1998 OPEL FRONTERA engine oil

ENGINE FUEL 6C – 15
12. Remove high pressure oil pump
13. Remove high pressure oil pump assembly
Legend
(1) O-ring
(2) High pressure oil pump
(3) Nut
(4) O-ring
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Legend
(1) Reservoir
(2) Repair Kit
(3) Fuel Pump and Bolt(4) Bearing
(5) Oil Rail Pressure Control Valve
(6) High Pressure Oil Pump Body

6C – 16 ENGINE FUEL
INSPECTION AND REPAIR
The high pressure oil pump is made precisely,
therefore, disassembly is not recommended to repair,
only replace special parts.
Special parts
1. Reservoir
2. Fuel pump assembly
3. Bearing
4. Oil Rail Pressure Control Valve
5. High pressure oil pump
6. Repair kit
INSTALLATION
1. Set O-ring to high pressure oil pump assembly.
Install the pump assembly into the rear of timing
gear case.
Tighten nut to specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
Legend
(1) O-ring
(2) High Pressure Oil Pump Assembly
(3) Nuts
(4) O-ring
2. Tighten high pressure oil pump assembly bracket
together with two way valve bracket.
Torque: 27 Nꞏm (2.8 kgꞏm/20.2 lb ft)Legend
(1) High Pressure Oil Pump Assembly
(2) Nut
(3) Two Way Valve Bracket
(4) Bolt
3. Install the pump gear to align timing mark with idle
gear A.
Tighten high pressure pump gear fixing bolt to the
specified torque.
Apply engine oil to thread and seat of bolt.
Torque: 75 Nꞏm (7.6 kgꞏm/55 lb ft)
Legend
(1) O-ring
(2) Pump Gear
(3) Bolt
(4) Timing Mark
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GEAR:O/PUMP
IDLE GEAR A
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ENGINE FUEL 6C – 17
4. Remove lock bolt of idle gear A.
5. Install timing gear case cover.
Refer to “Timing gear” in this manual.
6. Install front plate.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
7. Install timing pulley of high pressure oil pump.
Torque: 10 Nꞏm (1.0 kgꞏm/7.2 lb ft)
8. Install timing belt and tighten timing belt tensioner
assembly.
Refer to “Cylinder head” in this manual.
Legend
(1) Align Mark
(2) Camshaft Pulley
(3) Timing Belt
(4) High Pressure Oil Pump Pulley
(5) Bolt
(6) Tensioner Assembly
(7) Tensioner Bolt
(8) Tensioner Spring
9. Install CMP sensor bracket.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
10. Connect CMP sensor cable.
11. Install timing belt cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
12. 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 engine starting will be longer.
13. Immediately install high pressure oil pipe and
tighten to specified torque.
NOTE:
1) Use new O-ring.
2) Clean O-ring groove and fitting surface of parts.
3) Apply engine oil to O-ring.
Torque: 80 Nꞏm (8.1 kgꞏm/57.9 lb ft)14. Install the crankshaft damper pulley with specified
torque.
Torque: 220 Nꞏm (22 kgꞏm/159 lb ft)
15. Install the intercooler assembly.
Refer to “Intercooler” in this manual.
16. Install air cleaner cover and air duct.
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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.
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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
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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.

6D – 12 ENGINE ELECTRICAL
2) Inspect the brush springs for wear, damage or other
abnormal conditions.
Standard: 28 – 35 N (2.9 – 3.6 kg/6.4 – 7.9 lb)
Magnetic switch
1) Continuity of shunt coil
Check for continuity between terminals S and coil
case.
Replace, if there is not continuity (i.e., coil is
disconnected.)2) Continuity of series coil
Check for continuity between terminals S and M.
Replace, if there is no continuity (i.e., coil is
disconnected).
3) Continuity of contacts
With the plunger faced downward, push down the
magnetic switch. In this state, check for continuity
between terminals B and M. Replace, if there is no
continuity (i.e., contacts are faulty).
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6D – 14 ENGINE ELECTRICAL
MAGNETIC SWITCH
Pull-out test
Connect the magnetic switch to the battery as shown.
The negative side to the “M” terminal and the magnetic
switch body (housing); the positive side to the “S”
terminal. If the pinion has been ejected, the pull-in coil
is satisfactory.
Legend
(1) Terminal “S”
(2) Terminal “M”
(3) Starter
(4) For Return Test
(5) For Hold-In Test
Hold-in test
1. Next disconnect the “M” terminal.
2. The pinion should remain in the ejected position.
Return test
When the switch body is disconnected, the pinion
should return quickly.
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ENGINE ELECTRICAL 6D – 15
CHARGING SYSTEM
GENERAL DESCRIPTION
GENERATOR
CHARGING CIRCUIT
The charging system is the IC integral regulator
charging system and its main components are
connected as shown in Figure.
The regulator is a solid state type and it is mounted
along with the brush holder assembly inside the
generator installed on the rear end cover.The generator does not require particular maintenance
such as voltage adjustment. The rectifier connected to
the stator coil has nine diodes to transform A.C. voltage
into D.C. voltage. This D.C. voltage is connected to the
output terminal of generator.
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Condenser
GeneratorStator Coil
IC RegulatorStarter
SW
Rotor Coil
Battery
P F
EBS LRelay B
S
L
QOS
C/U
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