil pressure unit.
4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach normal
operating temperature (About 80
C).
6. Measure the oil pressure.
Oil pressure should be:
392–550 kPa (56.9–80.4 psi) at 3000 rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure unit.
10. Start the engine and check for leaks.

6A–18
ENGINE MECHANICAL
Cylinder Head Cover LH
Removal
1. Disconnect battery ground cable.
2. Drain engine coolant from faucet bottom of radiator.
3. Remove engine cover from the dowels on the
common chamber.
F06RW018
4. Remove air cleaner duct assembly (3) and air cleaner
element (4).
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
NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.5. Disconnect following wiring connectors and bonding
cable:
Manifold Absolute Pressure (MAP) sensor
Vacuum Switching Valve (VSV) for Induction Air
Control Valve (IACV) actuator
Ignition coils for left bank
Fuel injectors for left bank
Idle air control (IAC) valve
Throttle position sensor (TPS)
Bonding cable
Others as necessitated
6. Disconnect following vacuum hoses:
Brake master VAC
Canister
VSV for IACV actuator
Duty solenoid valve
PCV
7. Disconnect radiator upper and lower hoses
8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
F06RW019

6A–21
ENGINE MECHANICAL
Cylinder Head Cover RH
Removal
1. Disconnect battery ground cable.
2. Remove battery from the vehicle.
3. Drain engine coolant from faucet bottom of radiator.
4. Remove engine cover from the dowels on the
common chamber.
F06RW018
5. Remove air cleaner duct assembly (3) and air cleaner
element (4).
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
NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.
6. Disconnect following wiring connectors and bonding
cable:
Exhaust Gas Recirculation (EGR) valve
Fuel injectors for right bank
Ignition coils for right bank
Bonding cable
Othres as necessitated
7. Disconnect radiator upper and lower hoses.
8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
F06RW019
Legend
(1) Crankshaft Pulley
(2) Generator
(3) Auto Tensioner
(4) Idle Pulley
(5) Cooling Fan Pulley
(6) Power Steering Oil Pump
(7) Drive Belt
(8) Air Conditioner Compressor
12. Remove fan pulley and bracket assembly.
13. Remove idle pulley assembly.
14. Remove auto tensioner assembly.
15. Remove crankshaft pulley using 5–8840–0133–0
crankshaft holder.

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–83
ENGINE MECHANICAL
Attach the piston to the connecting rod with the
piston front mark and the connecting rod front mark
on the same side.
015RS036
With 5–8840–0551–0 Piston pin service set and a
press, press fit the piston pin.
NOTE: Heat the connecting rod small end to a suitable
temperature to ensure smooth installation.
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
4. Install piston ring with the piston ring expander.
The compression ring must be set with the T mark (1)
facing up.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring
015RS027
Install piston rings in the following sequence.
1. Oil ring
1. Expander ring
2. Upper side rail
3. Lower side rail
2. 2nd compression ring
3. 1st compression ring
The compression rings must be set with the T or T2
mark facing up.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring
After installation, apply engine oil to the entire
circumference of the piston rings. Check to see that
all the rings rotate smoothly.
015RS038
5. Install piston and connecting rod assembly.
Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces and
nuts.