1998 OPEL FRONTERA Workshop Manual

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Page 4577 of 6000

OPEL FRONTERA 1998 Workshop Manual 6A–81
ENGINE MECHANICAL
Connecting Rods (11)
1. Check the connecting rod alignment If either the bend
or the twist exceeds the specified limit, the connecting
rod must be replaced.
Bend per 100 mm (

Page 4578 of 6000

OPEL FRONTERA 1998 Workshop Manual 6A–82
ENGINE MECHANICAL
4. Reinstall the rod caps (12) to their original
positions.
Tighten the rod cap nuts.
Torque: 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
NOTE: Do not allow the crankshaft to rotat

Page 4579 of 6000

OPEL FRONTERA 1998 Workshop Manual 6A–83
ENGINE MECHANICAL
Attach the piston to the connecting rod with the
piston front mark and the connecting rod front mark
on the same side.
015RS036
With 5–8840–0551–0 Piston pin se

Page 4580 of 6000

OPEL FRONTERA 1998 Workshop Manual 6A–84
ENGINE MECHANICAL
Tighten the connecting rod cap nuts
Torque : 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
NOTE: Do not apply engine oil to the bearing back faces.
6. Oil gallery, refer to “Crankshaft an

Page 4581 of 6000

OPEL FRONTERA 1998 Workshop Manual 6A–85
ENGINE MECHANICAL
Cylinder Block
Cylinder Block and Associated Parts
012RW010
Legend
(1) Cylinder Head Assembly
(2) Cylinder Head Gasket
(3) Crankcase with Oil Pan
(4) Oil Pipe and O-Ring
(5)

Page 4582 of 6000

OPEL FRONTERA 1998 Workshop Manual 6A–86
ENGINE MECHANICAL
11. Remove rear oil seal retainer assembly.
12. Remove main bearing cap.
13. Remove crankshaft.
14. Remove cylinder block.
Inspection and Repair
1. Remove the cylinder hea

6A–86
ENGINE MECHANICAL
11. Remove rear oil seal retainer assembly.
12. Remove main bearing cap.
13. Remove crankshaft.
14. Remove cylinder block.
Inspection and Repair
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 the oil pump, rear oil seal retainer,
and crankcase assembly installation surface seal.
3. Wipe the cylinder block clean.
4. Visually inspect the cylinder block. If necessary, use a
flaw detector to perform a dye penetrate and
hydraulic (or air pressure) test. If cracking or other
damage is discovered, the cylinder block must either
be repaired or replaced.
Flatness
1. Using a straight–edge and feeler gauge, check that
the upper surface of the cylinder block is not warped.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
2. The cylinder block must be reground or replaced if the
warpage exceeds the limit.
Warpage
Limit : 0.15 mm (0.0059 in)
Maximum repairable limit: 0.15 mm (0.0059 in)
012RS004
Cylinder Bore
Use a cylinder gauge to measure the cylinder bore
diameter in both the axial and thrust directions. Each
measurement should be made at six points.CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
Cylinder Bore Inside Diameter
Limit : 93.530 (3.6823)
If the measurement exceed the specified limit, the
cylinder block must be replaced.
Diameter
Grade A : 93.400 mm–93.410 mm
(3.6772 in–3.6776 in)
Grade B : 93.411 mm–93.420 mm
(3.6776 in–3.6779 in)
Grade C : 93.421 mm–93.430 mm
(3.6780 in–3.6783 in)
012RS005
NOTE: For information on piston diameter, please refer
to the section ”Inspection of the Piston and Connecting
Rod Assembly” in this manual.
The ”Grade” mark (1) is stamped at the position
illustrated.

Page 4583 of 6000

OPEL FRONTERA 1998 Workshop Manual 6A–87
ENGINE MECHANICAL
012RS006
Reassembly
1. Install cylinder block.
2. Install crankshaft.
Install the main bearings to the cylinder block and
the main bearing caps.
Be sure that they are positio

Page 4584 of 6000

OPEL FRONTERA 1998 Workshop Manual 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.

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