1998 OPEL FRONTERA Gas

6A – 82 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 Nꞏm (2.0 kgꞏm/14.5 lbꞏft)
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 Gear13. 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 Nꞏm (2.0 kgꞏm/14.5 lb ft)
12
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

6A – 92 ENGINE MECHANICAL
CYLINDER BLOCK
1
15
14
13
8
11
16
17
10
9
72
12
3
465
18
012RW023
Legend
(1) Cylinder Head
(2) Cylinder Head Gasket
(3) Flywheel
(4) Cylinder Block Rear Plate (A/T)
Flywheel Housing (M/T)
(5) Crankshaft Rear Oil Seal
(6) Retainer
(7) Timing Gear Case Cover
(8) Crankshaft Front Oil Seal(9) Timing Gear Case
(10) Gasket
(11) Balance Shaft
(12) Crank Case
(13) Piston Cooling Oil Pipe
(14) Main Bearing Cap
(15) Crankshaft
(16) Crankshaft Timing Gear
(17) Piston and Connecting Rod Assembly
(18) Cylinder Block

ENGINE MECHANICAL 6A – 93
DISASSEMBLY
1. Cylinder Head Assembly
Refer to “Cylinder Head” in this manual.
2. Cylinder Head Gasket.
3. Flywheel
4. Cylinder Block Rear Plate (A/T), or Flywheel
housing (M/T).
5. Crankshaft Rear Oil Seal.
Install the special tool as shown in the illustration
and remove the oil seal.
Oil Seal Remover: 5-8840-2360-0
6. Retainer
7. Timing Gear Case Cover
8. Crankshaft Front Oil Seal
1) Use a plastic hammer and a screwdriver to tap
around the oil seal to free it from the gear case
cover.
9. Timing Gears
Refer to “Timing Gear” in this manual.
10. Timing gear case
11. Gasket
12. Balance shaft right
13. Crank case assembly
14. Piston cooling oil pipe
15. Piston assembly
16. Main bearing cap
17. Crankshaft assembly
18. Cylinder block side cover right and left
19. Cylinder block
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
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 liquid gasket, which was used
when assembled, from gear case, rear oil seal
retainer and crank case.
3. Wipe the cylinder block clean and visually check it.
4. Use a straight edge and a feeler gauge to measure
the four sides and the two diagonals of the cylinder
block upper face.
If the measured values exceed the limit, the cylinder
block must be replaced.
Limit: 0.20 mm (0.0079 in)
015RV002
012RW122

6A – 96 ENGINE MECHANICAL
NOTE: Check to see that the crankshaft turns
smoothly by rotating it manually.
4. Piston Assembly
1) Refer to “Piston and connecting rod” in this
manual.
5. Cylinder Block Side Cover Right and Left
6. Balance Shaft Right.
7. Timing Gear Case
1) Cut out the liquid gasket forced out from
between the contact surface of cylinder block
and crankshaft.
2) Apply liquid gasket (TB1207B or equivalent) to
the fitting surface of the cylinder block and
crankcase.
3) Install timing gear case with gasket to cylinder
block and tighten to specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)8. Crankshaft Gear
Force key into crankshaft and force in crankshaft
gear along the key groove using a special tool (1)
with the crank gear (2) timing mark facing outside.
9. Install timing gear align the timing mark on each
timing gear.
For alignment of timing marks refer to “Timing
Gear” in this manual.
NOTE: Remove the locking bolt or pin from idle gear A
and idle gear C.
10. Assembling the gear case cover.
1) Install the oil seal on the oil pump assembly
before installing the gear case cover.
2) Apply liquid gasket to timing gear case.
NOTE: Be sure to apply liquid gasket evenly.
84159
610
237
012RW027
012RW064
12
2
012RW066
2
2~2.5mm
2~2.5mm
Apply liquid gasket around inside
of the bolt hole
Bolt hole
Inside
Outside
F06HX00001

6A – 98 ENGINE MECHANICAL
OIL PUMP ASSEMBLY
2
1
5
6
3
4
012RW097
Legend
(1) Flywheel
(2) Rear Plate (A/T)
(3) First Oil Pump Assembly(4) Second Oil Pump Assembly
(5) O-Ring (For first oil pump)
(6) O-Ring (For second oil pump)
REMOVAL
1. Disconnect battery ground cable
2. Lift up car
3. Drain engine oil
NOTE: Install drain plug with new gasket.
4. Flywheel
5. Rear Plate (A/T) or Flywheel Housing (M/T)
6. First Oil Pump Assembly and Second Oil Pump
Assembly
1) Remove oil pump assembly from cylinder block
and crankcase.
INSTALLATION
1. First oil pump assembly
1) Set O-ring to oil pump.
2) Install oil pump drive gear to the rear end of the
balance shaft RH.
3) Apply engine oil to pump gear, install pump gear
to rear end of cylinder block with specified
torque.Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
2. Second oil pump assembly
1) Set O-ring to oil pump.
2) Install oil pump drive gear to the rear end of the
balance shaft LH.
3) Apply engine oil to pump gear, install pump gear
to rear end of crank case with specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
3. Install rear plate (A/T) or flywheel housing (M/T)
Torque: 97 Nꞏm (9.9 kgꞏm/72 lb ft)
4. Install flywheel
1) Apply engine oil to bolt and tighten with angular
tightening method.
First step: 59 Nꞏm (6.0 kgꞏm/43 lb ft)
Second step: 60° to 90°

6A – 100 ENGINE MECHANICAL
REMOVAL
1. Disconnect battery ground cable
2. Drain engine coolant
3. Remove front exhaust pipe
4. Remove heat protector
5. Remove exhaust valve assembly
6. Oil cooler assembly
1) Remove water hoses from inlet and outlet pipe.
2) Put rag beneath side of oil cooler to prevent oil
leaking.
3) Remove fixing bolts and oil cooler assembly.
INSTALLATION
1. Oil Cooler
1) Tighten oil cooler fixing bolt to the specified
torque and connect water hose.
Torque: 29 Nꞏm (3.0 kgꞏm/22 lb ft)
2. Exh. Valve Assembly
1) Install exhaust valve assembly with gasket and
tighten fixing bolts to the specified torque.
Torque: 27 Nꞏm (2.7 kgꞏm/20 lb ft)
3. Heat Protector
4. Front Exhaust Pipe
1) Install front exhaust pipe and tighten fixing bolts
to the specified torque.
Exh. Valve Side: 67 Nꞏm (6.8 kgꞏm/50 lb ft)
Intermediate Pipe Side: 43 Nꞏm (4.4 kgꞏm/32 lb ft)
5. Fill engine coolant.
6. Connect battery ground cable.
7. Start engine and check for oil and water leakage
carefully.

6B – 6 ENGINE COOLING
REMOVAL
1. Drain coolant.
2. AC Generator Drive Belt
1) Loosen AC Generator mounting bolt, adjust
plate lock bolt, and remove the drive belt.
3. Cooling Fan Assembly
1) Remove lock nut and take out cooling fan
assembly with cooling fan clutch.
4. Water Pump Assembly
INSPECTION
Make necessary repair and parts replacement if
excessive wear or damage is found during inspection.
Should any of the following problems occur, the entire
water pump assembly must be replaced.
1) Cracks in the water pump body
2) Coolant leakage from the seal unit
3) Excessive play in radial direction or abnormal noise
4) Excessive play in thrust direction
5) Cracks or corrosion in the impeller
INSTALLATION
1. Gasket
1) Set gasket to gear case.
2. Water Pump Assembly
1) Install water pump assembly, and tighten to
specified torque.Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
3. Cooling Fan Assembly
1) Install cooling fan assembly, and tighten to
specified torque.
Torque: 8 Nꞏm (0.8 kgꞏm/5.8 lb ft)
4. AC Generator Drive Belt
1) Install AC Generator drive belt and adjust belt
tension.
Torque: 40 Nꞏm (4.1 kgꞏm/29.7 lb ft)
For ACG to bracket
20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
For ACG to adjust plate
5. Fill coolant to specified capacity.
12
Legend
(1) Fan Pulley
(2) Water Pump Assembly
030RW009
ON-VEHICLE SERVICE
WAT E R P U M P

ENGINE COOLING 6B – 7
THERMOSTAT
REMOVAL
1. Disconnect battery ground cable.
2. Drain coolant from the radiator and engine.
3. Thermostat housing
1) Remove mounting bolt and remove thermostat
housing together with radiator hose.
4. Gasket
5. Thermostat
INSPECTION
Make necessary repair and parts replacement if
excessive wear or damage is found during inspection.
Submerge the thermostat assembly in the water.
Place wooden blocks on the bottom of the water
container.
Do not heat the thermostat directly.
Gradually increase the water temperature. Stir the
water so that the entire water is the same temperature.
1) Make sure that valve begins to open at the
specified temperature.
Valve Opening Temperature: 85°C (185°F)
2) Make sure that valve opens fully at the specified
temperature.
Valve Full Open Temperature: 100°C (212°F)
1
2
3
4
Legend
(1) Bolt
(2) Thermostat Housing
(3) Thermostat
(4) Intake Manifold
035RW002
031RS003