Opel Frontera UBS. Service manual — part 1332
6A – 78 ENGINE MECHANICAL
2) Apply liquid gasket (TB1207B or equivalent)
between the cylinder block and the crankcase
fitting surfaces.
3) Install the timing gear case to the cylinder body.
4) Tighten the timing gear case bolt together with
the timing gear case gasket to the specified
torque.
Torque: 20 N·m (2.0 kg·m/14.5 lb·ft)
12. Crankshaft Gear
1) Set key to crankshaft key groove.
2) The timing mark on the crankshaft gear must be
facing outward.
3) Use the crankshaft gear installer to install the
crankshaft gear.
Crankshaft installer: 9-8522-0021-0
Legend
(1) Crankshaft Gear Installer
(2) Crankshaft Gear
13. Installation of the Timing Gear
1) Align teeth on the scissors gear and lock them
before install timing gear.
2) Align timing marks on each timing gear and
assemble them.
3) Refer to timing gear detail in this manual.
14. Timing Gear Case Cover
1) Remove lock bolt from idle gear A and remove
lock pin from idle gear C.
2) Install oil pump gear oil seal before assembling
timing gear case cover.
3) Clean fitting surface and apply liquid gasket
(TB1207C or equivalent) to fitting surface.
4) Tighten bolts to specified torque.
Torque: 20 N·m (2.0 kg·m/14.5 lb ft)
1
2
2
012RW066
2
2~2.5mm
2~2.5mm
Apply liquid gasket around inside
of the bolt hole
Bolt hole
Inside
Outside
F06HX00001
012RW024
012RW064
15. Crankshaft Front Oil Seal
1) Set oil seal with special tool.
2) Install front oil seal to timing gear case cover.
Crankshaft Front Oil Seal Installer: 5-8840-2061-0
3) Remove special tool and check oil seal position
from front surface of timing gear case.
Oil Seal Position: 0.5 – 2.5 mm (0.0197 – 0.0984 in)
16. Cylinder Head
1) Refer to “Cylinder head” in this manual.
ENGINE MECHANICAL 6A – 79
015RW074
6A – 80 ENGINE MECHANICAL
PISTON AND CONNECTING ROD
5
8
7
3
1
2
6
4
012RW061
Legend
(1)
Cylinder Head Assembly
(2)
Crank Case
(3)
Connecting Rod Bearing Cap
(4)
Connecting Rod
(5)
Piston Ring
(6)
Piston Pin
(7)
Piston Pin Snap Ring
(8)
Piston
ENGINE MECHANICAL 6A – 81
DISASSEMBLY
1. Cylinder Head Assembly
1) Refer to “Cylinder head” in this manual.
2. Crank Case Assembly
1) Refer to “Crank Case” in this manual.
3. Connecting Rod Bearing Cap
4. Piston and Connecting Rod
1) Remove carbon deposits from the upper portion
of the cylinder wall with a scraper before
removing the piston and connecting rod.
5. Piston Ring
Remove the piston rings with a piston ring
expander.
Arrange the removed piston rings in the cylinder
number order.
6. Piston Pin Snap Ring
1) Use a pair of pliers to remove the piston pin
snap rings.
7. Piston Pin
1) Remove piston pin from piston assembly.
NOTE: Keep the parts removed from each cylinder
separate. All parts must be reinstalled in their original
positions.
8. Piston
9. Connecting Rod
INSPECTION AND REPAIR
PISTON AND PISTON RING
Pistons
Carefully clean away all the carbon adhering to the
piston head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston for
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are present, the piston
must be replaced.
Piston Diameter
1. Measure the piston outside diameter with
micrometer at the piston grading position.
Piston Grading Position: 69.75 mm (2.7461 in)
from piston head
Piston Outside Diameter
mm(in)
Grade Mark
Outside Diameter
A
95.320 – 95.329 (3.7527 – 3.7531)
B
95.330 – 95.339 (3.7531 – 3.7535)
C
95.340 – 95.349 (3.7535 – 3.7539)
015RW082
015RW077
015LV014
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