1998 OPEL FRONTERA lock

6A–38
ENGINE MECHANICAL
2. Install common chamber.
Refer to installation procedure for Common
Chamber in this manual.
3. Install cylinder head cover RH.
Refer to installation procedure for Cylinder Head
Cover RH in this manual.
4. Install cylinder head cover LH.
Refer to installation procedure for Cylinder Head
Cover LH in this manual.
5. Install timing belt.
Refer to installation procedure for Timing Belt in this
manual.
6. 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.
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–43
ENGINE MECHANICAL
6. Remove oil pump assembly.
Refer to removal procedure for Oil Pump in this
manual.
7. Remove cylinder body side bolts.
8. Remove oil gallery.
9. Remove flywheel.
10. Remove rear oil seal retainer.
Refer to removal procedure for Rear Oil Seal in this
manual.
11. Remove connecting rod caps.
12. Remove crankshaft main bearing caps.
13. Remove crankshaft and main bearings.
Installation
1. Install crankshaft and main bearings.
Install main bearing in the cylinder block and main
bearing cap respectively.
Apply new engine oil to upper and lower main
bearings.
NOTE:
Do not apply engine oil to the bearing back faces.
Make sure that main bearings are in correct position.
Install crankshaft with care.
Apply engine oil to the thrust washer.
Install thrust washer on No.3 journal.
Oil grooves in thrust washer must face the
crankshaft.
015RS012
015RS013
2. Install crankshaft main bearing caps.
Apply engine oil to the thread and seating surface of
each bearing cap fixing bolt.
NOTE:
Do not apply engine oil to the bearing back faces.
Install bearing caps in the order of numbers, starting
with cylinder block front side.
Tighten main bearing fixing bolts to the specified
torque.
Torque : 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
After tightening the bolts, make sure that the
crankshaft rotates smoothly.
3. Install connecting rod caps.
The cap number must be same as connecting rod
number.
Apply engine oil to the thread and seating surface of
each nut.
Tighten nuts to the specified torque.
Torque : 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
After tightening the nuts, make sure that the
crankshaft rotates smoothly.
4. Install rear oil seal retainer.
Remove oil on cylinder block and retainer fitting
surface.
Apply sealant (TB1207B or equivalent) to retainer
fitting surface as shown in illustration.

6A–44
ENGINE MECHANICAL
The oil seal retainer must be installed within 5
minutes after sealant application before the sealant
hardens.
015RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
Apply engine oil to oil seal lip and align a dowel pin
hole in the cylinder block with that in the retainer.
Tighten retainer fixing bolts to the specified torque.
Torque : 18 Nꞏm (1.8 Kgꞏm/13 lb ft)
015RW001
5. Install flywheel.
Clean tapped holes in the crankshaft.
Remove oil on crankshaft and flywheel fitting
surface.
NOTE:
Do not reuse the bolts.
Do not apply oil or thread lock to the bolts.
Tighten fixing bolts to the specified torque.
Torque : 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
015RS018
6. Install oil gallery.
Clean contact surface of oil gallery and main
bearing cap.
Apply engine oil to oil gallery fixing bolts and tighten
the bolts in two steps, in the order shown in
illustration.
To r q u e :
1st step : 29 Nꞏm (3.0 Kgꞏm/21 lb ft)
2nd step : 55
–65
7. Install cylinder body side bolts and tighten bolts in
order to the specified torque.
Torque : 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
NOTE: Do not apply the oil to the bolts.
012RS007
8. Install oil pump assembly.
Remove oil on cylinder block and oil pump mounting
surface.

6A–45
ENGINE MECHANICAL
Apply sealant (TB1207B or equivalent) to the oil
pump mounting surface.
The oil pump assembly must be installed within 5
minutes after sealant application before the sealant
hardens.
Apply engine oil to oil seal lip.
Install oil pump in the cylinder block and tighten
fixing bolts to the specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
051RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
051RW001
9. Install oil strainer with O-ring, tighten to the specified
torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
10. Install oil pipe with O-ring, tighten fixing bolts to the
specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)11. Install crankcase.
Remove oil on crankcase mounting surface and dry
the surface.
Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the crankcase
mounting surface. The bead must be continuous.
The crankcase must be installed within 5 minutes
after sealant application before the sealant
hardens.
Tighten fixing bolts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
013RW010
013RW004
12. Install oil pan
Remove oil on oil pan mounting surface and dry the
surface.
Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the oil pan
mounting surface. The bead must be continuous.
The oil pan must be installed within 5 minutes after
sealant application to prevent premature hardening
of sealant.

6A–47
ENGINE MECHANICAL
Rear Oil Seal
Removal
1. Remove transmission assembly.
Refer to removal procedure for Transmission
section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil seal
retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal using
5–8840–2286–0.
015RS017
2. Install flywheel.
Clean tapped holes in the crankshaft.
Remove oil on the crankshaft and flywheel
mounting surface.
Tighten fixing bolts to the specified torque.
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
Torque : 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
015RS018
3. Install transmission.
See Transmission section in this manual.
CAUTION: W h e n a s s e m b l i n g t h e e n g i n e a n d
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
Otherwise, the transmission may be damaged.
012RS009

6A–50
ENGINE MECHANICAL
9. Install air conditioner compressor to engine and
tighten to the specified torque.
Torque :
M8 bolts : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
M10 bolts : 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
10. Install power steering pump, tighten fixing bolt to the
specified torque.
Torque :
M8 bolts : 22Nꞏm (2.2 Kgꞏm/16 lb ft)
M10 bolts : 46 Nꞏm (4.7 Kgꞏm/34 lb ft)
11. 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) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt
12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of right
dash panel.19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.
24. Install air cleaner assembly.
25. Reconnect air duct.
26. Reconnect accelerator cable and automatic cruise
control cable to throttle valve on common chamber.
035RW007
Legend
(1) Throttle Valve Assembly
(2) Throttle Lever
(3) Idle Air Control Valve
(4) Throttle Position Sensor
27. Install engine hood to the original position.
Refer to installation procedure for Body section in
this manual.
Accelerator pedal cable adjustment
1. Loosen adjusting nut and lock nut.
2. Pull outer cable while fully closing the throttle
valve.
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
s u r e t h a t t h e v a l v e l e v e r r e t u r n s u p t o t h e s t o p p e r
screw.

6A–51
ENGINE MECHANICAL
If it does not reach the stopper screw, repeat from
step 1.
130RW004
Legend
(1) Clearance
(2) Lock Nut
(3) Adjusting Nut

6A–61
ENGINE MECHANICAL
5. Install lower valve spring seat, valve spring and upper
valve spring seat then put split collars on the upper
spring seat, using the 5–8840–2446–0 valve spring
compressor and 5–8840–2547–0 valve spring
compressor adapter to install the split collars.
014RW042
6. Install tappet with shim.
7. Install camshaft assembly.
Refer to installation procedure for Camshaft in this
manual.
Valve Clearance Adjustments
NOTE: To adjust valve clearance, apply engine oil to the
cam as well as to the adjusting shim (2) with the cylinder
head built on the cylinder block, give a few turns to the
camshaft by means of timing pulley tightening bolt, and
measure valve clearance when the nose of cam is just
opposite to maximum cam lift (1) as shown in illistration
below.
014RW081
Legend
(1) Cam
(2) Shim
(3) Tappet
Valve Clearance Standard Value (cold)
Intake: 0.23 mm–0.33 mm
(0.0091 in–0.0130 in)
Exhaust: 0.25 mm–0.35 mm
(0.0098 in–0.0138 in)
Selection of Adjusting Shim
Shim to be selected = (Thickness of removed shim) +
(Valve clearance measurement – Standard valve)
Based on the above formula, the best suited shim should
be selected from 41 sorts of shim (differently thick at
0.02mm (0.0008 in) intervals from 2.40mm (0.0945 in)
through 3.2mm (0.1260 in) thick). Install the shim and
check valve clearance.