Opel Frontera UE. Manual - part 159

6A–60

ENGINE MECHANICAL (X22SE 2.2L)

Reassembly

1. Install connecting rod

2. Install piston

3. Install piston pin

• Apply a thin coat of engine oil to the piston pin. 

Try to insert the piston pin into the piston pin hole 
with normal finger pressure.

NOTE:  When changing piston / connecting rod 
combinations, do not change the piston / piston pin 
combination and do not reuse the old piston pin.

• Attach the piston to the connecting rod with the 

piston front mark and the connecting rod front 
mark on the same side.

• Heat the connecting rod small end to a suitable 

temperature to ensure smooth installation.

4. Install piston ring with the piston ring expander.

• New piston rings with “Top" uppermost — use 

commercially available pliers.

• Position ring gaps:

1 — Compression rings 180

°

to each other as 

illustrated.
2 — Offset oil control rings 25 to 50 mm/1 to 2 in. 
from gap of second compression ring.

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• After installation, apply engine oil to the entire 

circumference of the piston rings. Check to see 
that all the rings rotate smoothly.

5. Install piston and connecting rod assembly.

• Insert the bearings into the connecting rods and 

caps. Apply new engine oil to the bearing faces 
and nuts.

• Tighten the connecting rod cap nuts in 3 steps:

1st step : 35 N·m (3.6Kg·m/26lbft)

2nd step: 45

°°°°

3rd step: 15

°°°°

Crankshaft grinding dimensions

mm  (in)

(continued)

Production and Service

Con–rod bearing journal dia.

Standard size

(no color code)

48.970 to 48.988 (1.9098–1.9105)

Undersize 0.25 (0.0097)

blue

48.720 to 48.738 (1.9001–1.9008)

Undersize 0.5 (0.0195)

white

48.470 to 48.488 (1.8903–1.891)

Con–rod bearing journal width

Standard size

(no color code)

26.460 to 26.580 (1.0319–1.036)

Undersize 0.25 (0.0097)

blue

26.460 to 26.580 (1.0319–1.036)

Undersize 0.5 (0.0195)

white

26.460 to 26.580 (1.0319–1.036)

Con–rod width

26.338 to 26.390 (1.0271–1.0292)

ENGINE MECHANICAL (X22SE 2.2L)

6A–61

NOTE:  Do not apply engine oil to the bearing back 
faces.

6. Oil gallery, refer to “Crankshaft and Main Bearing" in 

this manual.

7. Oil strainer and O-ring.

8. Install balance unit assembly, refer to “Balance Unit 

Assembly: in this manual.

9. Install oil pan support assembly, refer to “Oil Pan 

and Oil Pan Support" in this manual.

10. Install cylinder head gasket.

11. Install cylinder head assembly.

• Refer to “Cylinder Head" in this manual.

Cylinder Block

Cylinder Block and Associated Parts

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Legend

EndOFCallout

(1) Cylinder Head Assembly
(2) Oil Pump Assembly
(3) Oil Pan
(4) Oil Pan Support
(5) Oil Strainer

(6) Balance Unit Assembly
(7) Piston and Connecting Rod Assembly
(8) Main Bearing Cap
(9) Crankshaft

(10) Cylinder Block

6A–62

ENGINE MECHANICAL (X22SE 2.2L)

Disassembly

1. Remove cylinder head assembly.

2. Remove cylinder head gasket.

3. Remove oil pan assembly.

4. Remove oil pan support.

5. Remove oil strainer.

6. Remove oil pump assembly.

7. Remove balance unit assembly.

8. Remove piston and connecting rod assembly.

9. Remove flywheel.

10. Remove rear oil seal retainer assembly.

11. Remove main bearing cap.

12. Remove crankshaft.

13. 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 : 0.40 mm (0.0156 in)

Maximum repairable limit: 0.40 mm (0.0156 in)

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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.
If the measurement exceeds the specified limit, the 
cylinder block must be replaced.

Diameter

Grade 1 : 85.975 mm–85.985 mm

(3.3530 in–3.3534 in)

Grade 2 : 85.985 mm–86.025 mm

(3.3534 in–3.3550 in)

Oversize : 0.5 mm (0.0195 in)

NOTE:  For information on piston diameter, please refer 
to the section “Inspection of the Piston and Connecting 
Rod Assembly" in this manual.

ENGINE MECHANICAL (X22SE 2.2L)

6A–63

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 positioned correctly.

• Apply new engine oil to the upper and lower main 

bearing faces.

NOTE:  Do not apply engine oil to the bearing back 
faces.

• Carefully mount the crankshaft.

• Apply engine oil to the thrust washer.

3. Install rear oil seal.

• Coat lip of seal rings thinly with protective grease.

• Install seal ring into cylinder block, use 5–8840–

2660–0 (1) and 5–8840–2597–0 (2).

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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. Use stopper (5–8840–2661–0) to hold the 

crankshaft.
Prevent from rotating.
Tighten the flywheel bolts in 3 steps:

1st step: 65 N·m (6.6Kg·m/48lbft)

2nd step: 30

°

3rd step: 15

°

NOTE:  Do not reuse the bolt.

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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.

• Position ring gaps:

1 — Compression rings 180

°

 to each other as 

illustrated (A).
2 — Offset oil control rings 25 to 50 mm/1 to 2 in. 
from gap of second compression ring (B).

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6. Install balance unit assembly and tighten the bolts in 

2 steps in the order shown:

1st step : 20 N·m (2.0Kg·m/14lbft)

2nd step : 45

°°°°

7. Install oil pump assembly, refer to “Oil Pump" in this 

manual.

8. Install oil strainer.