1998 OPEL FRONTERA balance shaft

6A – 52 ENGINE MECHANICAL
TIMING GEAR
REMOVAL
1. Loosen fixing bolt for generator and remove
generator assembly.
2. Remove fixing nuts, then remove cooling fan
assembly and fan pulley.
3. Remove crankshaft damper pulley.
4. Belt cover
1) Disconnect harness connector of CMP
(camshaft position) sensor.
2) Remove CMP sensor.
3) Remove belt cover.
5. Loosen belt tensioner to remove timing belt.
6. Remove camshaft pulley.
7. Remove high pressure oil pump pulley.
8. Remove front plate.
9. Remove vacuum pump.
10. Remove power steering pump.
11. Remove gear cover assembly.
12. Idle gear A.
1) Set two bolts to sub gear of idle gear A and turn
it to align the tooth of idle gear A then lock them
by bolt as show in the illustration.
2) Remove idle gear A fixing bolts.
3) Remove idle gear A.Legend
(1) Sub-Gear
(2) Main Gear
(3) Bar
(4) Locking Bolt
2
3
4
5 8
7
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020RW028
Legend
(1) Idle Gear A
(2) High Pressure Oil Pump Gear
(3) Vacuum Pump Gear
(4) Power Steering Pump Gear(5) Balance Gear LH
(6) Idle Gear C
(7) Crankshaft Gear
(8) Balance Gear RH
(9) Idle Gear B
4 1
2
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ENGINE MECHANICAL 6A – 53
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear A
(4) Idle Gear A Shaft
(5) Align Mark
(6) Crankshaft Gear
(7) O-Ring
13. Idle gear C
1) Use the special tool on idle gear C, turning the
sub gear to align the teeth, then set lock pin.
2) Remove idle gear C fixing bolt then remove the
idle gear C with flange.
Camshaft Gear Tool : 5-8840-2591-0
Legend
(1) Lock pin
(2) Camshaft Gear ToolLegend
(1) Bolt
(2) Retainer
(3) Idle Gear C
(4) Idle Gear C Shaft
(5) Align Mark
(6) Align Mark
(7) Idle Gear A
(8) Balance Shaft Gear LH
(9) Timing Mark
14. Idle gear B
1) Loosen idle gear B fixing bolt to remove idle
gear B with flange.
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear B
(4) Idle Gear B Shaft
(5) Align Mark
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4
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014R200007
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6A – 54 ENGINE MECHANICAL
15. High pressure oil pump
1) Remove oil pump gear fixing bolt then remove
oil pump.
Legend
(1) O-Ring
(2) High Pressure Oil Pump Gear
(3) Bolt
(4) Timing Mark
16. Remove balance shaft gear LH. and RH.
17. Remove crankshaft gear.
INSTALLATION
1. Crankshaft gear
1) Force key into the crankshaft and insert
crankshaft gear with the crankshaft gear key
groove set on the key.Legend
(1) Crankshaft Gear Installer
(2) Crankshaft Gear
2. Balance shaft gear
1) Install the balance shaft gear RH to balance
shaft, tighten center bolt to the specified torque.
Torque : 32 Nꞏm (3.2 kgꞏm/23 lb ft)
2) Install thrust plate for balance shaft LH before
installing the balance shaft gear LH.
Torque : 25 Nꞏm (2.5 kgꞏm/18 lb ft)
3) Install balance shaft gear LH to balance shaft,
tighten center bolt to the specified torque.
Torque : 32 Nꞏm (3.2 kgꞏm/23 lb ft)
Legend
(1) Center Bolt
(2) Plate
(3) Balance Shaft Gear RH
(4) Timing Mark
4
GEAR:O/PUMP
IDLE GEAR A
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040RW005
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ENGINE MECHANICAL 6A – 55
3. Idle gear A
1) Insert idle gear A shaft to align alignment mark
between idle gear A shaft and timing gear case.
2) Apply engine oil to the shaft surface.
3) Install the idle gear A to align the timing mark
with the crankshaft gear.
4) Install the flange, tighten bolts to the specified
torque.
Torque: 25 Nꞏm (2.5 kgꞏm/18 lb ft)
Legend
(1) Bolt
(2) Retainer
(3) Idle Gear A
(4) Idle Gear A Shaft
(5) Align Mark
(6) Crankshaft Gear
(7) O-Ring
NOTE: Conform not difference timing marks between
each others.
4. Idle gear C
1) Insert idle gear C shaft to align alignment mark
between idle gear C shaft and timing gear case.
2) Apply engine oil to the shaft surface.
3) Align timing mark on idle gear C with balance
shaft gear LH and idle gear A timing marks, then
insert idle gear C.
4) Set position of idle gear C flange with a dowel
pin, tighten bolt to the specified torque.
Torque: 25 Nꞏm (2.5 kgꞏm/18 lb ft)Legend
(1) Bolt
(2) Retainer
(3) Idle Gear C
(4) Idle Gear C Shaft
(5) Align Mark
(6) Align Mark
(7) Idle Gear A
(8) Balance Shaft Gear LH
(9) Timing Mark
5. Idle gear B
1) Insert idle gear B shaft to align alignment mark
between idle gear B shaft and timing gear case.
2) Apply engine oil to the shaft surface.
3) Align timing mark on idle gear B with balance
shaft gear RH and crankshaft gear timing marks,
then insert idle gear B.
4) Install flange and tighten the bolt to the specified
torque.
Torque: 51 Nꞏm (5.2 kgꞏm/38 lb ft)
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4
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6A – 72 ENGINE MECHANICAL
CRANK CASE
REMOVAL
1. Drain engine oil.
2. Remove transmission assembly.
3. Remove crankshaft damper pulley.
4. Remove timing belt cover, timing belt, pulley and
front plate.
5. Remove timing gear case cover.
6. Remove timing gears.
NOTE: Do not forget to set lock bolt for idle gear A and
lock pin for idle gear C.
7. Remove timing gear case.
8. Remove oil level gauge guide assembly.
9. Remove flywheel assembly.
CAUTION:
1) The flywheel heavy; be careful not to drop it.
2) Be careful no to let it slip because the hexagon
of the bolt is thin.10. Remove rear plate (for A/T) or flywheel housing (for
MT).
11. Remove retainer.
NOTE:
1) Be careful not to damage the oil seal; it can be
reused.
2) Inspect installation portion for distortion and flow on
the slinger; also inspect for flow on the oil seal lip.
3) If there is some flow oil seal/slinger, replace a set.
12. Remove bolts from thrust plate of balance shaft LH
then remove balance shaft.
13. Loosen crank case fixing bolts.
14. Use seal cutter to take off the liquid gasket.
Seal cutter: 5-8840-2153-0
15. Remove crank case assembly.
CAUTION:
Do not give shock to crank case for prevention take
off applied vibration insulation material on the
crank case.
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012RW029
Legend
(1) Crank Case
(2) Oil Pan
(3) Drain Plug

ENGINE MECHANICAL 6A – 73
INSTALLATION
1. Install relief valve (if it was removed).
Torque: 30 Nꞏm (3.1 kgꞏm / 22 lb ft)
2. Insert O-ring to strainer, install strainer and tighten
to specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
3. Apply liquid gasket (TB1207B or equivalent) to
surface of oil pan and tighten bolt to the specified
torque.
Torque: 19 Nꞏm (1.9 kgꞏm / 13.7 lb ft)
4. Apply engine oil to the balance shaft and insert it
into crank case.
NOTE:
Do not damage bearing when inserting the balance
shaft.
Make sure it rotates smoothly.
5. Tighten thrust plate of balance shaft LH.
Torque: 25 Nꞏm (2.5 kgꞏm / 18 lb ft)
6. Set O-ring port of oil gallery on the cylinder block.
7. Apply liquid gasket (TB1207C or equivalent) to
crankcase fixing surface then tighten bolts to the
specified torque.
Torque: 25 Nꞏm (2.5 kgꞏm / 18 lb ft)
NOTE: Make sure there is no oil, dust or scratches on
the surface coated with liquid gasket and mount within
five minutes of gasket application.8. Install retainer with oil seal.
9. Install rear plate (A/T) or flywheel housing (MT),
tighten bolt to the specified torque.
Torque: 97 Nꞏm 9.9 kgꞏm / 72 lb ft)
10. Install flywheel assembly with applied engine oil to
the bolt, tighten the bolt using angular tightening
method.
1st step: 59 Nꞏm (6.0 kgꞏm / 43 lb ft)
2nd step: 60° to 90°
11. Install oil level gauge guide assembly.
12. Install timing gear case.
Torque: 20 Nꞏm (2.5 kgꞏm / 14.5 lb ft)
13. Install timing gears
Refer to “Timing Gear” in this manual.
14. Remove lock bolt from idle gear A and remove lock
pin from idle gear C.
15. Install timing gear case cover.
Torque: 20 Nꞏm (2.5 kgꞏm / 14.5 lb ft)
16. Install oil pump pulley.
Torque: 10 Nꞏm (1.0 kgꞏm / 7.2 lb ft)
17. Install camshaft pulley tighten bolt with angular
tightening method.
To r q u e :
1st step: 40 Nꞏm (4.0 kgꞏm / 29 lb ft)
2nd step: 75°
18. Install timing belt and belt tensioner.
Refer to “Timing Gear” in this manual.
19. Install crankshaft damper pulley.
Torque: 220 Nꞏm (22 kgꞏm / 159 lb ft)
20. Fill engine oil.
2
2~2.5mm
2~2.5mm
Apply liquid gasket around inside
of the bolt hole
Bolt hole
Inside
Outside
F06HX00001
2
2~2.5mm
2~2.5mm
Apply liquid gasket around inside
of the bolt hole
Bolt hole
Inside
Outside
F06HX00001

6A – 74 ENGINE MECHANICAL
CRANKSHAFT
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012RW023
Legend
(1) Cylinder Head
(2) Cylinder Head Gasket
(3) Flywheel
(4) Cylinder Block Rear Plate (for A/T) or Flywheel
Housing (for M/T)
(5) Crankshaft Rear Oil Seal
(6) Retainer
(7) Timing Gear Case
(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

6A – 92 ENGINE MECHANICAL
CYLINDER BLOCK
1
15
14
13
8
11
16
17
10
9
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3
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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