1998 OPEL FRONTERA lock

6A–3
ENGINE MECHANICAL
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.
Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance:
When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick–up unit.
The 12–volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.
Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum die–cast casting
for 75
V–type six cylinders. It has a rear plate integrated
structure and employs a deep skint. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width of No.3 bearing
on the body side is different in order to support the thrust
bearing. The bearing cap is made of nodular cast iron and
each bearing cap uses four bolts and two side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent–roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V–type design. The ports are cross–flow
type.
Va l v e Tr a i n
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast–iron. Pins and
journals are graded for correct size selection for their
bearing.
Engine Lubrication
The oil discharged by a trochoid–type oil pump driven by
the crankshaft is fed through full–flow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.

6A–25
ENGINE MECHANICAL
3. Tighten adjusting nut and lock nut temporarily.
4. Loosen adjusting nut by three turns and tighten
lock nut.
Then manually operating the throttle valve, make
sure that the valve lever returns up to the stopper
screw.
If it does not reach the stopper screw, repeat from
step 1.
035RW004
Legend
(1) Clearance
(2) Lock Nut
(3) Adjusting Nut
10. Install air cleaner duct assembly.
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element.
(5) Mass Air Flow Sensor

6A–29
ENGINE MECHANICAL
Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench
then remove drive belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt
5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10. Remove crankshaft pulley assembly using
5–8840–0133–0 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
13. Remove pusher.CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.
014RW011
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its core
could be damaged. The belt should not be bent at
a radius less than 30 mm.
2. Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during installation.
4. Store timing belt in a cool and dark place. Never
expose the belt direct sunlight or heat.

6A–31
ENGINE MECHANICAL
2. Align the alignment mark on the RH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover RH (3).
3. Align the alignment mark (white line) on the timing
belt (1) with alignment mark on the RH bank
camshaft drive gear pulley (2) (on the left side as
viewed from the front of the vehicle) and put the
timing belt on the camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
014RW00004
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.
4. Align the alignment mark on the LH bank
camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover LH (3).
5. Align the alignment mark (white line) on the timing
belt (1) with the alignment mark on the LH bank
camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench to
turn the camshaft drive gear pulley, then set the
timing mark between timing belt and camshaft
drive gear pulley and put the timing belt on the
camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
NOTE: It is recommended for easy installation that the
belt be secured with a double clip or equivalent clip after
it is installed the timing belt to each pulley.
014RW00005
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear
Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.
6. Install crankshaft pulley temporarily and tighten
center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give some
belt slack between the crankshaft timing pulley
and the RH bank camshaft drive gear pulley.
2. Install pusher and tighten bolt to the specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
1. Install the pusher while pushing the tension pulley
to the belt.
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).
014RW011

6A–32
ENGINE MECHANICAL
Legend
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin
3. Remove double clips or equivalent clips, from
timing belt pulleys.
Turn the crankshaft pulley clockwise by two turns.
3. Install timing belt cover.
Remove crankshaft pulley that was installed in step
1 item 5.
Tighten bolts to the specified torque.
Torque: 19 Nꞏm (1.9 Kgꞏm/14 lb ft)
020RW004
Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower
020RW003
Legend
(1) Timing Belt Cover
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body
4. Install crankshaft pulley using 5–8840–0133–0, hold
the crankshaft pulley and tighten center bolt to the
specified torque.
Torque : 167 Nꞏm (17.0 Kgꞏm/123 lb ft)
5. Install fan pulley bracket and tighten fixing bolts to the
specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
6. Install power steering pump assembly and tighten to
the specified torque.
To r q u e :
M8 bolt : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
M10 bolt : 46 Nꞏm (4.7 Kgꞏm/34 lb ft)
7. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in) for fan and
clutch assembly.
8. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Auto Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt
9. Install radiator upper fan shroud.
10. Install air cleaner assembly.

6A–35
ENGINE MECHANICAL
014RW024
Legend
(1) Right Bank
(2) Left Bank(3) Alignment Mark on Camshaft Drive Gear
(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer
3. Tighten twenty bolts on numerical order an one
side bank as shown in the illustration.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
014RW031
5. Install cylinder head cover RH.
Refer to installation procedure for CYLINDER
HEAD COVER RH in this manual.
6. Install cylinder head cover LH.
Refer to installation procedure for CYLINDER
HEAD COVER LH in this manual.
7. Install timing belt.
Refer to installation procedure for TIMING BELT in
this manual.8. Install crankshaft pulley.
Refer to installation procedure for CRANKSHAFT
PULLEY in this manual.
Accelerator pedal cable adjustment
1. Loosen adjusting nut and lock nut.
2. Pull outer cable while closing fully the throttle
valve.
3. Tighten adjusting nut and lock nut temporarily.

6A–36
ENGINE MECHANICAL
4. Loosen adjusting nut by three turns and tighten
lock nut.
Then, manually operating the throttle valve, make
sure that the valve lever returns up to the stopper
screw.
If it does not reach the stopper screw, repeat from
step 1.
035RW004
Legend
(1) Clearance
(2) Lock Nut
(3) Adjusting Nut

6A–37
ENGINE MECHANICAL
Cylinder Head
Removal
1. Remove engine hood.
2. Disconnect battery ground cable.
3. Drain radiator coolant.
4. Drain engine oil.
5. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
6. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
7. Remove cylinder head cover LH.
Refer to removal procedure for Cylinder Head
Cover LH in this manual.
8. Remove cylinder head cover RH.
Refer to removal procedure for Cylinder Head
Cover RH in this manual.
9. Remove common chamber.
Refer to removal procedure for Common Chamber
in this manual.
10. Remove cylinder head assembly.
1. Loosen eights bolts for tight cylinder head.
2. Remove cylinder head assembly.
014RW028
Legend
(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft
Installation
1. Install cylinder head assembly to cylinder block.
1. Put cylinder head gasket on the cylinder block.NOTE: There is discrimination mark “R” for right bank
and “L” for left bank on the cylinder head gasket as shown
in the illustration.
Do not reuse cylinder head gasket.
011RW005
2. Align dowel pin hole to dowel pin on the cylinder
block.
3. Tighten two bolts temporarily by hand to prevent
the cylinder head assembly from moving.
4. Using 9–8511–4209–0 cylinder head bolt wrench,
tighten bolts in numerical order as shown in the
illustration to the specified torque.
NOTE: Do not reuse cylinder head bolts.
Do not apply any lubricant to the cylinder head bolts.
To r q u e :
Temporary : 29 Nꞏm (3.0 Kgꞏm/21 lb ft)
Final : 64 Nꞏm (6.5 Kgꞏm/47 lb ft)
014RW029