1998 OPEL FRONTERA low oil pressure

6A – 44 ENGINE MECHANICAL
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove air cleaner and air duct.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Remove PCV hose.
7. Remove EGR vacuum hose.
8. Disconnect harness connector around the cylinder
head.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out fan belt.
12. Remove heat protector and remove valve
assembly.
13. Remove water hose and oil pipe from turbocharger.
14. Remove turbocharger assembly.
15. Remove water hose between thermostat and
radiator.
16. Remove cylinder head noise insulator cover.
NOTE: Do not make damage to the harness.
17. Remove high pressure pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner and remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove water pipe between cylinder head and
water pump.
24. Remove fuel pipe between fuel pump and intake
manifold.
25. Remove fuel return pipe.
26. Remove intake manifold assembly.
27. Disconnect glow plug wiring and remove glow plug.
28. Remove cylinder head cover.
29. Drain oil from oil rail.
30. Disconnect injector harness connector.
31. Disconnect harness connector from oil pressure
sensor and oil temperature sensor on the oil rail.
32. Disconnect injector harness assembly.
33. Remove injector clamp.
34. Remove injector spacer (If equipped.).
35. Remove injector assembly.
36. Remove oil rail assembly.
37. Remove camshaft carrier.
38. Remove cylinder head assembly.
39. Remove cylinder gasket.
INSTALLATION
1. Install cylinder head gasket with top mark up.
NOTE: Determine cylinder head gasket grade by
measuring projection of piston head.2. Selection cylinder head gasket.
1) Measure the piston head projection by dial
gauge.
2) Measure the projection of piston head at the
nearest possible point to the cylinder bore.
3) Obtain the largest measurement from among all
cylinders.
4) Determine cylinder head gasket grade by
maximum value of measuring projection of
piston head.
Legend
(1) Top Mark
(2) Grade Mark
012RW073
2 1
011RW043

ENGINE MECHANICAL 6A – 45
Cylinder head gasket and piston projection mm
CAUTION:
The projection of each piston should be 0.333
mm or more and less than 0.483 mm.
Maximum difference in projection between
pistons should be less than 0.1 mm.
If the piston projection is without standard,
reassemble the engine all over again.
3. Install cylinder head assembly, tighten bolts by
angular tightening method.
To r q u e :
1st step; 49 Nꞏm (4.9 kgꞏm/35.4 lb ft)
2nd step; 60°
3rd step; 60°
CAUTION: The cylinder head bolts cannot be
reused.
4. Install camshaft carrier assembly.
Refer to “Camshaft” in this manual.
5. Install oil rail and injector assembly.
Refer to “Oil rail and injector” in this manual.
6. Install injector harness to connect harness
connector.
Note: Apply liquid gasket (TB 1207B or equivalent) to
the rubber seal of the camshaft end, injector harness
gasket area and No. 1 camshaft bracket. Refer to the
Cylinder head cover.
7. Install cylinder head cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
8. Install glow plug to tighten specified torque.
Torque: 15 Nꞏm (1.5 kgꞏm/11 lb ft) and connectglow plug harness.
9. Install intake manifold.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
10. Install fuel return pipe.
11. Install fuel pipe in between fuel pump and intake
manifold.
12. Install water pipe in between cylinder head and
water pump.
Tighten flange bolt to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
13. Install front plate.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
14. Install camshaft pulley, tighten with angular
tightening method.
1st step 40 Nꞏm (4.0 kgꞏm/29 lb ft)
2nd step 60°
NOTE: Apply engine oil to camshaft pulley bolt.
15. Align timing mark oil pump pulley and camshaft
pulley to front plate then put the timing belt and
tighten tensioner bolt.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) for M8
50 Nꞏm (5.1 kgꞏm/37 lb ft)
16. Install CMP sensor bracket.
17. Install timing belt cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
18. Fill with about 300 cc of engine oil from the high
pressure oil pipe installing port of oil rail using an oil
filler.
If assembled without filling the oil rail with oil, the
time for engine start will be longer.
19. Immediately install high pressure oil pipe to tighten
with specified torque.
Torque: 80 Nꞏm (8 kgꞏm/57.9 lb ft)
20. Install cylinder head noise insulator cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
Grade A Grade B Grade C
011RW042
Grade Piston projectionGasket
thickness
A more 0.333 to less 0.383 1.35
B more 0.383 to less 0.433 1.40
C more 0.433 to less 0.483 1.45

6A – 60 ENGINE MECHANICAL
VALVE STEM SEAL, VALVE SPRING AND ADJUSTER
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove the air duct from between air cleaner and
turbocharger.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Disconnect PCV hose.
7. Disconnect EGR vacuum hose.
8. Disconnect harness connectors around the cylinder
head such as the injector, CMP sensor, MAP
sensor, EGR sensor, EVRV, IAT sensor, A/C
compressor, TP stepping motor, TP sensor and fuel
temperature sensor etc.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out drivebelt.
12. Remove heat protector, remove exhaust valve
assembly.
13. Remove water cooling hose and lubrication pipe for
turbocharger.
14. Remove turbocharger assembly.
15. Remove hose between thermostat and radiator.
16. Remove noise insulator cover of cylinder head.
NOTE: Do not damage injector harness.
17. Remove high pressure oil pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner then remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove engine coolant pipe between cylinder
head and water pump.
1
2
3
4
5
6
9
10
7
8
011RW031
Legend
(1) Adjuster
(2) Tappet
(3) Split Collar
(4) Spring Seat Upper
(5) Valve Spring(6) Spring Seat Lower
(7) Valve Stem Seal
(8) Valve Guide
(9) Valve Seat
(10) Valve

ENGINE MECHANICAL 6A – 61
24. Remove fuel pipe between fuel pump and intake
manifold.
25. Remove fuel return pipe from rear of cylinder head.
26. Remove intake manifold assembly.
27. Disconnect glow plug harness and remove glow
plug.
28. Remove cylinder head cover.
29. Remove injector harness connector.
30. Disconnect harness connector from oil pressure
sensor and oil temperature sensor on the oil rail.
31. Remove injector harness assembly.
32. Remove injector clamp.
33. Remove injector is fixed bolts.
34. Remove injector assembly.
35. Remove oil rail.
36. Remove camshaft carrier assembly with camshaft.
37. Remove cylinder head assembly.
38. Disassemble valve spring according to the following
method.
1) Use valve spring compressor then remove split
collars.
2) Valve spring compressor: 5-8840-2441-0
NOTE: Put removed valve spring in order of cylinder
number.
39. Valve stem seal.
1) Use a screwdriver or pliers to remove valve
stem seal.
NOTE: Do not reuse removed valve stem seal.
INSPECTION AND REPAIR
Make the necessary adjustments, repairs and part
replacements if excessive wear or damage is
discovered during inspection.
Va l v e s p r i n g
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is
evident.
1. Free height
1) Measure the free height of the springs. The
springs must be replaced if the height is below
the specified limit.
Standard: 45.85 mm (1.8051in)
Limit: 43.9 mm (1.7283 in)
2. Squareness
1) Measure the valve spring squareness with a
steel square.
2) Replace the valve springs if the measured value
exceeds the specified limit.
Limit: 1.6 mm (0.063 in)
014rw042
014rs004
014rs005

6A – 66 ENGINE MECHANICAL
INSTALLATION
1. Valve stem seal
1) Use the special tool to install the stem seal to the
valve guide.
Stem Seal Installer: 5-8840-2033-0
2. Valve spring.
1) Install the lower valve seat spring, valve spring,
then the upper valve spring seat.
2) Use valve spring compressor to compress the
spring then install the split collar.
Valve spring compressor: 5-8840-2441-0
NOTE: Make sure the split collar installs completely.
3. Install cylinder head assembly.
Refer to “Cylinder Head” in this manual.
4. Install the camshaft carrier with camshaft.
Refer to “Camshaft” in this manual.
5. Install oil rail assembly.
Refer to “Oil rail and injector” in this manual.
6. Install injector assembly.
Refer to “Oil rail and injector” in this manual.
7. Install the injector harness assembly.
Refer to “Injector” in this manual.
8. Reconnect harness connecter to oil pressure
sensor and oil temperature sensor on the oil rail.
9. Reconnect Injector harness connecter to injector.
Refer to “Injector” in this manual.
10. Install cylinder head cover with gasket.
Refer to “Cylinder Head Cover” in this manual.
11. Install glow plug with specified torque.
Torque: 15 Nꞏm (1.5 kgꞏm / 10.8 lb ft)
12. Install the intake manifold assembly.
Refer to “Intake Manifold” in this manual.
13. Install the fuel pipe.14. Install the water pipe between the cylinder head
and water pump.
Torque: 20 Nꞏm (2.0 kꞏm / 14.5 lb ft)
15. Install the front plate.
16. Install the camshaft pulley.
Refer to “Timing Gear” in this manual.
17. Install timing belt and set the tensioner.
Refer to “Timing Belt” in this manual.
18. Install CMP sensor bracket.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
19. Install timing belt cover.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
20. Fill the oil rail with engine oil then immediately
install the high pressure oil pipe with the specified
torque.
Torque: 80 Nꞏm (8.1 kgꞏm / 57.9 lb ft)
21. Install the noise insulator cover.
22. Reconnect hose between thermostat and radiator.
23. Install turbocharger assembly.
Refer to “Turbocharger” in this manual.
24. Install water hose and oil pipe for turbocharger.
Refer to “Turbocharger” in this manual.
25. Install the valve assembly and install heat protector.
26. Install generator and set the fan belts.
27. Install A/C compressor bracket, compressor
assembly and set drive belt.
28. Reconnect harness connector around cylinder
head.
29. Reconnect vacuum hose to EGR valve.
30. Reconnect PCV hose.
31. Install oil level gauge guide assembly.
32. Install intercooler assembly.
Refer to “Intercooler” in this manual.
33. Install the air duct assembly.
34. Fill engine coolant.
35. Connect battery ground cable.
014RW042

6A – 68 ENGINE MECHANICAL
3. Determine the thickness of the adjuster as follows.
1) Measure the thickness of the removed adjuster
with a micrometer.
2) Calculate the thickness of a new adjuster.
Calculation
TA: Thickness of new adjuster
M: Valve clearance measurement.
TO: Thickness of the removed adjuster
For intake side: TA=TO+(M–0.15) mm
For exhaust side: TA=TO+(M–0.25) mm
Select a new adjuster whose thickness is as
close to the estimated value as possible.
4. Install oil rail and tighten it temporarily.
5. Install injector assembly.
NOTE:
1) Do not forget to insert the O-ring between injector
and oil rail.
2) Install the injector to the same position as before
removal.
6. Install the injector fixing bolts and temporarily
tighten.
7. Install the injector clamp and tighten temporarily.
8. Tighten injector fixing bolts to the specified torque.
Torque: 6.5 Nꞏm (0.7 kgꞏm / 5.1 lb ft)
9. Tighten injector clamp nut to the specified torque
with special method.
Torque: loosen one turn and tighten again to
specified torque.
Torque: 25 Nꞏm (2.4 kgꞏm / 17.4 lb ft)
10. Tighten oil rail to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
11. Install injector harness and reconnect connector.
12. Install cylinder head cover.
Refer to”Cylinder Head” in this manual.
13. Fill with about 300cc of engine oil at the high
pressure oil pipe installation port on the oil rail using
an oil filler.
If assembled without filling the oil rail with oil, the
time for engine starting will be longer.
14. Immediately install high pressure oil pipe to tighten
with specified torque.
Torque: 80 Nꞏm (8.1 kgꞏm / 57.9 lb ft)
15. Install cylinder head noise insulator cover.
Refer to “Cylinder Head” in this manual.

ENGINE MECHANICAL 6A – 69
OIL RAIL AND INJECTOR
REMOVAL
Prior to removal, be sure to confirm and record the
group code of the injector installed using Tech2.
1. Disconnect battery ground cable.
2. Remove air cleaner cover and air duct.
3. Remove intercooler.
Refer to “Intercooler” in this manual.
4. Remove PCV hose and pipe.
5. Remove cylinder head noise insulator cover.
6. Remove high pressure oil pipe.
CAUTION:
1) Sleeve nut should be loosened with cloth tied
around it to prevent oil from spurting due to the
remaining pressure.
2) The high pressure pipe should be disconnected
with a cloth tied around the intake manifold
glow plug to prevent oil from flowing out of the
oil rail.7. Loosen eye bolt of fuel pipe at fuel pump side.
NOTE: Cloth should be put around the loosened eye
bolt to prevent fuel from flowing out.
8. Remove fuel return hose at chassis side.
9. Remove PCV hose to cylinder head cover.
10. Remove cylinder head cover.
11. Drain the oil from oil rail assembly.
12. Record the identification marking of injector for
each cylinder which is indicated on the upper
portion of injector.
There are nine kinds of identification marking
available, one alphabet letter and one numeral
letter.
In case three kinds of markings are given, one
alphabet letter (sometimes printed) and one
numeral letter, top priority is given to the one
alphabet letter and one numeral letter.
1
6
27
3
5
4
With
spacer type
Without
spacer type
012R200005
Legend
(1) Injector Clamp
(2) Injector Assembly
(3) Oil Rail Assembly(4) Camshaft Bracket
(5) Camshaft
(6) O-Ring
(7) Drain Plug

6A – 70 ENGINE MECHANICAL
(For example)
If you find identification marking “A”, “RA” and “2”
on the injector, you can use injector grade “A”. (The
“RA” is sometimes printed, but can be ignored)
Legend
(1) Part Number
(2) Two Alphabet Letter
(3) Serial Number
(4) Bar Code
(5) One Alphabet Letter
(6) One Numeral Letter
13. Remove harness connector from each injector.
14. Loosen nuts and bolts for oil rail.
15. Remove injector fixing bolts.
16. Remove injector clamp.
17. Remove injector assembly.
NOTE: Do not drop O-ring INSTALLATION
1. Install oil rail, tighten temporarily
2. Install injector assembly.
NOTE: Do not forget to install O-ring between injector
and oil rail.
3. Install injector fixing bolts, tighten temporarily.
4. Install injector clamp, tighten nut temporarily.
5. Tighten injector bolts to the specified torque.
Torque: 6.5 Nꞏm (0.7 kgꞏm / 5.1 lb ft)
6. Tighten injector clamp nut to the specified torque
with special method.
Torque: 30 Nꞏm (3.1 kgꞏm / 22 lb ft) then loose a
time again tighten as following torque.
Torque: 25 Nꞏm (2.4 kgꞏm / 17.4 lb ft)
7. Tighten oil rail to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
8. Install injector harness assembly, reconnect
harness connecter to injector.
9. Record the identification marking of injector for
each cylinder that is indicated on the upper portion
of injector.
Legend
(1) Part Number
(2) Two Alphabet Letter
(3) Serial Number
(4) Bar Code
(5) One Alphabet Letter
(6) One Numeral Letter
10. Install cylinder head assembly.
Refer to “Cylinder Head” in this manual.
11. Fill with about 300cc of engine oil from the high
pressure oil pipe at the high pressure oil pipe
installation port on the oil rail using an oil filler.
If assembled without filling the oil rail with oil, the
time for engine starting will be longer.
1
4
3
265
055RW021-1
1
4
3
265
055RW021-1
Identification
One Alphabet One Numeral
Marking
Letter Letter
Grade
A1
AA2
A3
B1
BB2
B3
C1
CC2
C3