1998 OPEL FRONTERA oil pump

6G–12
ENGINE LUBRICATION
Oil Pump Oil Seal
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
4. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
5. Remove timing pulley from crankshaft.
6. Remove oil pump oil seal using a sealer puller.
NOTE: Take care not to damage sealing surfaces of oil
pump and crankshaft when removing oil seal.
Installation
1. Install oil pump oil seal, apply engine oil to oil seal lip,
then install oil seal using 5–8840–2287–0 installer.
015RS001
2. Install timing pulley to crankshaft.
3. Install timing belt.
Refer to installation procedure for Timing Belt in this
manual.
4. Install crankshaft pulley.
Refer to installation procedure for Crankshaft
Pulley in this manual.
5. Refill engine oil until full level.

6G–13 ENGINE LUBRICATION
Oil Filter
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove oil filter using 5-8840-0203-0 filter wrench.
Installation
1. Clean filter fitting surface and apply small amount of
engine oil to sealing surface.
2. Install oil filter cartridge by hand until it comes in
contact with sealing surface then rotate additional 2/3
turn to tighten using 5-8840-0203-0 filter wrench.
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Filter
(5) To Filter
3. Fill engine oil until full level on dipstick.
4. Reconnect battery ground cable.

6G–14
ENGINE LUBRICATION
Main Data and Specification
General Specification
ItemSpecificationsItem6VD16VE1
Oil capacity5.3 liters
Torque Specifications
Crankcase, Oil pan, Timing belt tensioner, Timing
pulley, timing belt cover, Oil pump, Oil gallery, Oil
strainer Nꞏm (Kgꞏm/lb ft)
E06RW045

6G–15 ENGINE LUBRICATION
Special Tool
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2287–0
(J–39202)
Installer; Oil pump oil
seal
5–8840–2153–0
(J–37228)
Seal cutter
5–8840–2005–0
(J–29107)
Universal pitman arm
puller
5–8840–0203–0
(J–36390)
Wrench; Oil filter

ENGINE MECHANICAL 6A – 1
ENGINE
ENGINE MECHANICAL
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . 6A–2
Service Information . . . . . . . . . . . . . . . . . . . . 6A–3
Service Standard . . . . . . . . . . . . . . . . . . . . . . 6A–6
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–9
Tightening Torque . . . . . . . . . . . . . . . . . . . . . 6A–14
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . 6A–25
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . 6A–28
Engine Mount (RH) . . . . . . . . . . . . . . . . . . . . 6A–30
Engine Mount (LH). . . . . . . . . . . . . . . . . . . . . 6A–31
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–32
Cylinder Head Cover . . . . . . . . . . . . . . . . . . . 6A–33
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . 6A–35
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . 6A–36
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . 6A–38Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . 6A–41
Cylinder Head Gasket . . . . . . . . . . . . . . . . . . 6A–43
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–47
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–52
Valve Stem Seal, Valve Spring and Adjuster . . 6A–60
Valve Clearance Adjustment. . . . . . . . . . . . . . 6A–67
Oil Rail and Injector . . . . . . . . . . . . . . . . . . . . 6A–69
Crank Case . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–72
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–74
Piston and Connecting Rod . . . . . . . . . . . . . . 6A–84
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . 6A–92
Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . 6A–98
Oil Filter Cartridge . . . . . . . . . . . . . . . . . . . . . 6A–99
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–99

6A – 10 ENGINE MECHANICAL
8. Check the engine oil level and replenish to the
specified level if required.
9. Start the engine and check for oil leakage from the
main oil filter.
FUEL SYSTEM
Fuel filter
Replacement Procedure
1. Loosen the used fuel filter by turning it
counterclockwise with the filter wrench.
Filter Wrench : 5-8840-0203-0
2. Clean the filter cover fitting faces.
This will allow the new fuel filter to seat properly.
3. Apply a light coat of engine oil to the O-ring.
4. Turn the fuel filter until the sealing face comes in
contact with the O-ring.
5. Turn the fuel filter with a filter wrench 2/3 of a turn
until sealed.
Filter Wrench: 5-8840-0203-0Legend
(1) Priming pump
6. Operate the priming pump until the air is discharged
completely from fuel system.
NOTE: The use of an Isuzu genuine fuel filter is
strongly recommended.
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator
reserve tank as necessary.
If the coolant level falls below the “‘MIN” line, carefully
check the cooling system for leakage. Then add
enough coolant to bring the level up to the “MAX” line.
NOTE: Do not overfill the reserve tank.
012RW112
012RW078
1
012RW111
012RW080

ENGINE MECHANICAL 6A – 29
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.
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.
To r q u e : 4 0 N ꞏm ( 4 k g ꞏm / 2 9 l b ꞏf t )
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
For E urope
F06R200005

ENGINE MECHANICAL 6A – 35
INTAKE MANIFOLD
REMOVAL
1. Drain engine coolant and disconnect water hose
from thermostat hosing.
2. Remove intercooler assembly
Refer to “Intercooler” in this manual.
3. Remove bracket bolt of oil level gauge guide tube.
4. Remove PCV Hose.
5. Remove hoses from EGR, EGR vacuum sensor
and inlet/outlet of heater.
6. Disconnect harness connector form MAP sensor,
EGR vacuum sensor, ETC sensor, water
temperature unit, IAT sensor and EVRV.
7. Remove high pressure oil pipe.
8. Remove the two way valve.
9. Remove fuel pipe from between intake manifold
and high pressure oil pump.
10. Remove fixing bolts and nuts on the intake
manifold, then remove the intake manifold
assembly.
INSTALLATION
1. Install the intake manifold, tighten bolts and nuts to
the specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) for bolt and nut
2. Install the fuel pipe and tighten to the specified
torque.To r q u e :
M16 bolt (apply engine oil) 4 Nꞏm (0.4 kgꞏm/2.9
lb ft)
Cap nut (M10) 13Nꞏm (1.3 kgꞏm/9.4 lb ft)
Fuel pipe (M10 apply engine oil) 14 Nꞏm (1.4
kgꞏm/10 lb ft)
3. Install two way valve.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
4. Fill with about 300 cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil filler. If assembled without filling the oil rail
with oil, the time for starting the engine will be
longer.
5. Install the high pressure oil pipe immediately and
tighten the sleeve nut to the specified torque.
Torque : 80 Nꞏm (8 kgꞏm/57.9 lb ft)
6. Reconnect harness connector to MAP sensor, EGR
vacuum sensor, ETC sensor, Water temperature
unit, IAT sensor and EVRV.
7. Connect the hoses to EGR valve, EGR vacuum
sensor, and water inlet/outlet pipe for heater.
8. Connect PCV hose.
9. Install the oil level gauge guide tube and tighten
bracket bolt.
10. Install the intercooler assembly.
Refer to “Intercooler” in this manual.
11. Connect the hose to the thermostat housing and fill
with engine coolant.
For Europe
2
1
3
3 1 42
025R200005
Legend
(1) Intake Manifold
(2) Throttle Valve Assembly
(3) EGR Valve
(4) Gasket