engine oil OPEL FRONTERA 1998 Workshop Manual

ENGINE MECHANICAL 6A – 55
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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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.
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GEAR:O/PUMP
IDLE GEAR A
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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
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6A – 58 ENGINE MECHANICAL
14. Camshaft pulley
1) Align TDC mark with crankshaft pulley and gear
case cover.
2) Set camshaft stopper on the end of intake and
exhaust camshaft.
Camshaft Stopper: 5-8840-2592-0
3) Install key to camshaft and install camshaft
pulley.
4) Apply engine oil to camshaft pulley fixing bolt
and tighten bolt with angular tightening method.
First step: 40 Nꞏm (4.0 kgꞏm / 29 lb ft)
Second step: 60° to 90°
15. Timing belt
1) Install tensioner and tighten the bolt temporarily.
2) Align timing mark with camshaft pulley timing
mark and timing gear case timing mark.
3) Set No.1 cylinder TDC position.4) Install the timing belt in the following order
camshaft pulley, oil pump pulley, tensioner.
NOTE:
1) It is recommended for easy installation that the belt
be secured with a double clip after it is installed to
each pulley.
2) The “ISUZU” mark should be read from the front of
the engine when installing the timing belt.
5) Install the belt tensioner.
6) Conform not phase difference each pulley.
7) Tension the timing belt with two turns of the
crankshaft.
8) Tighten the tensioner bolt in order A to B to the
specified torque.
Torque: Bolt A 5 Nꞏm (0.5 kgꞏm/3.6 lb ft)
Bolt B 2 Nꞏm (0.2 kgꞏm/1.4 lb ft)
Legend
(1) Align Mark
(2) Camshaft Pulley
(3) Timing Belt
(4) Oil Pump Pulley
(5) Bolt B
(6) Tensioner Assy
(7) Tensioner Bolt A
(8) Tensioner Spring
16. CMP sensor bracket
1) Install CMP sensor bracket and tighten bolt to
the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
17. Timing belt cover
1) Install timing belt cover and tighten bolt to the
specified torque.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
2) Tighten CMP sensor to the specified torque.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
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6A – 60 ENGINE MECHANICAL
VALVE STEM SEAL, VALVE SPRING AND ADJUSTER
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove the air duct from between air cleaner and
turbocharger.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Disconnect PCV hose.
7. Disconnect EGR vacuum hose.
8. Disconnect harness connectors around the cylinder
head such as the injector, CMP sensor, MAP
sensor, EGR sensor, EVRV, IAT sensor, A/C
compressor, TP stepping motor, TP sensor and fuel
temperature sensor etc.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out drivebelt.
12. Remove heat protector, remove exhaust valve
assembly.
13. Remove water cooling hose and lubrication pipe for
turbocharger.
14. Remove turbocharger assembly.
15. Remove hose between thermostat and radiator.
16. Remove noise insulator cover of cylinder head.
NOTE: Do not damage injector harness.
17. Remove high pressure oil pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner then remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove engine coolant pipe between cylinder
head and water pump.
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011RW031
Legend
(1) Adjuster
(2) Tappet
(3) Split Collar
(4) Spring Seat Upper
(5) Valve Spring(6) Spring Seat Lower
(7) Valve Stem Seal
(8) Valve Guide
(9) Valve Seat
(10) Valve

ENGINE MECHANICAL 6A – 61
24. Remove fuel pipe between fuel pump and intake
manifold.
25. Remove fuel return pipe from rear of cylinder head.
26. Remove intake manifold assembly.
27. Disconnect glow plug harness and remove glow
plug.
28. Remove cylinder head cover.
29. Remove injector harness connector.
30. Disconnect harness connector from oil pressure
sensor and oil temperature sensor on the oil rail.
31. Remove injector harness assembly.
32. Remove injector clamp.
33. Remove injector is fixed bolts.
34. Remove injector assembly.
35. Remove oil rail.
36. Remove camshaft carrier assembly with camshaft.
37. Remove cylinder head assembly.
38. Disassemble valve spring according to the following
method.
1) Use valve spring compressor then remove split
collars.
2) Valve spring compressor: 5-8840-2441-0
NOTE: Put removed valve spring in order of cylinder
number.
39. Valve stem seal.
1) Use a screwdriver or pliers to remove valve
stem seal.
NOTE: Do not reuse removed valve stem seal.
INSPECTION AND REPAIR
Make the necessary adjustments, repairs and part
replacements if excessive wear or damage is
discovered during inspection.
Va l v e s p r i n g
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is
evident.
1. Free height
1) Measure the free height of the springs. The
springs must be replaced if the height is below
the specified limit.
Standard: 45.85 mm (1.8051in)
Limit: 43.9 mm (1.7283 in)
2. Squareness
1) Measure the valve spring squareness with a
steel square.
2) Replace the valve springs if the measured value
exceeds the specified limit.
Limit: 1.6 mm (0.063 in)
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ENGINE MECHANICAL 6A – 63
Valve Guide Replacement
1. Using the special tool, drive out the valve guide
from the combustion chamber side.
Valve guide replacer: 9-8523-1212-0
2. Apply engine oil to the outside of the valve guide.
Using the special tool, drive in a new valve guide
from cylinder head upper face side, and check the
valve guide height.
Valve guide replacer: 9-8523-1212-0
Height: 8.0 mm (0.315 in)
NOTE: If the valve guide has been removed, both the
valve and the valve guide must be replaced as a set.
Va l v e T h i c k n e s s
1. Measure the valve thickness.
2. If the measured value is less than the specified
limit, the valve and the valve guide must be
replaced as a set.
Inlet
Standard: 1.2 mm (0.0472 in)
Limit: 1.1 mm (0.0433 in)
Exhaust
Standard: 1.2 mm (0.0472 in)
Limit: 1.1 mm (0.0433 in)
Contact surface angle on valve seat on
valve
1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace
valve, valve guide and valve seat as a set.
Standard: 68°
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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.
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ENGINE MECHANICAL 6A – 67
VALVE CLEARANCE ADJUSTMENT
NOTE:
1. Valve clearance should be inspected and adjusted
while the engine is cool.
2. The tightening of the camshaft bearing cap and
camshaft carrier assembly should be checked
before inspecting and adjusting valve clearance.
INSPECTION
1. Remove cylinder head noise insulator cover and
cylinder head cover.
Refer to “Cylinder Head” in this manual.
2. Disconnect all harness connecters of the injector
and remove harness assembly.
3. Drain oil from oil rail assembly.
4. Remove injector clamp nuts and fixing bolts to take
out injector assembly.
5. Loosen oil rail bolts, remove oil rail assembly.
6. Set cylinder No.1 to the TDC at the compression
stroke. Make sure that there is play in cylinder No.1
tappets on inlet and exhaust sides and that there is
no play in cylinder No.4 tappets.
7. Measure valve clearance at No.1 TDC (Refer to the
black circles indicated in the illustration).
Standard Valve clearance:
Intake valve: 0.15 mm (0.0059 in) ± 0.05 mm (0.0020 in)
Exhaust valve: 0.25 mm (0.0098 in) ± 0.05 mm (0.0020 in)
8. Turn the crankshaft one turn to set No.4 cylinder
TDC at the compression stroke.
9. Measure valve clearance at No.4 TDC (Refer to the
black circles indicated in the illustration).
Standard Valve clearance:
Intake valve: 0.15 mm (0.0059 in) ± 0.05 mm (0.0020 in)
Exhaust valve: 0.25 mm (0.0098 in) ± 0.05 mm (0.0020 in)
10. If measured value is outside standard value,
readjust the valve clearance.
ADJUSTMENT
For valve clearance adjustment, follow the procedure
given below.
1. Set cylinder No.1 or No.4 to the TDC at the
compression stroke.
Set the valve clearance adjusting tool on the tappet
requiring adjustment.
After making sure of the correct setting of the
special tool, depress the tappet by turning the bolt.
Valve Clearance Adjusting Tool: 5-8840-2590-0
NOTE: Before depressing the tappet, set the tappet
notch in the direction where adjuster can be easily
taken out.
2. Take out the adjuster using a small screw driver and
finger magnet.
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6A – 68 ENGINE MECHANICAL
3. Determine the thickness of the adjuster as follows.
1) Measure the thickness of the removed adjuster
with a micrometer.
2) Calculate the thickness of a new adjuster.
Calculation
TA: Thickness of new adjuster
M: Valve clearance measurement.
TO: Thickness of the removed adjuster
For intake side: TA=TO+(M–0.15) mm
For exhaust side: TA=TO+(M–0.25) mm
Select a new adjuster whose thickness is as
close to the estimated value as possible.
4. Install oil rail and tighten it temporarily.
5. Install injector assembly.
NOTE:
1) Do not forget to insert the O-ring between injector
and oil rail.
2) Install the injector to the same position as before
removal.
6. Install the injector fixing bolts and temporarily
tighten.
7. Install the injector clamp and tighten temporarily.
8. Tighten injector fixing bolts to the specified torque.
Torque: 6.5 Nꞏm (0.7 kgꞏm / 5.1 lb ft)
9. Tighten injector clamp nut to the specified torque
with special method.
Torque: loosen one turn and tighten again to
specified torque.
Torque: 25 Nꞏm (2.4 kgꞏm / 17.4 lb ft)
10. Tighten oil rail to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
11. Install injector harness and reconnect connector.
12. Install cylinder head cover.
Refer to”Cylinder Head” in this manual.
13. Fill with about 300cc of engine oil at the high
pressure oil pipe installation port on the oil rail using
an oil filler.
If assembled without filling the oil rail with oil, the
time for engine starting will be longer.
14. Immediately install high pressure oil pipe to tighten
with specified torque.
Torque: 80 Nꞏm (8.1 kgꞏm / 57.9 lb ft)
15. Install cylinder head noise insulator cover.
Refer to “Cylinder Head” in this manual.