Opel Frontera UBS. Manual - part 414

FUEL SYSTEM 6C – 13

•

Apply a wrench as illustrated, and tighten the
holder nut to the specified torque using a special
tool.

wrench: nozzle holder 5-8840-0259-0

CAUTION

•

After tightening the holder nut, make sure that the
drilled hole makes ± 5° or smaller with the cylinder
head-side positioning boss.

•

When mounting leak off pipe, injection nozzle and
pipe, clean then with air so that dust may not enter.

4.

Leak Off Pipe

•

Mount using a new copper waker

3.

Injection Pipe

•

Connect injection pipe to nozzle holder.

•

Tighten the injection pump side.

•

Fit pipe clip in specified position.

2.

Air Cleaner Cover & Air duct

1.

Intercooler Assembly

•

Refer to “Intercooler” installation in section 6A2.

64 (6.5/47)

N·m (Kg·m/lb.ft)

6C – 14 FUEL SYSTEM

INJECTION PUMP ASSEMBLY

Removal Steps

1.

Air cleaner cover & air duct

2.

Intercooler assembly

3.

Radiator assembly

4.

Cooling fan assembly

5.

P/S pump drive belt

6.

AC generator drive belt

7.

Timing gear

8.

Fuel filter assembly

9.

Injection pump harness

10. Fuel hose and CSD hose
11. Injection pump Control cable
12. Injection pipe
13. Injection pump assembly

Installation Steps

To install, follow the removal steps in
the reverse order.

FUEL SYSTEM 6C – 15

REMOVAL

Preparation:

•

Disconnect battery ground cable.

•

Drain coolant.

1.

Air Cleaner Cover & Air Duct

2.

Intercooler Assembly (4JG2-T ONLY)

•

 Refer to Intercooler Assembly removal.

3.

Radiator Assembly

•

Disconnect upper and lower hoses on the engine
side.

4.

Cooling Fan Assembly

•

Remove cooling fan asm and remove fan pulley
and spacer.

5.

P/S Pump Drive Belt

•

Loosen P/S pump lock bolt and adjust bolt remove
two drive belts.

6.

AC Generator Drive Belt

•

Loosen AC generator mounting bolt (under side)
and adjust, bolt and remove drive belt.

7.

Timing Gear

•

Refer to Timing Gear Removal

•

Remove the loosened nut and fixing bolt and
remove the timing gear.

8.

Fuel Filter Assembly

9.

Injection Pump Harness

•

Remove tachometer sensor, throttle sensor, and
fuel cut solenoid, harness.

10. Fuel Hose & CSD Hose

•

Disconnect inlet hose and outlet hose and keep
hose end up to prevent fuel from coming out.

•

Disconnect CSD hose.

11. Injection Pump Control Cable
12. Injection Pipe

•

Release pipe clip.

•

Remove the flare nut on the pump side.

•

Remove the flare nut on the injection nozzle side,
and remove the injection pipe.

CAUTION

•

Be sure to plug the injection nozzle holder and
delivery holder to prevent the entry of foreign
matter.

13. Injection Pump Assembly

•

Remove pump mounting nut

•

Loosen injection pump rear bracket adjuster lock
bolt.

•

Remove the mounting bolt on the engine side, and
pull out the pump behind the engine.

6C – 16 FUEL SYSTEM

20 (2.0/15)

N·m (Kg·m/lb·ft)

•

Tighten the injection pump bracket bolts 8 to the
specified torque..

40 (4.1/30)

N·m (Kg·m/lb·ft)

12. Injection Pipe

•

Connect the pump side and nozzle side of the pipe,
and tighten securely.

•

Install clip where it was.

11. Injection Pump Control Cable

•

See adjustment of accelerator control cable.

10. Fuel Hose & CSD Hose
9.

Injection Pump Harness

•

Mount engine harness and connect it to switches.

8.

Fuel Filter Assembly

7.

Timing Gear

•

Refer to Timing Gear in Section 6A2.

6.

AC Generator Drive Belt

•

Mount AC Generator drive belt and adjust belt
tension.

•

See drive belt adjustment in section 6B.

5.

P/S Pump Drive Belt

•

Mount P/S pump drive belt and adjust belt tension.

•

See drive belt adjustment in section 6B.

4.

Cooling Fan Assembly

•

Mount fan pulley, distance piece, and cooling fan
asm (in this order) on the water pump, and tighten
to the specified torque.

3.

Radiator Assembly

2.

Intercooler Assembly (4JG2-T ONLY)

•

See installation of intercooler.

•

Pour coolant.

•

Connect battery ground cable.

1.

Air Cleaner Cover & Air Duct

INSTALLATION

13. Injection Pump Assembly

•

Tighten the injection pump bracket bolts 7 to the
specified torque..

8 (0.8/69)

N·m (Kg·m/lb·in)