1998 OPEL FRONTERA torque

6A–65
ENGINE MECHANICAL
Runout
Limit : 0.1 mm (0.0039 in)
014RW044
4. Measure the camshaft journal oil clearance.
1. Measure the camshaft bracket housing inside
diameter.
NOTE: Tighten camshaft bracket (2) to specified torque
before measuring the camshaft bracket inside diameter.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
014RW031
2. Subtract the camshaft outside diameter from the
camshaft bracket housing inside diameter.
Oil Clearance
Standard : 0.027 mm–0.078 mm
(0.0011 in–0.0031 in)
Limit : 0.11 mm (0.0043 in)
014RW037
5. Replace the cylinder head and/or camshaft if the
measured oil clearance exceeds the specified limit.
1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
2. Install camshaft assembly and camshaft brackets
(2), tighten twenty bolts (1) on one side bank to
the specified torque.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)
014RW031
3. Measure the camshaft thrust clearance with a dial
indicator. Replace the camshaft and/or the
cylinder head if the camshaft thrust clearance
exceeds the specified limit.
Camshaft thrust Clearance
Standard : 0.03 mm–0.08 mm
(0.0012 in.–0.0031 in.)

6A–66
ENGINE MECHANICAL
Limit : 0.12 mm (0.0047 mm)
014RW035
Reassembly
1. Install camshaft drive gear assembly and tighten
three bolts to specified torque.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)
2. Tighten sub gear setting bolt.
1. Use 5–8840–2443–0 to turn sub gear to right
direction until the M5 bolt hole aligns between
camshaft driven gear and sub gear.
2. Tighten M5 bolt suitable torque for prevent
moving the sub gear.
014RW041
3. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the specified
torque.
1. Apply engine oil to camshaft journal and bearing
surface of camshaft bracket.2. Align timing mark on intake camshaft (one dot for
right bank, two dots for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).
014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discerning Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust

6A–67
ENGINE MECHANICAL
014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin
014RW024
Legend
(1) Right Bank
(2) Left Bank(3) Alignment Mark on Camshaft Drive Gear
(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer
3. Tighten twenty bolts in numerical order on one
side bank as shown in the illustration.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)

6A–68
ENGINE MECHANICAL
014RW031
4. If the oil seal requires replacement, use the
5–8840–2445–0 to install the oil seal.
014RW034
5. Tighten bolt for camshaft drive gear pulley to the
specified torque using the 5–8840–2447–0 universal
holder.
Torque: 98 Nꞏm (10.0 Kgꞏm/72 lb ft)
014RW060

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–71
ENGINE MECHANICAL
NOTE: Do not apply engine oil to the crank case side
bolts.
Main bearing cap bolts.
Torque: 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
Oil gallery fixing bolts.
Torque:
1st step: 29 Nꞏm (3.0 Kgꞏm/21 lb ft)
2nd step 55
65
Crank case side bolts
Torque : 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
NOTE: Do not allow the crankshaft to rotate.
015RS006
10. Remove the main bearing caps in the sequence
shown in the illustration.
015RS004
11. Measure the plastigage width and determine the oil
clearance. If the oil clearance exceeds the specified
limit, replace the main bearings as a set and/or
replace the crankshaft.
Standard : 0.019 mm–0.043 mm
(0.0007 in–0.0017 in)Limit : 0.08 mm (0.0031 in)
015RS008
12. Clean the plastigage from the bearings and the
crankshaft.
Remove the crankshaft and the bearings.
Crankshaft (12) Inspection
Inspect the surface of the crankshaft journal and crank
pins for excessive wear and damage. Inspect the oil seal
fitting surfaces for excessive wear and damage. Inspect
the oil ports for obstructions.
Inspection and Repair
1. Carefully set the crankshaft on the V–blocks. Slowly
rotate the crankshaft and measure the runout. If the
crankshaft runout exceeds the specified limit, the
crankshaft must be replaced.
Runout : 0.04 mm (0.0016 in)
015RS007

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–75
ENGINE MECHANICAL
4. Piston and connecting rod assembly (8)
Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins.
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 must be facing the front of the engine.
Match the numbered caps with the numbers on the
connecting rods. Align the punched marks on the
connecting rods and caps.
Apply engine oil to the threads and seating faces of
the nuts.
Tighten the nuts.
Torque: 54 Nꞏm (5.5 Kgꞏm/40 lb ft)
After tightening the cap nuts, check to see that the
crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back faces.
015RS020
5. Install oil gallery (7) 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
051RS009
6. Cylinder block side bolts (6)
Tighten all the bolts to the specified torque in the
order shown.
NOTE: Do not apply engine oil to the crank case side
bolts.
Torque: 39 Nꞏm (4.0 Kgꞏm/29 lb ft)