Opel Frontera UBS. Service manual — part 392
ENGINE MECHANICAL 6A – 41
5.
Piston and Connecting Rod
•
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.
•
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.
4.
Connecting Rod Bearing Cap
•
Apply engine oil to screw and seat of bearing cap
bolts and nuts.
•
Tighten the cap nuts in 2 steps, using angular
tightening method as shown in the following
specifications.
N·m (kg·m/lb·ft)
45
°
~ 60
°
1st step
2nd step
29 (3.0/22)
After tightening the cap nuts, check to see that the
crankshaft rotates smoothly.
3.
Oil Pump Assembly
2.
Crankcase Assembly
•
Refer to “Crankcase” in Section 6A2.
1.
Cylinder Head Assembly
•
Refer to “Cylinder head” in Section 6A2.
6A – 42 ENGINE MECHANICAL
CYLINDER BLOCK
DISASSEMBLY
1.
Cylinder Head Assembly
•
Refer to “Cylinder head” in Section 6A2.
2.
Cylinder Head Gasket
3.
Flywheel
4.
Cylinder Block Rear Plate
5.
Crankshaft Rear Oil Seal
•
With the oil seal pushed in deep, install the special
tool as shown in the illustration and remove the oil
seal.
Oil Seal Remover : 5-8840-2362-0
6.
Crankcase Assembly
•
Refer to “Crankcase” in Section 6A2
7.
Oil Pump Assembly
ENGINE MECHANICAL 6A – 43
8.
Camshaft Timing Gear
9.
Camshaft Thrust Plate
10. Camshaft
11. Crankshaft Front Oil Seal
•
With the oil seal pushed in deep, install the special
tool as shown in the illustration and remove the oil
seal.
Oil Seal Remover : 5-8840-2362-0
12. Timing Gear Case
13. Tappet
14. Piston Assembly
15. Main Bearing Cap Assembly
16. Crankshaft
17. Piston Cooling Oil Pipe
18. Cylinder Block
6A – 44 ENGINE MECHANICAL
INSPECTION REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered
during inspection.
1.
Remove the 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 oil pan installation surface seal.
3.
Wipe the cylinder block clean.
Cylinder Liner Projection Inspection
1.
Hold a straight edge 1 along the top edge of the cylinder
liner to be measured.
2.
Use a feeler gauge 2 to measure each cylinder liner
projection.
The difference in the cylinder liner projection height
between any two adjacent cylinders must not exceed
0.03 mm (0.0012 in).
0.0 – 0.1 (0.0000 – 0.0039)
mm(in.)
Standard
Flatness
1.
Remove the cylinder body dowel.
2.
Set the cylinder liner remover to the cylinder liner.
3.
Check that the remover shaft ankle is firmly gripping the
cylinder liner bottom edge.
4.
Slowly turn the remover shaft handle counterclockwise
to pull the cylinder liner free.
Cylinder Liner Remover Ankle: 5-8840-2304-0
Cylinder Liner Remover: 9-8523-1169-0
NOTE:
Take care not to damage the cylinder body upper during the
cylinder liner removal procedure.
5.
Use a straight edge 1 and a feeler gauge 2 to measure the
four sides and the two diagonals of the cylinder body
upper face.
If the measured values exceed the limit, the cylinder
body must be replaced.
0.20 (0.0079)
mm(in.)
Limit
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