engine OPEL FRONTERA 1998 Workshop Manual

6A – 42 ENGINE MECHANICAL
Legend
(1) Cylinder Head Noise Insulator Cover
(2) Insulator
(3) Bolt
(4) Oil Seal
(5) Gasket
(6) Cylinder Head Cover
(7) Bolt
21. Install water hose between thermostat and radiator.
22. Install turbocharger assembly to exhaust manifold.
Torque: 27 Nꞏm (2.8 kgꞏm/20.2 lb ft)
23. Install water hose and oil pipe for turbocharger.
24. Install exhaust valve assembly and heat protector.
Torque: 27 Nꞏm (2.8 kgꞏm/20.2 lb ft) for valve
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft) for heat protector25. Install generator assembly.
Torque: 40 Nꞏm (4.0 kgꞏm/29 lb ft) for ACG bracket
Torque: 40 Nꞏm (4.0 kgꞏm/29 lb ft) between ACG and
bracket
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) between ACG
and adjuster plate
26.Fix the A/C compressor bracket and install A/C
compressor.
Torque: 47 Nꞏm (4.7 kgꞏm/34 lb ft) for A/C bracket
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) for belt tensioner
27. Reconnect harness connector around cylinder
head.
28. Connect EGR vacuum hose.
29. Install oil level gauge guide assembly.
Tighten nuts lower portion and tighten bolt.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
30. Install intercooler assembly.
Refer to “Intercooler” in this manual.
31. Install air duct between air cleaner and
turbocharger.
32. Fill engine coolant.
33. Reconnect battery.
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ENGINE MECHANICAL 6A – 43
CAMSHAFT
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Legend
(1) Nut and Washer
(2) Injector Clamp
(3) Nut
(4) Bolt
(5) Oil Rail Assembly
(6) Bolt
(7) Injector Assembly(8) Camshaft
(9) Camshaft Carrier
(10) Plug
(11) Oil Seal
(12) Camshaft Bracket
(13) Gasket
(14) Gasket

6A – 44 ENGINE MECHANICAL
DISASSEMBLY
1. Injector clamp and spacer.
2. Injector assembly
3. Oil rail assembly
4. Camshaft bracket
5. Camshaft
6. Oil seal
7. Plug
NOTE: Before starting disassembly above, drain oil
from oil rail to prevent oil from entering the cylinder.
REASSEMBLY
1. Camshaft
1) Before reassembling the camshaft to the
camshaft carrier, align the holes between the
main gear and the sub gear on the intake side of
the camshaft gear with a special tool.
2) Set lock pin to gear holes from sub gear side.
Camshaft Gear Tool: 5-8840-2591-0
Legend
(1) Locking pin
(2) Special tool
3) Apply engine oil to the camshaft gear tooth.
4) Apply engine oil to the journal on the camshaft
carrier.
5) Align the timing mark on the intake and exhaust
camshaft gear and put on the camshaft carrier.Legend
(1) Locking pin
(2) Intake side camshaft gear
(3) Exhaust side camshaft gear
6) Apply liquid gasket (TB1207B or equivalent) to
No. 1 camshaft bracket matching surface.
7) Set No. 1 to No. 5 camshaft bracket on camshaft
carrier.
8) Temporarily tighten bracket bolts B and C.
Temporal Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
9) Put gasket on the cylinder head.
10) Install camshaft carrier onto the cylinder head
and tighten bolts to specified torque.
Torque: A; 21.6 Nꞏm (2.2 kgꞏm/15.9 lb ft)
B; 38.0 Nꞏm (3.9 kgꞏm/28.2 lb ft)
C; 21.6 Nꞏm (2.2 kgꞏm/15.9 lb ft)
D; 38.0 Nꞏm (3.9 kgꞏm/28.2 lb ft)
Remove locking pin.
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ENGINE MECHANICAL 6A – 45
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
1. Camshaft Journal diameter
1) Use a micrometer to measure each camshaft
journal diameter in two directions (1) and (2). If
the measured value is less than the specified
limit, the camshaft must be replaced.
Standard: 29.939 – 29.96 mm (1.1787 – 1.1795 in)
Limit: 29.84 mm (1.17 in)
2. Cam Height
1) Measure the cam height (H) with a micrometer.
If the measured value is less than the specified
limit, the camshaft must be replaced.
Standard: IN 46.62 mm (1.8354 in)
EX 46.72 mm (1.8394 in)
Limit: IN 46.57 mm (1.8335 in)
EX 46.67 mm (1.8374 in)3. Cam Run-Out
1) Mount the camshaft on V-blocks.
2) Measure the cam height (H) with a micrometer.
If the measured value is less than the specified
limit, the camshaft must be replaced.
Standard: 0.02 mm (0.0008 in) or less
Limit: 0.10 mm (0.0039 in)
4. Camshaft oil clearance
1) Clean the camshaft, camshaft bracket and
camshaft carrier.
2) Put camshaft carrier on the cylinder head.
3) Put camshaft on the camshaft carrier.
4) Put plastigauge on the camshaft journal.
5) Install camshaft bracket to original position and
tighten bolts to specified torque in the numerical
order shown in the illustration.
Torque: A; 21.6 Nꞏm (2.2 kgꞏm/15.9 lb ft)
B; 38.0 Nꞏm (3.9 kgꞏm/28.2 lb ft)
C; 21.6 Nꞏm (2.2 kgꞏm/15.9 lb ft)
D; 38.0 Nꞏm (3.9 kgꞏm/28.2 lb ft)
(1)Ft Rr
(2)
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6A – 46 ENGINE MECHANICAL
NOTE: Do not allow the camshaft to rotate.
6) Remove the camshaft bracket and measure the
plastigauge width and determine the oil
clearance. If the oil clearance exceeds the
specified limit, replace the camshaft carrier
and/or camshaft.
Oil clearance.
Standard: 0.040 – 0.082 mm (0.0016 – 0.0032 in)
Limit: 0.12 mm (0.0047 in)
7) Clean the plastigauge from the camshaft bracket
and camshaft carrier.
5. Camshaft thrust clearance.
1) Clean the camshaft, camshaft bracket and
camshaft carrier.
2) Put camshaft carrier on the cylinder head.
3) Put camshaft on the camshaft carrier.
4) Put plastigauge on the camshaft journal.5) Install camshaft bracket to original position and
tighten bolts to specified torque in the numerical
order shown in the illustration.
Torque: A; 21.6 Nꞏm (2.2 kgꞏm/15.9 lb ft)
B; 38.0 Nꞏm (3.9 kgꞏm/28.2 lb ft)
C; 21.6 Nꞏm (2.2 kgꞏm/15.9 lb ft)
D; 38.0 Nꞏm (3.9 kgꞏm/28.2 lb ft)
6) Use a dial indicator to measure the camshaft
thrust clearance. If the camshaft thrust
clearance exceeds the specified limit, replace
the camshaft carrier and/or camshaft.
Camshaft thrust clearance
Standard: 0.1 mm (0.0002 in)
Limit: 0.2 mm (0.0078 in)
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ENGINE MECHANICAL 6A – 47
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6A – 48 ENGINE MECHANICAL
TIMING GEAR
REMOVAL
1. Loosen fixing bolt for generator and remove
generator assembly.
2. Remove fixing nuts, then remove cooling fan
assembly and fan pulley.
3. Remove crankshaft damper pulley.
4. Belt cover
1) Disconnect harness connector of CMP
(camshaft position) sensor.
2) Remove CMP sensor.
3) Remove belt cover.
5. Loosen belt tensioner to remove timing belt.
6. Remove camshaft pulley.
7. Remove high pressure oil pump pulley.
8. Remove front plate.
9. Remove vacuum pump.
10. Remove power steering pump.
11. Remove gear cover assembly.
12. Idle gear A.
1) Set two bolts to sub gear of idle gear A and turn
it to align the tooth of idle gear A then lock them
by bolt as show in the illustration.
2) Remove idle gear A fixing bolts.
3) Remove idle gear A.Legend
(1) Sub-Gear
(2) Main Gear
(3) Bar
(4) Locking Bolt
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020RW028
Legend
(1) Idle Gear A
(2) High Pressure Oil Pump Gear
(3) Vacuum Pump Gear
(4) Power Steering Pump Gear(5) Balance Gear LH
(6) Idle Gear C
(7) Crankshaft Gear
(8) Balance Gear RH
(9) Idle Gear B
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ENGINE MECHANICAL 6A – 49
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear A
(4) Idle Gear A Shaft
(5) Align Mark
(6) Crankshaft Gear
(7) O-Ring
13. Idle gear C
1) Use the special tool on idle gear C, turning the
sub gear to align the teeth, then set lock pin.
2) Remove idle gear C fixing bolt then remove the
idle gear C with flange.
Camshaft Gear Tool : 5-8840-2591-0
Legend
(1) Lock pin
(2) Camshaft Gear ToolLegend
(1) Bolt
(2) Retainer
(3) Idle Gear C
(4) Idle Gear C Shaft
(5) Align Mark
(6) Align Mark
(7) Idle Gear A
(8) Balance Shaft Gear LH
(9) Timing Mark
14. Idle gear B
1) Loosen idle gear B fixing bolt to remove idle
gear B with flange.
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear B
(4) Idle Gear B Shaft
(5) Align Mark
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6A – 50 ENGINE MECHANICAL
15. High pressure oil pump
1) Remove oil pump gear fixing bolt then remove
oil pump.
Legend
(1) O-Ring
(2) High Pressure Oil Pump
(3) Bolt
(4) Timing Mark
16. Remove balance shaft gear LH. and RH.
17. Remove crankshaft gear.
INSTALLATION
1. Crankshaft gear
1) Force key into the crankshaft and insert
crankshaft gear with the crankshaft gear key
groove set on the key.Legend
(1) Crankshaft Gear Installer
(2) Crankshaft Gear
2. Balance shaft gear
1) Install the balance shaft gear RH to balance
shaft, tighten center bolt to the specified torque.
Torque : 32 Nꞏm (3.2 kgꞏm/23 lb ft)
2) Install thrust plate for balance shaft LH before
installing the balance shaft gear LH.
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
3) Install balance shaft gear LH to balance shaft,
tighten center bolt to the specified torque.
Torque : 32 Nꞏm (3.2 kgꞏm/23 lb ft)
Legend
(1) Center Bolt
(2) Plate
(3) Balance Shaft Gear RH
(4) Timing Mark
4
GEAR:O/PUMP
IDLE GEAR A
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ENGINE MECHANICAL 6A – 51
3. Idle gear A
1) Insert idle gear A shaft to align alignment mark
between idle gear A shaft and timing gear case.
2) Apply engine oil to the shaft surface.
3) Install the idle gear A to align the timing mark
with the crankshaft gear.
4) Install the flange, tighten bolts to the specified
torque.
Torque: 25 Nꞏm (2.5 kgꞏm/18 lb ft)
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear A
(4) Idle Gear A Shaft
(5) Align Mark
(6) Crankshaft Gear
(7) O-Ring
NOTE: Conform not difference timing marks between
each others.
4. Idle gear C
1) Insert idle gear C shaft to align alignment mark
between idle gear C shaft and timing gear case.
2) Apply engine oil to the shaft surface.
3) Align timing mark on idle gear C with balance
shaft gear LH and idle gear A timing marks, then
insert idle gear C.
4) Set position of idle gear C flange with a dowel
pin, tighten bolt to the specified torque.
Torque: 25 Nꞏm (2.5 kgꞏm/18 lb ft)Legend
(1) Bolt
(2) Retainer
(3) Idle Gear C
(4) Idle Gear C Shaft
(5) Align Mark
(6) Align Mark
(7) Idle Gear A
(8) Balance Shaft Gear LH
(9) Timing Mark
5. Idle gear B
1) Insert idle gear B shaft to align alignment mark
between idle gear B shaft and timing gear case.
2) Apply engine oil to the shaft surface.
3) Align timing mark on idle gear B with balance
shaft gear RH and crankshaft gear timing marks,
then insert idle gear B.
4) Install flange and tighten the bolt to the specified
torque.
Torque: 51 Nꞏm (5.2 kgꞏm/38 lb ft)
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