1998 OPEL FRONTERA engine

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.

6C – 20 ENGINE FUEL
FUEL TANK
REMOVAL
1. Disconnect battery ground cable.
2. Remove fuel filler cap.
3. Drain fuel.
After drain the fuel tighten the drain plug with
specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14 lb ft)
4. Remove fuel filler hose and let air pull off hose.
5. Remove breather hose.
6. Remove fuel feed hose and fuel return hose.
7. Disconnect harness connector from fuel gauge unit.
8. Remove under cover.
9. Remove fuel tank assembly.
INSTALLATION
1. Fuel tank assembly.
1) Place a flange on right side of tank on the
bracket.
2) Install a flange to left side of the bracket from the
bottom, and tighten bolts to the specified torque.
Torque : 36 Nꞏm (3.7 kgꞏm/26.8 lb ft)
2. Install fuel hose and fuel return hose.
3. Install the breather hose.
4. Reconnect harness connector to fuel gauge unit.
5. Install under cover.
6. Install fuel filler hose and let air pull off hose.
7. Fill fuel tank with fuel and tighten filler cap.
8. Reconnect battery ground cable.
1
2
6
7
4
5
3
Legend
(1) Fuel Tank Assembly
(2) Gauge Unit
(3) Under Cover(4) Fuel Filler Hose
(5) Fuel Filler Cap
(6) Breather Hose
(7) Control Valve (Except EC)
140RX023

ENGINE FUEL 6C – 21
FUEL GAUGE UNIT
1
2
6
7
4
5
3
140RX023
REMOVAL
1 Disconnect battery ground cable.
2 Loosen fuel filler cap.
3 Drain fuel.
After drain the fuel tighten the drain plug with
specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14 lb ft)
4. Disconnect harness connector from fuel gauge unit.
5. Fuel Gauge Unit
1) Remove the fixing screws, then the fuel gauge
unit.
INSTALLATION
1. Fuel Gauge Unit
2 Connect the harness connector to the fuel gage
unit.
3 Fill the tank with fuel and tighten fuel filler cap.
4 Connect battery ground cable.
FUEL FILLER CAP
The fuel filler cap contains a vacuum valve. If a
negative pressure develops in the fuel tank, the
external valve of the fuel filler cap opens to allow the
fresh air to flow into the fuel tank through the vacuum
valve.
INSPECTION
Check the seal ring in the filler cap for presence of any
abnormality and for seal condition.
Replace the filler cap, if abnormal.Legend
(1) Vacuum Valve
(2) Pressure Valve Legend
(1) Fuel Tank Assembly
(2) Fuel Gauge Unit
(3) Under Cover(4) Filler Hose
(5) Filler Cap
(6) Breather Hose
(7) Control Valve (Except EC)
1
2
060RW098

ENGINE ELECTRICAL 6D – 1
ENGINE ELECTRICAL
CONTENTS
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–1
General Description . . . . . . . . . . . . . . . . 6D–1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 6D–1
On Vehicle Service . . . . . . . . . . . . . . . . . 6D–3
Main Data and Specification . . . . . . . . . . 6D–4
Starting System . . . . . . . . . . . . . . . . . . . . . 6D–5
General Description . . . . . . . . . . . . . . . . 6D–5
On Vehicle Service . . . . . . . . . . . . . . . . . 6D–7
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–7
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 6D–8Charging System . . . . . . . . . . . . . . . . . . . . 6D–15
General Description . . . . . . . . . . . . . . . . 6D–15
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 6D–16
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 6D–17
Main Data and Specification . . . . . . . . . . 6D–22
QOS4 Preheating System . . . . . . . . . . . . . . 6D–23
General Description . . . . . . . . . . . . . . . . 6D–23
System Diagram . . . . . . . . . . . . . . . . . . . 6D–23
Inspection of QOS4 System Operation . . 6D–24
BATTERY
GENERAL DESCRIPTION
DIAGNOSIS
There are six battery fluid caps at the top of the battery.
These are covered by a paper label.
The battery is completely sealed except for the six
small vent holes at the side. These vent holes permit
the escape of small amounts of gas generated by the
battery.
This type of battery has the following advantages over
conventional batteries:1. There is no need to add water during the entire
service life of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an excessive
charge.
(A conventional battery will accept an excessive
charge, resulting in gassing and loss of battery
fluid.)
3. The battery is much less vulnerable to self-
discharge than a conventional type battery.
1. VISUAL INSPECTION (Step 1)
Inspect the battery for obvious physical damage, such
as a cracked or broken case, which would permit
electrolyte loss.
Replace the battery if obvious physical damage is
discovered during inspection.
Check for any other physical damage and correct it as
necessary. If not, proceed to Step 2.
2. HYDROMETER CHECK (Step 2)
There is a built-in hydrometer (Charge test indicator) at
the top of the battery. It is designed to be used during
diagnostic procedures.
Before trying to read the hydrometer, carefully clean the
upper battery surface.
If your work area is poorly lit, additional light may be
necessary to read the hydrometer.
a. BLUE RING OR DOT VISIBLE – Go to Step 4.
b. BLUE RING OR DOT NOT VISIBLE – Go to
Step 3.3. FLUID LEVEL CHECK (Step 3)
The fluid level should be between the upper level line
and lower level line on side of the battery.
a. CORRECT FLUID LEVEL – Charge the battery.
b. BELOW LOWER LEVEL – Replace battery.
4. VOLTAGE CHECK (Step 4)
(1) Put voltmeter test leads to battery terminals.
a. VOLTAGE IS 12.4V OR ABOVE – Go to Step 5.
b. VOLTAGE IS UNDER 12.4V – Go to procedure
(2) below.
(2) Determine fast charge amperage from
specification. (See Main Data and Specifications in
this section.)
Fast charge battery for 30 minutes at amperage
rate no higher than specified value.
Take voltage and amperage readings after charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE – Replace battery.

6D – 2 ENGINE ELECTRICAL
b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE – Drop charging voltage to
15V and charge for 10 – 15 hours.
Then go to Step 5.
c. VOLTAGE IS BETWEEN 12V AND 16V –
Continue charging at the same rate for an
additional 3-1/2 hours. Then go to Step 5.
d. VOLTAGE IS BELOW 12V – Replace battery.
5. LOAD TEST (Step 5)
(1) Connect a voltmeter and a battery load tester
across the battery terminals.
(2) Apply 300 ampere load for 15 seconds to remove
surface charge from the battery.
Remove load.
(3) Wait 15 seconds to let battery recover. Then apply
specified load from specifications (See Main Data
and Specifications in this section).
Read voltage after 15 seconds, then remove load.
a. VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN FOLLOWING TABLE –
The battery is good and should be returned to
service.
b. VOLTAGE IS LESS THAN MINIMUM LISTED –
Replace battery.
ESTIMATED
TEMPERATUREMINIMUM
°F °CVOLTAGE
70 21 9.6
60 16 9.5
50 10 9.4
40 4 9.3
30 –1 9.1
20 –7 8.9
10 –12 8.7
0–188.5
The battery temperature must be estimated by feel
and by the temperature the battery has been
exposed to for the preceding few hours.

ENGINE ELECTRICAL 6D – 3
ON-VEHICLE SERVICE
BATTERY CHARGING
Observe the following safety precautions when
charging the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during the
charging procedure.
Battery charging should be discontinued or the rate
of charge reduced if the battery feels hot to the
touch.
Battery charging should be discontinued or the rate
of charge reduced if the battery begins to gas or
spew electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue
dot or ring, it may be necessary to jiggle or tilt the
battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be
either quick-charged or slow-charged in the same
manner as other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
JUMP STARTING
JUMP STARTING WITH AN AUXILIARY
(BOOSTER) BATTERY
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: Failure to carefully follow the jump
starting procedure could result in the following:
1. Serious personal injury, particularly to your
eyes.
2. Property damage from a battery explosion,
battery acid, or an electrical fire.
3. Damage to the electronic components of one or
both vehicles.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode. Remove any rings, watches, or other jewelry
before working around the battery. Protect your eyes by
wearing an approved set of goggles.
Never allow battery fluid to come in contact with your
eyes or skin.
Never allow battery fluid to come in contact with fabrics
or painted surfaces.
Battery fluid is a highly corrosive acid.Should battery fluid come in contact with your eyes,
skin, fabric, or a painted surface, immediately and
thoroughly rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of the reach of young
children.
JUMP STARTING PROCEDURE
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector lever in the “PARK”
position.
If the vehicle is equipped with a manual
transmission place the shift lever in the “NEUTRAL”
position.
Turn “OFF” the ignition.
Turn “OFF” all lights and any other accessory
requiring electrical power.
2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the
positive terminal of the discharged battery.
Do not allow the vehicles to touch each other.
This will cause a ground connection, effectively
neutralizing the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the
negative terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the A/C compressor
bracket or the generator mounting bracket) of the
vehicle with the discharged battery.
This ground connection must be at least 450 mm
(18 in) from the battery of the vehicle whose battery
is being charged.
WARNING: Never attach the end of the jumper
cable directly to the negative terminal of the dead
battery.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical
accessories have been turned “OFF”.
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above
directions in the reverse order.
Be sure to first disconnect the negative cable from
the vehicle with the discharged battery.

6D – 4 ENGINE ELECTRICAL
REMOVAL AND INSTALLATION OF THE
BATTERY
REMOVAL
1. Negative cable
2. Positive cable
3. Retainer screw and rods
4. Retainer
5. Battery
INSTALLATION
To install the battery, follow the removal procedure in
the reverse order, noting the following points:
1. Make sure that the rod is hooked on the body side.
065RW029
MAIN DATA AND SPECIFICATIONS
Model (JIS) 80D26R–MF 75D26R–MF
Voltage (V) 12 12
Cold-Cranking Performance (Amp) 582 490
Reserve Capacity (Min) 133 123
Load Test (Amp) 300 300
Fast Charge Maximum Amperage (Amp) 6.5 6.5