engine OPEL FRONTERA 1998 Workshop Manual

ENGINE MECHANICAL 6A – 93
DISASSEMBLY
1. Cylinder Head Assembly
Refer to “Cylinder Head” in this manual.
2. Cylinder Head Gasket.
3. Flywheel
4. Cylinder Block Rear Plate (A/T), or Flywheel
housing (M/T).
5. Crankshaft Rear Oil Seal.
Install the special tool as shown in the illustration
and remove the oil seal.
Oil Seal Remover: 5-8840-2360-0
6. Retainer
7. Timing Gear Case Cover
8. Crankshaft Front Oil Seal
1) Use a plastic hammer and a screwdriver to tap
around the oil seal to free it from the gear case
cover.
9. Timing Gears
Refer to “Timing Gear” in this manual.
10. Timing gear case
11. Gasket
12. Balance shaft right
13. Crank case assembly
14. Piston cooling oil pipe
15. Piston assembly
16. Main bearing cap
17. Crankshaft assembly
18. Cylinder block side cover right and left
19. Cylinder block
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
1. Remove the cylinder head gasket and any other
material adhering to the upper surface of the
cylinder block.
Be very careful not to allow any material to
accidentally drop into the cylinder block.
Be very careful not to scratch the cylinder block.
2. Carefully remove liquid gasket, which was used
when assembled, from gear case, rear oil seal
retainer and crank case.
3. Wipe the cylinder block clean and visually check it.
4. Use a straight edge and a feeler gauge to measure
the four sides and the two diagonals of the cylinder
block upper face.
If the measured values exceed the limit, the cylinder
block must be replaced.
Limit: 0.20 mm (0.0079 in)
015RV002
012RW122

6A – 94 ENGINE MECHANICAL
Cylinder Bore Measurement
1. Use a cylinder gauge to measure the cylinder bore
measuring direction for thrust and radial at
measuring points.
Legend
Measuring Point 1; 20 mm
2; 90 mm
3; 160 mm
2. Select the right piston grade by the averaged
cylinder bore measurement (maximum and
minimum value eliminated).
Cylinder bore diameter mm(in)
Grade mark Standard
A 95.421 – 95.430 (3.7567 – 3.7571)
B 95.431 – 95.440 (3.7571 – 3.7575)
C 95.441 – 95.450 (3.7575 – 3.7579)
3. If measured values exceed the limit, replace or
adjust the cylinder block honing or boring.
Limit 95.950 mm (3.7776 in)
4. Boring of the cylinder bore is allowed until it is
0.5 mm (0.0197 in) diameter and oversized piston
is available as a service part.
Boring Cylinder Block
1. Use an oversized piston on the basis of above
mentioned cylinder using the largest inside
diameter.
2. Measure the piston outside diameter at right angles
with piston pin at a piston grade measuring point
69.75 mm (2.7461 in) from piston top surface and
calculate a inside diameter for cylinder boring.
3. Calculation of cylinder bore boring.
D + C – H (mm)
D; Outside diameter piston (mm)
C; Clearance between Cylinder bore and piston
0.092 – 0.110 mm (0.0036 – 0.0043 in)
H; Honing allowance
Less than 0.03 mm (0.0012 in)
The oversize pistons are available three grades.
4. Honing the cylinder bore after boring.
5. Measure cylinder bore after honing.
Difference between each cylinder bore
Less than 0.02 mm (0.0008 in)
Cylinder bore and piston grade (After boring) mm(in)
GradeOversize Piston Bore
Mark
Outside Diameter Diameter
A95.820 – 95.829 95.921 – 95.930
(3.7724 – 3.7728) (3.7764 – 3.7768)
B95.830 – 95.839 95.931 – 95.940
(3.7728 – 3.7732) (3.7768 – 3.7772)
C95.840 – 95.849 95.941 – 95.950
(3.7732 – 3.7736 ) (3.7772 – 3.7776)
REASSEMBLY
1. Cylinder Block
2. Piston Cooling Oil Pipe
1) Fix the cooling jet pipes with knock pins on the
cylinder block.
2) Install the oil pipe for piston cooling in the
cylinder block, tightening a relief valve (1) and
four joint bolts (2) to the specified torque.
If oil jet pipe is forcibly assembled, the end of oil
jet may bend. It could make it impossible to
supply oil to the piston cooling hole, sometimes
causing piston seizure.
Sufficient care should be taken to pipe assembly
work.
321
012RW117

ENGINE MECHANICAL 6A – 95
Oil pipe fixing bolts
M8: 20 Nꞏm (2.0 kgꞏm/14 lb ft)
M6: 8 Nꞏm (0.8 kgꞏm/69 lb in)
Relief valve fixing bolts : 30 Nꞏm (3.1 kgꞏm/22 lb ft)
CAUTION: After installing the piston assembly,
check and see that there is appropriate clearance
between pistons and oil jet pipes by rotating
crankshaft slowly.
3. Crankshaft
1) Install the main bearings to the cylinder body
and the main bearing caps.
2) Be sure that they are positioned correctly.
3) Apply new engine oil to the upper and lower
main bearing faces.
4) Carefully mount the crankshaft.5) Apply engine oil to the thrust washer.
6) Assemble the thrust washer to the No. 3
bearing journal. The oil grooves must face the
crankshaft.
4. Main Bearing Cap Assembly
1) Install the bearing caps with the bearing cap
head arrow mark facing the front of the engine.
2) Apply engine oil to the crankshaft bearing cap
bolts.
3) Tighten the crankshaft bearing cap bolts to the
specified torque a little at a time in the sequence
shown in the illustration.
Torque: 167 Nꞏm (17.0 kgꞏm/123 lb ft)
321
012RW076
012RW038
012RW047
12345
012RW025

6A – 96 ENGINE MECHANICAL
NOTE: Check to see that the crankshaft turns
smoothly by rotating it manually.
4. Piston Assembly
1) Refer to “Piston and connecting rod” in this
manual.
5. Cylinder Block Side Cover Right and Left
6. Balance Shaft Right.
7. Timing Gear Case
1) Cut out the liquid gasket forced out from
between the contact surface of cylinder block
and crankshaft.
2) Apply liquid gasket (TB1207B or equivalent) to
the fitting surface of the cylinder block and
crankcase.
3) Install timing gear case with gasket to cylinder
block and tighten to specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)8. Crankshaft Gear
Force key into crankshaft and force in crankshaft
gear along the key groove using a special tool (1)
with the crank gear (2) timing mark facing outside.
9. Install timing gear align the timing mark on each
timing gear.
For alignment of timing marks refer to “Timing
Gear” in this manual.
NOTE: Remove the locking bolt or pin from idle gear A
and idle gear C.
10. Assembling the gear case cover.
1) Install the oil seal on the oil pump assembly
before installing the gear case cover.
2) Apply liquid gasket to timing gear case.
NOTE: Be sure to apply liquid gasket evenly.
84159
610
237
012RW027
012RW064
12
2
012RW066
2
2~2.5mm
2~2.5mm
Apply liquid gasket around inside
of the bolt hole
Bolt hole
Inside
Outside
F06HX00001

ENGINE MECHANICAL 6A – 97
11. Use the special tool to install the crankshaft front oil
seal to timing gear case.
Front Oil Seal Installer: 5-8840-2061-0
1) Check fit-of the oil seal and gear case cover at
the front end.
Standard: 0.5 – 2.5 mm (0.0197 – 0.0984 in)
NOTE: Apply engine oil to oil seal lip before installation
of the seal.
12. Install the oil pan assembly to original position and
tighten to specified torque.
Torque: 22 Nꞏm (2.2 kgꞏm/15.9 lb ft)
13. Crankshaft Rear Oil Seal
1) Tighten the adapter to the crankshaft rear end
with 2 bolts.
2) Insert the oil seal into 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) With the seal pressed in, check the dimension of
the oil seal outside end and crankshaft end.
Standard Dimension = 12.5 ± 0.3 mm
Oil Seal Installer: 5-8840-2359-014. Cylinder Block Rear Plate (A/T Model)
1) Tighten the cylinder block rear plate fixing bolts
to the specified torque.
Torque: 97 Nꞏm (9.9 kgꞏm/72 lb ft)
15. Flywheel Housing (M/T Model)
1) Install flywheel housing aligned with the dowel
pin on the cylinder block.
2) Tighten the flywheel housing fixing bolts to the
specified torque.
Torque: 97 Nꞏm (9.9 kgꞏm/72 lb ft)
16. Flywheel
1) Refer to “Crankshaft” in this manual.
17. Cylinder Head Assembly
1) Refer to “Cylinder Head” in this manual.
015RW074
12.5 + 0.3–
012RW067

6A – 98 ENGINE MECHANICAL
OIL PUMP ASSEMBLY
2
1
5
6
3
4
012RW097
Legend
(1) Flywheel
(2) Rear Plate (A/T)
(3) First Oil Pump Assembly(4) Second Oil Pump Assembly
(5) O-Ring (For first oil pump)
(6) O-Ring (For second oil pump)
REMOVAL
1. Disconnect battery ground cable
2. Lift up car
3. Drain engine oil
NOTE: Install drain plug with new gasket.
4. Flywheel
5. Rear Plate (A/T) or Flywheel Housing (M/T)
6. First Oil Pump Assembly and Second Oil Pump
Assembly
1) Remove oil pump assembly from cylinder block
and crankcase.
INSTALLATION
1. First oil pump assembly
1) Set O-ring to oil pump.
2) Install oil pump drive gear to the rear end of the
balance shaft RH.
3) Apply engine oil to pump gear, install pump gear
to rear end of cylinder block with specified
torque.Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
2. Second oil pump assembly
1) Set O-ring to oil pump.
2) Install oil pump drive gear to the rear end of the
balance shaft LH.
3) Apply engine oil to pump gear, install pump gear
to rear end of crank case with specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
3. Install rear plate (A/T) or flywheel housing (M/T)
Torque: 97 Nꞏm (9.9 kgꞏm/72 lb ft)
4. Install flywheel
1) Apply engine oil to bolt and tighten with angular
tightening method.
First step: 59 Nꞏm (6.0 kgꞏm/43 lb ft)
Second step: 60° to 90°

ENGINE MECHANICAL 6A – 99
OIL COOLER
For Europe1
2050R200001
Legend
(1) Oil Cooler Assembly
(2) Oil Filter Cartridge
OIL FILTER CARTRIDGE
REMOVAL
1. Place a receptacle beneath the oil filter to contain
the drained oil.
2. Remove the oil filter cartridge using filter wrench.
Filter wrench : 5-8840-0203-0
INSTALLATION
1, Lightly apply oil to the O-ring of oil filter cartridge.
2. Turn the new oil filter cartridge by hand until the
sealing face is fitted against the O-ring.
3. Use the filter wrench to turn the oil filter an
additional one and 1/8 turns.
4. Start the engine and check for oil leakage from oil
filter.

6A – 100 ENGINE MECHANICAL
REMOVAL
1. Disconnect battery ground cable
2. Drain engine coolant
3. Remove front exhaust pipe
4. Remove heat protector
5. Remove exhaust valve assembly
6. Oil cooler assembly
1) Remove water hoses from inlet and outlet pipe.
2) Put rag beneath side of oil cooler to prevent oil
leaking.
3) Remove fixing bolts and oil cooler assembly.
INSTALLATION
1. Oil Cooler
1) Tighten oil cooler fixing bolt to the specified
torque and connect water hose.
Torque: 29 Nꞏm (3.0 kgꞏm/22 lb ft)
2. Exh. Valve Assembly
1) Install exhaust valve assembly with gasket and
tighten fixing bolts to the specified torque.
Torque: 27 Nꞏm (2.7 kgꞏm/20 lb ft)
3. Heat Protector
4. Front Exhaust Pipe
1) Install front exhaust pipe and tighten fixing bolts
to the specified torque.
Exh. Valve Side: 67 Nꞏm (6.8 kgꞏm/50 lb ft)
Intermediate Pipe Side: 43 Nꞏm (4.4 kgꞏm/32 lb ft)
5. Fill engine coolant.
6. Connect battery ground cable.
7. Start engine and check for oil and water leakage
carefully.

ENGINE COOLING 6B – 1
ENGINE COOLING
CONTENTS
General Description . . . . . . . . . . . . . . . . . . 6B–2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 6B–6
Water Pump . . . . . . . . . . . . . . . . . . . . . . 6B–6Thermostat . . . . . . . . . . . . . . . . . . . . . . . 6B–7
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . 6B–9
Drive Belt Adjustment . . . . . . . . . . . . . . . 6B–11

6B – 2 ENGINE COOLING
Legend
(1) Turbocharger
(2) Thermostat
(3) Reservoir Tank
(4) Radiator
(5) Bypass(6) Oil Cooler
(7) Cooling fan
(8) Water Pump
(9) Thermo Valve
(10) Car Heater
(11) EGR Cooler
GENERAL DESCRIPTION
COOLANT FLOW
1
6
9
9
For Europe only
10
8
4
325
7
11
032R200001
The cooling system is a pressurized coolant forced
circulation type which consists of water pump,
thermostat, cooling fan, radiator and other components. The circulating coolant cools the lubricating oil in the oil
cooler and turbocharger.