Gas OPEL FRONTERA 1998 Workshop Manual

ENGINE MECHANICAL 6A – 47
CAMSHAFT
2 1
6With
spacer type
Without
spacer type
13 14
8
12
11
109
3
4
7
5
012R200004
Legend
(1) Nut and Washer
(2) Injector Clamp
(3) Nut
(4) Bolt
(5) Oil Rail Assembly
(6) Spacer (If equipped) and Bolt
(7) Injector Assembly(8) Camshaft
(9) Camshaft Carrier
(10) Plug
(11) Oil Seal
(12) Camshaft Bracket
(13) Gasket
(14) Gasket

6A – 48 ENGINE MECHANICAL
DISASSEMBLY
1. Injector clamp
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; 22 Nꞏm (2.2 kgꞏm/15.9 lb ft)
B; 38 Nꞏm (3.9 kgꞏm/28.2 lb ft)
C; 22 Nꞏm (2.2 kgꞏm/15.9 lb ft)
D; 38 Nꞏm (3.9 kgꞏm/28.2 lb ft)
Remove locking pin.
1
2
014RW183
321
014RW184
CC
D
B
CC
B
CC
D
CC
B
C
A AA A A A
AAAA
011RW035

6A – 56 ENGINE MECHANICAL
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear B
(4) Idle Gear B Shaft
(5) Align Mark
6. High pressure oil pump
1) Install O-ring on the high pressure oil pump.
2) Install the high pressure oil pump to the timing
gear case, tighten the nut to the specified
torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
NOTE: Be sure to set O-ring completely.
Legend
(1) O-ring (large)
(2) High pressure oil pump
(3) Nut
(4) O-ring (small)7. High pressure oil pump
1) Install O-ring on the oil pump shaft with grease
and install the gear with the idle gear A timing
mark set at the oil pump gear timing mark.
2) Tighten center bolt to the specified torque.
Torque: 75 Nꞏm (7.6 kgꞏm / 55 lb ft)
NOTE: Be sure to align timing marks with each other.
Legend
(1) O-ring
(2) High Pressure Oil Pump Gear
(3) Center Bolt
(4) Timing Mark
8. Remove lock from idle gear.
1) Remove lock bolt from idle gear A and remove
lock pin from idle gear C.
9. Timing gear case assembly
1) Clean fixing surface of timing gear case.
2) Install the gasket on the idle gear rear side end.
3) Apply liquid gasket to the timing gear case fitting
surface.
NOTE: Be sure to apply liquid gasket evenly.
4) Install timing gear case and tighten bolts to the
specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
NOTE: Must install within 5 minutes after applying liquid
gasket.
35
5
4
3
2
1
014R200008
1
2
43
040RW007
4
GEAR:O/PUMP
IDLE GEAR A
1
2
3
040RW005

ENGINE MECHANICAL 6A – 57
10. Vacuum pump
1) Install vacuum pump and tighten bolts to
specified torque.
Torque: 25 Nꞏm (2.5 kgꞏm / 18 lb ft)
2) Install noise insulator cover.
11. Power steering pump (P/S)
1) Install P/S pump.
Torque: 25 Nꞏm (2.5 kgꞏm / 18 lb ft)12. Install front plate.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
13. High pressure oil pump pulley.
1) Install oil pump pulley and tighten to specified
torque.
Torque:10 Nꞏm (1.0 kgꞏm / 7.2 lb ft)
2
2~2.5mm
2~2.5mm
Apply liquid gasket around inside
of the bolt hole
Bolt hole
Inside
Outside
F06HX00001
052RW001
430RW017
012RW035

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 – 72 ENGINE MECHANICAL
CRANK CASE
REMOVAL
1. Drain engine oil.
2. Remove transmission assembly.
3. Remove crankshaft damper pulley.
4. Remove timing belt cover, timing belt, pulley and
front plate.
5. Remove timing gear case cover.
6. Remove timing gears.
NOTE: Do not forget to set lock bolt for idle gear A and
lock pin for idle gear C.
7. Remove timing gear case.
8. Remove oil level gauge guide assembly.
9. Remove flywheel assembly.
CAUTION:
1) The flywheel heavy; be careful not to drop it.
2) Be careful no to let it slip because the hexagon
of the bolt is thin.10. Remove rear plate (for A/T) or flywheel housing (for
MT).
11. Remove retainer.
NOTE:
1) Be careful not to damage the oil seal; it can be
reused.
2) Inspect installation portion for distortion and flow on
the slinger; also inspect for flow on the oil seal lip.
3) If there is some flow oil seal/slinger, replace a set.
12. Remove bolts from thrust plate of balance shaft LH
then remove balance shaft.
13. Loosen crank case fixing bolts.
14. Use seal cutter to take off the liquid gasket.
Seal cutter: 5-8840-2153-0
15. Remove crank case assembly.
CAUTION:
Do not give shock to crank case for prevention take
off applied vibration insulation material on the
crank case.
1
2
3
012RW029
Legend
(1) Crank Case
(2) Oil Pan
(3) Drain Plug

ENGINE MECHANICAL 6A – 73
INSTALLATION
1. Install relief valve (if it was removed).
Torque: 30 Nꞏm (3.1 kgꞏm / 22 lb ft)
2. Insert O-ring to strainer, install strainer and tighten
to specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
3. Apply liquid gasket (TB1207B or equivalent) to
surface of oil pan and tighten bolt to the specified
torque.
Torque: 19 Nꞏm (1.9 kgꞏm / 13.7 lb ft)
4. Apply engine oil to the balance shaft and insert it
into crank case.
NOTE:
Do not damage bearing when inserting the balance
shaft.
Make sure it rotates smoothly.
5. Tighten thrust plate of balance shaft LH.
Torque: 25 Nꞏm (2.5 kgꞏm / 18 lb ft)
6. Set O-ring port of oil gallery on the cylinder block.
7. Apply liquid gasket (TB1207C or equivalent) to
crankcase fixing surface then tighten bolts to the
specified torque.
Torque: 25 Nꞏm (2.5 kgꞏm / 18 lb ft)
NOTE: Make sure there is no oil, dust or scratches on
the surface coated with liquid gasket and mount within
five minutes of gasket application.8. Install retainer with oil seal.
9. Install rear plate (A/T) or flywheel housing (MT),
tighten bolt to the specified torque.
Torque: 97 Nꞏm 9.9 kgꞏm / 72 lb ft)
10. Install flywheel assembly with applied engine oil to
the bolt, tighten the bolt using angular tightening
method.
1st step: 59 Nꞏm (6.0 kgꞏm / 43 lb ft)
2nd step: 60° to 90°
11. Install oil level gauge guide assembly.
12. Install timing gear case.
Torque: 20 Nꞏm (2.5 kgꞏm / 14.5 lb ft)
13. Install timing gears
Refer to “Timing Gear” in this manual.
14. Remove lock bolt from idle gear A and remove lock
pin from idle gear C.
15. Install timing gear case cover.
Torque: 20 Nꞏm (2.5 kgꞏm / 14.5 lb ft)
16. Install oil pump pulley.
Torque: 10 Nꞏm (1.0 kgꞏm / 7.2 lb ft)
17. Install camshaft pulley tighten bolt with angular
tightening method.
To r q u e :
1st step: 40 Nꞏm (4.0 kgꞏm / 29 lb ft)
2nd step: 75°
18. Install timing belt and belt tensioner.
Refer to “Timing Gear” in this manual.
19. Install crankshaft damper pulley.
Torque: 220 Nꞏm (22 kgꞏm / 159 lb ft)
20. Fill engine oil.
2
2~2.5mm
2~2.5mm
Apply liquid gasket around inside
of the bolt hole
Bolt hole
Inside
Outside
F06HX00001
2
2~2.5mm
2~2.5mm
Apply liquid gasket around inside
of the bolt hole
Bolt hole
Inside
Outside
F06HX00001

6A – 74 ENGINE MECHANICAL
CRANKSHAFT
1
15
14
13
8
11
16
17
10
9
72
12
3
465
18
012RW023
Legend
(1) Cylinder Head
(2) Cylinder Head Gasket
(3) Flywheel
(4) Cylinder Block Rear Plate (for A/T) or Flywheel
Housing (for M/T)
(5) Crankshaft Rear Oil Seal
(6) Retainer
(7) Timing Gear Case
(8) Crankshaft Front Oil Seal(9) Timing Gear Case
(10) Gasket
(11) Balance Shaft
(12) Crank Case
(13) Piston Cooling Oil Pipe
(14) Main Bearing Cap
(15) Crankshaft
(16) Crankshaft Timing Gear
(17) Piston and Connecting Rod Assembly
(18) Cylinder Block

6A – 80 ENGINE MECHANICAL
3. Piston and Connecting Rod Assembly
1) Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins
and each piston ring and piston.
2) Align the front mark (2) of piston and front mark
(3) of connecting rod then assemble them.
3) The N mark of the piston ring is faced toward the
top, check to see that the piston ring end gap is
correctly positioned.
Legend
(1) 1st piston ring end gap
(2) 2nd piston ring end gap
(3) Oil ring end gap4) Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
The front marks must be facing the front of the
engine.
Piston Ring Compressor: 5-8840-9018-0
5) Match the numbered caps with the numbers on
the connecting rods. Align the punched marks
on the connecting rods and caps.
6) Apply engine oil to the threads and seating faces
of the nuts.
7) Tighten the cap nuts in 2 steps, using angular
tightening method as shown in the following
specifications.
1st step: 29 Nꞏm (3.0 kgꞏm/22 lb ft)
2nd step: 45°– 60°
After tightening the cap nuts, check to see that
the crankshaft rotates smoothly
4. Piston Cooling Oil Pipe
If the piston cooling oil pipe is forcibly assembled,
the end of the oil jet may bend. It could make it
impossible to supply oil to the piston cooling holes,
which will sometimes cause piston seizure.
Sufficient care should be taken to pipe assembly
work.
1) Tighten the bolt and oil jet plug to the specified
torque.
Torque:
M6: 8 Nꞏm (0.8 kgꞏm/6 lb ft)
M8: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
Oiling Jet Plug: 30 Nꞏm (3.1 kgꞏm/22 lb ft)
5. Crank case
1) Refer to “Crank case” in this manual.
6. Apply liquid gasket (TB-1207C or equivalent) to
retainer then install it to rear end of cylinder block
within 5 minutes.
7. Crankshaft Rear Oil Seal
1) Tighten the adapter to the crankshaft rear and
section with 2 bolts.
2) Insert the oil seal into the peripheral section of
the adapter.
3) Insert the sleeve into the adapter and tighten it
with a bolt (M12 x 1.75L = 70) until the adapter
hits the sleeve.
4) Remove the adapter and the sleeve.
5) Check the dimension of the oil seal setting from
rear end of crankshaft.
Standard Dimension = 12.5 ± 0.3 mm
Oil Seal Installer: 5-8840-2359-0
2
3
1
015RW051
3
1
2
015RW083

ENGINE MECHANICAL 6A – 81
8. Cylinder Block Rear Plate (A/T)
Align the rear plate with the cylinder block dowel
pins.
Tighten the rear plate to the specified torque.
Torque: 97 Nꞏm (9.9 kgꞏm/72 lb ft)
9. Flywheel housing (M/T)
Align the flywheel housing with the cylinder block
dowel pins.
Tighten the bolt to the specified torque.
Torque: 97 Nꞏm (9.9 kgꞏm/72 lb ft)
10. Flywheel
1) Thoroughly clean and remove the oil from the
threads of crankshaft and flywheel fixing
surface.
2) Mount the flywheel on the crankshaft and then
install the washer.
3) Align the timing mark, cut out on the flywheel is
at lowest position for M/T model and
identification hole on the boss is highest position
for A/T model when cylinder No. 1 is at the TDC.
For M/T ModelFor A/T model
4) Tighten the flywheel bolts in 2 steps using
angular tightening method.
Torque: 1st step 60 Nꞏm (6.1 kgꞏm/44 lb ft)
Torque: 2nd step 60° – 90°
11. Timing Gear Case
1) Cut away the gasket protruding between the
cylinder block and the crank case fitting surfaces
(as shown in the illustration).
12.5 + 0.3–
012RW067
Timing mark
2
78
74
015RW121
Timing mark
7
4φ
304
015RW120
751
3
8
6 2 4
201RW021