Opel Frontera UE. Manual - part 276

6A–68

ENGINE MECHANICAL (6VD1 3.2L)

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–69

ENGINE MECHANICAL (6VD1 3.2L)

NOTE: Do not apply engine oil to the crank case side
bolts.

Main bearing cap bolts.
Torque: 39 N·m (4.0 Kg·m/29 lb ft)

Oil gallery fixing bolts.
Torque:
1st step: 29 N·m (3.0 Kg·m/21 lb ft)
2nd step 55

°

∼

 65

°

Crank case side bolts
Torque : 39 N·m (4.0 Kg·m/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 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–70

ENGINE MECHANICAL (6VD1 3.2L)

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–71

ENGINE MECHANICAL (6VD1 3.2L)

1 Size

Mark

Main Bearing

Bore Diameter

Crank Shaft Main

Journal Diameter

2 Size

Mark

Crank

Shaft

Bearing

Size Mark

(Upper

Side)

Crank

Shaft

Bearing

Size Mark

(Lower

Side)

Oil Clearance

(Reference)

1

68.994-69.000

63.918-63.925

(2.5165-2.5167)

2

Blue

Blue

0.030-0.049

(0.0012-0.0019)

1

(2.7163-2.7165)

63.926-63.933

(2.5168-2.5170)

1

Brown

Brown

0.028-0.047

(0.0011-0.0019)

2

68.987-68.993

63.918-63.925

(2.5165-2.5167)

2

Brown

Brown

0.029-0.048

(0.0011-0.0019)

2

(2.7160-2.7163)

63.926-63.933

(2.5168-2.5170)

1

Green

Green

0.027-0.046

(0.0011-0.0018)

3

68.980-68.986

63.918-63.925

(2.5165-2.5167)

2

Green

Green

0.028-0.047

(0.0011-0.0019)

3

(2.7157-2.7160)

63.926-63.933

(2.5168-2.5170)

1

Yellow

Yellow

0.026-0.045

(0.0010-0.0018)

Reassembly

1. Crankshaft

D

Install the main bearings to the cylinder block and
the main bearing caps.

D

Be sure that they are positioned correctly.

D

Apply new engine oil to the upper and lower main
bearing faces.

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

015RS012

D

Carefully mount the crankshaft.

D

Apply engine oil to the thrust washer.

D

Assemble the thrust washer to the No.3 bearing
journal. The oil grooves must face the crankshaft.

015RS013

2. Rear oil seal

D

Remove the oil from the cylinder block and the
retainer mounting surface.

D

Apply sealant (TB–1207B or equivalent) to the
retainer mounting surface, following the pattern
shown in the illustration.
The retainer must be installed within 5 minutes after
sealant application befor the sealant hardens.