1998 OPEL FRONTERA balance shaft

4C–37 DRIVE SHAFT SYSTEM
Front Propeller Shaft
General Description
Since the propeller shaft is balanced carefully, welding or
any other modifications are not permitted.Alignment marks should be applied to each propeller
shaft before removal.
401RW002

4C–48
DRIVE SHAFT SYSTEM
Rear Propeller Shaft
General Description
Since the propeller shaft is balanced carefully, welding or
any other modifications are not permitted.Alignment marks should be applied to each propeller
shaft before removal.
401RW003
Rear Propeller Shaft and Associated Parts
401RW059
Legend
(1) Bolt, Nut and Washer(2) Rear Propeller Shaft
(3) Bolt, Nut and Washer

4D1–38
TRANSFER CASE (STANDARD TYPE)
3. Install the sub–gear (23) to the counter gear (22).
4. Install the belleville spring (24).
5. Install the spacer (25) and put the snap ring (29) on
the sub–gear (23).
6. Install the ball bearing (26), using a bench press.
7. Select a snap ring that will allow the minimum axial
play.
Clearance : 0–0.1 mm (0–0.004 in)
Snap ring availability:
ThicknessColor–coding
1.50 mm (0.059 in)White
1.55 mm (0.061 in)Yellow
1.60 mm (0.063 in)Blue
8. Use a pair of snap ring pliers to install the snap ring
(27) to the counter gear (22).
226RS170
226RS021
Sub–Gear (anti–lash plate) Preload
1. Hook a length of piano wire (4) over one of the
sub–gear (5) teeth.
2. Attach the other end of the piano wire (4) to a
spring balancer.
3. Measure the sub–gear preload.
Preload : 59–98 N (6.0–10kg/13–22 lb)
226RS075
9. Install ball bearing (21), using a bench press.
10. Install snap ring (20).
11. Install the counter gear assembly (28) to the transfer
case (1).
12. Use a pair of snap ring pliers to install the snap ring
(29) to the transfer case (1).
NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.
13. Use a bench press to install the ball bearing (4) to the
front output shaft (5).
262RS012

TRANSFER CASE (STANDARD TYPE)
4D1–41
27. Use a pair of snap ring pliers to install the snap ring
(19) to the output shaft (5).
Sub gear (anti lash plate) preload (M/T)
1. Hook a length of piano wire (4) over one of the
sub–gear (5) teeth.
2. Attach the other end of the piano wire to (4) a
spring balancer.
3. Measure the sub–gear preload.
Preload: 59–98 N (6.0–10.0kg/13–22 lb)
(M/T)
226RS075
28. Install front output gear assembly (3) to the transfer
case (1).
29. Use a pair of snap ring pliers to install the snap ring (2)
to the transfer case (1).
NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.
30. Use a bench press to install the ball bearing (32) to the
input shaft (31).
265RS003
31. Install the plate (34), ball (35), and bearing collar (36)
and place the snap ring (33).
32. Install the needle bearing (37) and input gear (38).
33. The clutch hub face (with the heavy boss) must be
facing the transfer input gear side (7).
226RW136
34. Install the high–low clutch hub and sleeve (39), using
a bench press.
35. Install the input shaft assembly (30) to the transfer
case (1).
36. Install the snap ring (33) to the transfer case (1).
NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.
37. Install the front companion flange temporarily and use
the flange holder 5–8840–0133–0 (J–8614–11) and
lock nut wrench 5–8840–2156–0 (J–37219) to install
the lock nut (40).
Torque: 137 Nꞏm (14.0kgꞏm/101 lb ft)
226RW190
38. Use the punch to stake the lock nut (40) at one spot.

6A–72
ENGINE MECHANICAL
2. Measure the diameter and the uneven wear of main
journal and crank pin. If the crankshaft wear exceeds
the specified limit, crankshaft must be replaced.
Main journal diameter : 63.918 mm–63.933 mm
(2.5165 in–2.5170 in)
Crank pin diameter : 53.922 mm–53.937 mm
(2.1229 in.–2.1235 in.)
Uneven wear limit : 0.005 mm (0.0002 in)
015RS009
Crankshaft Bearing Selection
When installing new crankshaft bearings or replacing
bearings, refer to the selection table below. Select and
install the new crankshaft bearings, paying close
attention to the cylinder block journal hole.
1. Diameter size mark (1) and the crankshaft journal.
015RS010
2. Diameter size mark (1).
The diameter size marks are stamped on the No.1
crankshaft balancer as shown in the illustration.
015RS011
NOTE: Take care to ensure the bearings are positioned
correctly.
015RS012
Legend
(1) Number 1 and 4 main bearing upper and lower
(2) Number 2 and 3 main bearing upper
(3) Number 2 and 3 main bearing lower

6A – 48 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
6 91
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
3
014RW177

ENGINE MECHANICAL 6A – 49
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
3
6
5
4
3
2
17
014RW176
1
2
014RW181
12345 56
6 8
8 37
7
9
99
014RW175
4
3
5
5
4
3
2
1
014RW174

6A – 50 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
(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
1
2
3
040RW005
12
2
012RW066
3
4 2
1
014RW173