1998 OPEL FRONTERA rack

6G–5 ENGINE LUBRICATION
051RS005
Oil Strainer
Check the oil strainer for cracking and scoring. If cracking
and scoring are found, the oil strainer must be replaced.
051RS006
Reassembly
1. Install drive gear (11).
2. Install driven gear (10).
3. Install oil pump cover (9) and first, loosely tighten all of
the attaching screws. Next, tighten the attaching
screws to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
After installation, check that the gear rotates
smoothly.
4. Install relief valve (8) and apply engine oil to the relief
valve and spring (7).
5. Install spring (7).6. Install the plug (6).
Torque : 8 Nꞏm (0.8 Kgꞏm/69 lb in)
051RS007
7. Install oil pump assembly (5).
Carefully remove any oil from the cylinder body and
the pump. Apply sealant (TB–1207B or equivalent)
to the pump fitting face as shown in illustration. Take
care that sealant is not applied to oil port surfaces.
The oil pump assembly must be installed within 5
minutes after sealant application before the sealant
hardens.
CAUTION: Do not apply an excessive amount of
sealant to the contact surface. Applying too much
sealant will overflow the contact surfaces. This
could cause serious damage to the engine.
Attach oil pump assembly to cylinder body.
Tighten the oil pump fixing bolts.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lbꞏft)
051RW002

6H–2
ENGINE SPEED CONTROL SYSTEM
Accelerator Pedal Control Cable
Removal
1. Loosen the adjusting nut(5) on the cable bracket
mounted on the common chamber.
2. Remove cable clip(3).
3. Disconnect accelerator pedal (AP) control cable(6).
(on throttle valve side)
4. Disconnect AP control cable(1). (on AP pedal(7) side)
5. Remove molding cap(2).
6. Remove AP control cable(4).
101RW001
Inspection
Check the following items, and replace the control cable if
any abnormality is found:
The control cable should move smoothly.
The control cable should not be bent or kinked.
The control cable should be free of damage and
corrosion.
Installation
1. Install AP control cable(4).
2. Install molding cap(2).
3. Connect AP control cable(1). (on AP side)
4. Connect AP control cable(6). (on throttle valve side)
5. Install cable clip(3).
6. Install adjusting nut(5).
101RW001
Adjustment
1. Loosen adjusting nut and lock nut.
2. Pull outer cable while closing fully the throttle valve.
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

6H–3 ENGINE SPEED CONTROL SYSTEM
Accelerator Pedal
Accelerator Pedal and Associated
Parts
035RW028
Legend
(1) Accelerator Pedal Control Cable
(2) Accelerator Pedal Assembly
Removal
1. Accelerator Pedal control cable(1).
2. Accelerator Pedal assembly(2).
Installation
1. Accelerator pedal assembly(2).
2. Accelerator pedal control cable(1).
Adjustment
Manual Transmission:
Rotate counterclockwise to loosen the lock nut and
screw the stopper bolt in sufficiently.
Fully depress the pedal and hold it there with your
hand. Next, rotate the stopper bolt until it hits the
stopper of pedal bracket. Then, lock the stopper bolt
there.
Automatic Transmission:
Rotate counterclockwise to loosen the kickdown
switch sufficiently.
Fully depress the pedal and hold it there with your
hand. Rotate the switch clockwise and then rotate
further by 1/2 turn from the position where the switch
clicks. Lock the switch there.
Step on the accelerator pedal and make sure that you
can hear a clicking sound at the full stroke position.

6A – 12 ENGINE MECHANICAL
Drive Belt Adjustment
Check the drive belt tension
Depress the drive belt mid-portion with a 98 N (10 kg/
22 lb) force.
Drive Belt Deflection: 10 mm (0.39 in)
Check the drive belt for cracking and other damage.
Legend
(1) Crankshaft pulley
(2) Generator pulley
(3) Cooling fan pulley
(4) A/C compressor pulley
(5) Belt tensioner pulley
Cooling Fan Pulley Drive Belt
Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98 N (10 kg/
22 lb) force.Legend
(1) Crankshaft pulley
(2) Generator pulley
(3) Cooling fan pulley
Compressor Pulley Drive Belt
Move the tensioner pulley as required to adjust the
compressor drive belt tension.
Depress the drive belt mid-portion with a 98 N (10 kg/
22 lb) force.
Legend
(1) Crankshaft pulley
(2) Generator pulley
(3) Cooling fan pulley
(4) A/C compressor pulley
(5) Belt tensioner pulley
5
3
24
1
012RW110
3
2
1
012RW084
5
3
24
1
012RW110

ENGINE MECHANICAL 6A – 21
Engine Mount Bracket
Nꞏm (kgꞏm/lbꞏft)
50(5.1/37)
50(5.1/37)127(13/94)
127(13/94)
40(4/29)
40(4/29)
40(4/29)
022RW019

6A – 26 ENGINE MECHANICAL
ENGINE ASSEMBLY
F06RW048
REMOVAL
1. Remove battery.
2. Drain engine coolant
3. Disconnect window washer hose and remove
engine hood.
4. Radiator Hose
1) Disconnect upper and lower hoses from engine
side.
5. Fan Shroud
1) Disengage clips and remove upper and lower
fan shrouds.
6. Cooling Fan Assembly
1) Remove cooling fan assembly fixing nuts,
cooling fan assembly.
7. Radiator Assembly
1) Remove bracket and radiator assembly.
8. Air Cleaner Cover & Air Duct
9. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
10. Engine Ground Cable
1) Disconnect ground cable from A/C compressor
bracket.
11. AC Generator Harness
1) Disconnect B terminal and harness connector
from AC generator.12. A/C Compressor Assembly
1) Disconnect magnetic clutch harness connector.
2) Remove A/C compressor fixing bolt (rear under
side of compressor).
3) Remove fixing bolts (upper and front lower side
of compressor) and set A/C compressor
assembly with pipe lines on battery carrier.
13 Vacuum Hose
1) Disconnect vacuum hose from vacuum pump.
14. Starter Harness
1) Disconnect B terminal and put cable harness
close to chassis side.
2) Disconnect S terminal connector.
15. Engine Harness
1) Disconnect engine harness close to engine side.
16. Fuel Pipe
1) Remove fuel pipe from fuel pump and take care
not to spill fuel and let dust enter.
17. Engine Ground Cable
1) Disconnect ground cable from left rear side of
timing gear case.
18. Vacuum Hose: Vacuum Tank
Disconnect vacuum hose from vacuum pump side.
19. Glow Plug Harness
20. Transmission Assembly
1) Set transmission support tool under the
transmission.

ENGINE MECHANICAL 6A – 27
2) Remove transmission rear mount.
3) Remove transmission fixing bolt from rear of
engine assembly except two bolts.
4) Carefully hang up engine assembly with a hoist.
5) Remove remaining two transmission fixing bolts.
6) Remove transmission assembly.
7) Remove heater hose.
8) Disconnect wire harness connector for shift on
the fly.
9) Remove vacuum hose.
21. Prepare Engine Stand
22. Engine Assembly
1) Remove engine mount fixing bolts.
2) Carefully hang up the engine assembly.
3) Take out the engine assembly making sure not
to damage the brake oil pipe and other pipe etc.
INSTALLATION
1. Engine assembly
1) Install engine in mounting position by using
hoist.
2. Transmission Assembly
1) Refer to transmission installation steps in
section 7.
3. Engine Mounting
1) After all fixing bolts (left: two bolts, rights: two
bolts) were inserted in every hole, tighten fixing
bolts to the specified torque.
Torque: 40 Nꞏm (4 kgꞏm/29 lbꞏft)
4. Glow Plug Harness
5. Vacuum Hose
1) Connect Vacuum Hose to Vacuum Pump
6. Engine Ground Cable
7. Fuel Pipe
1) Install fuel pipe to fuel pump.
8. Engine Harness
9. Starter Harness
10. A/C Compressor Assembly
1) Tighten temporarily the fixing bolts (upper and
front lower sides of compressor.)
2) Tighten fixing bolt (rear under side of
compressor) to the specified torque.
3) Tighten fixing bolts (front upper and lower sides
of compressor) to the specified torque.
Torque: 40 Nꞏm (4 kgꞏm/29 lbꞏft)Legend
(1) Tensioner
(2) Bolt
(3) Bracket
(4) A/C compressor
(5) Bolt
11. A.C Generator Harness
12. Engine Ground Cable
1) Tighten ground cable to A/C compressor
bracket.
13. Air Cleaner cover & Duct
14. Intercooler Assembly
1) Refer to “Intercooler” in this manual.
15. Radiator Assembly
1) Install rubber cushion in under left and right part
of radiator and position radiator.
2) Fix radiator with bracket.
16. Cooling Fan Assembly
1) Install cooling fan assembly and tighten fixing
bolts to the specified torque.
Torque: 8 Nꞏm (0.8 kgꞏm/5.8 lb ft)
17. Fan Shroud
18. Radiator Hose
1) Connect upper and lower hose to engine side.
2) Pour coolant into radiator.
19. Install battery.
20. Connect window washer hose and install engine
hood.
1
2
3
4
5
F06RW054

6A – 28 ENGINE MECHANICAL
ENGINE MOUNT (RH)
REMOVAL
1. Disconnect battery ground cable
2. Hang the engine assembly.
3. Rubber engine mount.
1) Remove bolts from chassis frame bracket.
2) Remove nuts from rubber engine mount and
engine mounting bracket.
4. Remove bolt which is fixed between engine and
mounting bracket then remove the engine mounting
bracket.
INSTALLATION
Tighten the fixing bolts to the specified torque.
1. Engine mounting bracket to cylinder block.
Torque : 40 Nꞏm (4 kgꞏm/29 lb ft) (for M10)
127 Nꞏm (13 kgꞏm/94 lb ft) (for M14)
2. Rubber engine mount to chassis frame and engine
mounting bracket.
Torque :40 Nꞏm (4 kgꞏm/29 lb ft)
43
12
022RW018
Legend
(1) Rubber Engine Mount (LH)
(2) Engine Mounting Bracket (LH)
(3) Rubber Engine Mount (RH)
(4) Engine Mounting Bracket (RH)