Opel Frontera UBS. Service manual — part 254

6A–83

ENGINE MECHANICAL

D

Attach the piston to the connecting rod with the
piston front mark and the connecting rod front mark
on the same side.

015RS036

D

With 5–8840–0551–0 Piston pin service set and a
press, press fit the piston pin.

NOTE: Heat the connecting rod small end to a suitable
temperature to ensure smooth installation.

015RX001

Legend

(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin

4. Install piston ring with the piston ring expander.

The compression ring must be set with the T mark (1)
facing up.

Marked T : No.1 Compression ring

Marked T2 : No.2 Compression ring

015RS027

D

Install piston rings in the following sequence.

1. Oil ring

1. Expander ring
2. Upper side rail
3. Lower side rail

2. 2nd compression ring
3. 1st compression ring

D

The compression rings must be set with the T or T2
mark facing up.

Marked T : No.1 Compression ring

Marked T2 : No.2 Compression ring

D

After installation, apply engine oil to the entire
circumference of the piston rings. Check to see that
all the rings rotate smoothly.

015RS038

5. Install piston and connecting rod assembly.

D

Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces and
nuts.

6A–84

ENGINE MECHANICAL

D

Tighten the connecting rod cap nuts

Torque : 54 N·m (5.5 Kg·m/40 lb ft)

NOTE: Do not apply engine oil to the bearing back faces.

6. Oil gallery, refer to “Crankshaft and main bearing” in

this manual.

7. Oil strainer and O-ring.
8. Oil pipe and O-ring.
9. Install crankcase with oil pan, refer to “Oil pan and

Crankcase” in this manual.

10. Install cylinder head gasket.

11. Install Cylinder head assembly.

D

Refer to “Cylinder head” in this manual.

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.

D

The ”Grade” mark (1) is stamped at the position
illustrated.