lock OPEL FRONTERA 1998 Workshop Manual

6A–74
ENGINE MECHANICAL
015RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
Apply engine oil to the oil seal lip.
Align the cylinder block dowel pin holes with the rear
retainer dowel pins.
Tighten the rear retainer fixing bolts. New bolts
should be used when installing rear retainer.
Torque: 18 Nꞏm (1.8 Kgꞏm/13 lb ft)
NOTE: Be very careful not to disengage the oil seal garter
spring during installation of the rear retainer.
If the seal was removed from retainer for
replacement, apply engine oil to the oil seal lip and
install the oil seal using 5–8840–2286–0 oil seal
installer.
015RW001
015RS017
3. Flywheel (9)
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and flywheel
mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
4. Hold the crankshaft to prevent from rotating then
install the bolts in the order shown to the specified
torque.
Torque: 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
NOTE: Do not reuse the bolt and do not apply oil or thread
lock to the bolt.
015RS018

6A–75
ENGINE MECHANICAL
4. Piston and connecting rod assembly (8)
Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins.
Check to see that the piston ring end gaps are
correctly positioned.
015RS019
Legend
(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark
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.
Match the numbered caps with the numbers on the
connecting rods. Align the punched marks on the
connecting rods and caps.
Apply engine oil to the threads and seating faces of
the nuts.
Tighten the nuts.
Torque: 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
After tightening the cap nuts, check to see that the
crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back faces.
015RS020
5. Install oil gallery (7) and tighten the bolts in 2 steps, in
the order shown.
1st step: 29 Nꞏm (3.0 Kgꞏm/22 lb ft)
2nd step: 55
65
051RS009
6. Cylinder block side bolts (6)
Tighten all the bolts to the specified torque in the
order shown.
NOTE: Do not apply engine oil to the crank case side
bolts.
Torque: 39 Nꞏm (4.0 Kgꞏm/29 lb ft)

6A–79
ENGINE MECHANICAL
015RV014The size mark (1) for piston outside diameter is
represented as shown in illustration below.
Outside Diameter
Size Mark A : 93.360 mm–93.370 mm
(3.6756 in–3.6760 in)
Size Mark B : 93.371 mm–93.380 mm
(3.6760 in–3.6764 in)
Size Mark C : 93.381 mm–93.390 mm
(3.6764 in–3.6768 in)
015RS025Measure the cylinder bore inside diameter (refer to
“Cylinder Block” in this manual).
012RS002
Piston Rings (8)
Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.
1. Ring end gap measurement
Insert the piston ring into the bore.
Push the ring by the piston, at a right angle to the
wall, into the point at which the cylinder bore
diameter is the smallest.
Measure the ring end gap.
Compression Ring
1st ring
Standard:
0.300 mm–0.400 mm
(0.0118 in–0.0157 in)
Limit: 1.0 mm (0.0394 in)
2nd ring
Standard: 0.450 mm–0.600 mm
(0.0177 in–0.0236 in)
Limit: 1.2 mm (0.0472 in)
Oil ring
Standard:
0.150 mm–0.450 mm
(0.0059 in–0.0177 in)
Limit: 1.05 mm (0.0413 in)

6A–85
ENGINE MECHANICAL
Cylinder Block
Cylinder Block and Associated Parts
012RW010
Legend
(1) Cylinder Head Assembly
(2) Cylinder Head Gasket
(3) Crankcase with Oil Pan
(4) Oil Pipe and O-Ring
(5) Oil Strainer and O-Ring
(6) Oil Pump Assembly
(7) Cylinder Block Side Bolts(8) Oil Gallery
(9) Piston and Connecting Rod Assembly
(10) Flywheel
(11) Rear Oil Seal Retainer Assembly
(12) Main Bearing Cap
(13) Crankshaft
(14) Cylinder Block
Disassembly
1. Remove cylinder head assembly.
2. Remove cylinder head gasket.
3. Remove crankcase with oil pan.
4. Remove oil pipe and O-ring.5. Remove oil strainer and O-ring.
6. Remove oil pump assembly.
7. Remove crankcase side bolts.
8. Remove oil gallery.
9. Remove piston and connecting rod assembly.
10. Remove flywheel.

6A–86
ENGINE MECHANICAL
11. Remove rear oil seal retainer assembly.
12. Remove main bearing cap.
13. Remove crankshaft.
14. Remove cylinder block.
Inspection and Repair
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 the oil pump, rear oil seal retainer,
and crankcase assembly installation surface seal.
3. Wipe the cylinder block clean.
4. Visually inspect the cylinder block. If necessary, use a
flaw detector to perform a dye penetrate and
hydraulic (or air pressure) test. If cracking or other
damage is discovered, the cylinder block must either
be repaired or replaced.
Flatness
1. Using a straight–edge and feeler gauge, check that
the upper surface of the cylinder block is not warped.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
2. The cylinder block must be reground or replaced if the
warpage exceeds the limit.
Warpage
Limit : 0.15 mm (0.0059 in)
Maximum repairable limit: 0.15 mm (0.0059 in)
012RS004
Cylinder Bore
Use a cylinder gauge to measure the cylinder bore
diameter in both the axial and thrust directions. Each
measurement should be made at six points.CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
Cylinder Bore Inside Diameter
Limit : 93.530 (3.6823)
If the measurement exceed the specified limit, the
cylinder block must be replaced.
Diameter
Grade A : 93.400 mm–93.410 mm
(3.6772 in–3.6776 in)
Grade B : 93.411 mm–93.420 mm
(3.6776 in–3.6779 in)
Grade C : 93.421 mm–93.430 mm
(3.6780 in–3.6783 in)
012RS005
NOTE: For information on piston diameter, please refer
to the section ”Inspection of the Piston and Connecting
Rod Assembly” in this manual.
The ”Grade” mark (1) is stamped at the position
illustrated.

6A–87
ENGINE MECHANICAL
012RS006
Reassembly
1. Install cylinder block.
2. Install crankshaft.
Install the main bearings to the cylinder block and
the main bearing caps.
Be sure that they are positioned correctly.
Apply new engine oil to the upper and lower main
bearing faces.
NOTE: Do not apply engine oil to the bearing back faces.
015RS012
Legend
(1) Number 1 and 4 main bearing upper and lower.
(2) Number 2 and 3 main bearing upper.
(3) Number 2 and 3 main bearing lower.
Carefully mount the crankshaft.
Apply engine oil to the thrust washer.
Assemble the thrust washer to the No. 3 bearing
journal. The oil grooves must face the crankshaft.
015RS013
3. Install rear oil seal retainer.
Remove oil on cylinder block and retainer fitting
surface.
Apply sealant (TB1207B or equivalent) to retainer
fitting surface as shown in illustration.
The oil seal retainer must be installed within 5
minutes after sealant application before the sealant
hardens.
015RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
Apply engine oil to oil seal lip and align a dowel pin
hole in the cylinder block with that in the retainer.
Tighten retainer fixing bolts to the specified torque.
Torque: 25 Nꞏm (2.5 Kgꞏm/18.4 lb ft)

6A–88
ENGINE MECHANICAL
015RW001
4. Install flywheel
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and flywheel
mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
4. Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown.
Torque: 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
015RS018
5. Install piston and connecting rod assembly.
Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins.
NOTE: Do not apply engine oil to the bearing back faces.
Check to see that the piston ring end gaps are
correctly positioned.
015RS019
Legend
(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark
Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
The front marks (1) must be facing the front of the
engine.
015RS020
6. Install oil gallery and tighten the bolts in 2 steps in the
order shown.
1st step : 29 Nꞏm (3.0 Kgꞏm/22 lb ft)
2nd step : 55
65

6A–89
ENGINE MECHANICAL
012RS007
7. Install cylinder block side bolts (1) and tighten
crankcase bolts in sequence shown in the illustration.
Torque : 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
012RW005
8. Install oil pump assembly. Refer to “Oil Pump” in this
manual.
9. Install oil strainer and O-ring.
10. Install oil pipe and O-ring.
11. Install crankcase with oil pan.
1. Completely remove all residual sealant, lubricant
and moisture from the sealing surfaces. The
surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB– 1207C
or its equivalent) to the contact surfaces of the
crankcase. There must be no gaps in the bead.
3. The oil pan must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
4. Tighten the bolts and nuts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
013RW010
Legend
(1) Portion Between Both Holes
(2) Bolt Hole Portions
12. Install cylinder head gasket.
13. Install cylinder head assembly. Refer to “Cylinder
Head” in this manual.

ENGINE COOLING6B–1
ENGINE
ENGINE COOLING
CONTENTS
Service Precaution 6B–1. . . . . . . . . . . . . . . . . . . . . .
General Description 6B–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Refilling Cooling System 6B–6. . . . .
Water Pump 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump and Associated Parts 6B–7. . . . . . .
Removal 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat 6B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat and Associated Parts 6B–8. . . . . . . .
Removal 6B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 6B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator 6B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator and Associated Parts 6B–9. . . . . . . . . .
Removal 6B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Belt and Cooling Fan 6B–12. . . . . . . . . . . . . . .
Drive Belt and Associated Parts 6B–12. . . . . . . . .
Inspection 6B–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6B–13. . . . . . . . . . . . .
Special Tool 6B–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

6B–2
ENGINE COOLING
General Description
030RW001
Legend
(1) Water Pump
(2) Thermostat
(3) Radiator
(4) Reserve Tank
(5) Cooling Fan
(6) Cylinder Block(7) Cylinder Head
(8) Right Bank
(9) Throttle Body
(10) Cylinder Block
(11) Cylinder Head
(12) Left Bank
(13) Heater
The cooling system is a pressurized Engine Coolant (EC)
forced circulation type which consists of a water pump,
thermostat cooling fan, radiator and other components.
The automatic transmission fluid is cooled by the EC in
radiator.
Water Pump
The EC pump is a centrifugal impeller type and is driven
by a timing belt.
030RS001