1998 OPEL FRONTERA wheel bolt torque

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–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–49
ENGINE MECHANICAL
If the engine is assembled in the condition that the
dowels have not been mounted in the specified posi-
tions, the transmission may be damaged the trans-
mission.
012RS009
1. Install engine assembly. Tighten engine mount fixing
bolts to frame to the specified torque.
Torque: 41 Nꞏm (4.2 Kgꞏm/30 lb ft)
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to Transmission
section in this manual.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two (each
bank) rear exhaust flange nuts then tighten three stud
nuts (each bank) between exhaust manifold and
exhaust pipe, finally tighten rear side nuts to the
specified torque.
Torque:
Nuts: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
Stud nuts: 67 Nꞏm (6.8 Kgꞏm/49 lb ft)
150RW061
Legend
(1) Exhaust Front Pipe RH
(2) O
2 Sensor (for IGM)
150RW062
Legend
(1) Exhaust Front Pipe LH
7. Reconnect O2 sensor connector.
8. 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.

6A–70
ENGINE MECHANICAL
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8).
Refer to “Piston, Piston Ring and Connecting Rod” in
this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).
Inspection and Repair
1. Crankshaft
Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance. If the thrust
clearance exceeds the specified limit, replace the
thrust bearings as a set.
Thrust Clearance
Standard : 0.06 mm–0.24 mm
(0.0024 in–0.0094 in)
Limit : 0.30 mm (0.0118 in)
015RS003
Main Bearing Clearance
1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.
Arrange the removed main bearing caps in the
cylinder number order.
Remove the main bearings.
015RS004
3. Remove the crankshaft.
Remove the main bearings.
4. Clean the upper and lower bearings as well as the
crankshaft main journal.
5. Check the bearings for damage or excessive wear.
The bearings must be replaced as a set if damage or
excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to their
original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8. Apply plastigage to the crankshaft journal unit as
shown in the illustration.
NOTE: Do not set the plastigage on the oil hole.
015RS005
9. Install main bearing caps, oil gallery and crank case
bolts in the order shown, and tighten each bolt to the
specified torque.

6A–74
ENGINE MECHANICAL
015RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
Apply engine oil to the oil seal lip.
Align the cylinder block dowel pin holes with the rear
retainer dowel pins.
Tighten the rear retainer fixing bolts. New bolts
should be used when installing rear retainer.
Torque: 18 Nꞏm (1.8 Kgꞏm/13 lb ft)
NOTE: Be very careful not to disengage the oil seal garter
spring during installation of the rear retainer.
If the seal was removed from retainer for
replacement, apply engine oil to the oil seal lip and
install the oil seal using 5–8840–2286–0 oil seal
installer.
015RW001
015RS017
3. Flywheel (9)
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and flywheel
mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
4. Hold the crankshaft to prevent from rotating then
install the bolts in the order shown to the specified
torque.
Torque: 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
NOTE: Do not reuse the bolt and do not apply oil or thread
lock to the bolt.
015RS018

6A–88
ENGINE MECHANICAL
015RW001
4. Install flywheel
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and flywheel
mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
4. Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown.
Torque: 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
015RS018
5. Install piston and connecting rod assembly.
Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins.
NOTE: Do not apply engine oil to the bearing back faces.
Check to see that the piston ring end gaps are
correctly positioned.
015RS019
Legend
(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark
Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
The front marks (1) must be facing the front of the
engine.
015RS020
6. Install oil gallery and tighten the bolts in 2 steps in the
order shown.
1st step : 29 Nꞏm (3.0 Kgꞏm/22 lb ft)
2nd step : 55
65

6C–7
ENGINE FUEL
Fuel Pump Relay
General Description
In order to control the FP operation, the FP relay is
provided. When the starter switch is turned to “ON”
position, the FP relay operates the FP for 2 seconds.When it is turned to “START” position, the Power Train
Control Module (PCM) receives the reference pulse from
the Ignition Control Module and it operates the relay,
again causing the FP to feed fuel.
Fuel Tank
Fuel Tank and Associated Parts
035RW048
Legend
(1) Fender Liner
(2) Fuel Filler Hose and Air Breather Hose and
Evapo Hose
(3) Undercover(4) Fuel Tank Wiring Connector
(5) Evapo Fuel Hose
(6) Fuel Feed Tube and Fuel Return
Tube/Quick–Connect Fittings
(7) Fuel Tank
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission”.
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.3. Drain fuel.
Tighten drain plug to the specified torque after
draining fuel.
Torque: 20 Nꞏm (2.0 Kgꞏm/14 lb ft) — M8
4. Remove fender liner (1) of wheel well on rear right
side.
5. Fuel filler hose, air breather hose and evapo hose (2).
6. Remove undercover fixing bolts on both sides and
remove under cover(3).