Opel Frontera UE. Manual - part 748

ENGINE MECHANICAL (X22SE 2.2L)

6A–1

ENGINE

CONTENTS

Engine Mechanical.......................................... 6A -1
Engine Cooling ................................................ 6B -1
Engine Fuel ..................................................... 6C -1
Engine Electrical ............................................. 6D1 -1
Ignition System................................................ 6D2 -1
Starting and Charging System ........................ 6D3 -1

Driveability and Emissions .............................. 6E1 -1
Engine Exhaust ............................................... 6F -1
Engine Lubrication .......................................... 6G -1
Engine Speed Control System ........................ 6H -1

Induction .......................................................... 6J -1

ENGINE MECHANICAL (X22SE 2.2L)

CONTENTS

Service Precaution......................................... 6A - 2
General Description ....................................... 6A - 2

Engine Diagnosis........................................ 6A - 4

Cylinder Head Cover..................................... 6A - 17

Removal ..................................................... 6A - 17
Installation .................................................. 6A - 18

Exhaust Manifold........................................... 6A - 19

Removal ..................................................... 6A - 19
Installation .................................................. 6A - 19

Crankshaft Pulley .......................................... 6A - 20

Removal ..................................................... 6A - 20
Installation .................................................. 6A - 20

Intake Manifold .............................................. 6A - 21

Removal ..................................................... 6A - 21
Installation .................................................. 6A - 22

Cylinder Head Assembly............................... 6A - 24

Removal ..................................................... 6A - 24
Installation .................................................. 6A - 26

Timing Belt .................................................... 6A - 32

Removal ..................................................... 6A - 32
Installation .................................................. 6A - 33

Camshaft....................................................... 6A - 36

Removal ..................................................... 6A - 36
Installation .................................................. 6A - 37

Engine Assembly .......................................... 6A - 39

Engine and Associated Parts ..................... 6A - 39
Removal ..................................................... 6A - 39
Installation .................................................. 6A - 41

Cylinder Head ............................................... 6A - 43

Cylinder Head and Associated Parts .......... 6A - 43
Disassembly ............................................... 6A - 43
Inspection and Repair................................. 6A - 44
Reassembly ................................................ 6A - 45

Valve Spring, Valve, Valve Guide ................. 6A - 46

Valve Spring, Valve, Valve Guide and 

Associated Parts ................................... 6A - 46

Disassembly ............................................... 6A - 47
Inspection and Repair................................. 6A - 47
Reassembly ................................................ 6A - 48

Camshaft ....................................................... 6A - 49

Camshaft and Associated Parts ................. 6A - 49
Disassembly ............................................... 6A - 49
Reassembly ................................................ 6A - 50

Crankshaft ..................................................... 6A - 51

Crankshaft and Associated Parts ............... 6A - 51
Disassembly ............................................... 6A - 51
Inspection and Repair................................. 6A - 52
Inspection and Repair................................. 6A - 53
Reassembly ................................................ 6A - 54

Piston and Connecting Rod .......................... 6A - 57

Piston, Connecting Rod and 

Associate Parts ..................................... 6A - 57

Disassembly ............................................... 6A - 57
Inspection and Repair................................. 6A - 58
Reassembly ................................................ 6A - 60

Cylinder Block ............................................... 6A - 61

Cylinder Block and Associated Parts.......... 6A - 61
Disassembly ............................................... 6A - 62
Inspection and Repair................................. 6A - 62
Reassembly ................................................ 6A - 63

Cylinder Head Cover ..................................... 6A - 64

Cylinder Head Cover and 

Associated parts.................................... 6A - 64

Removal...................................................... 6A - 65
Installation................................................... 6A - 65

Balance Unit Assembly ................................. 6A - 67

Balance Unit Assembly Associated Parts... 6A - 67
Disassembly ............................................... 6A - 68
Adjustment.................................................. 6A - 68
Reassembly ................................................ 6A - 70

Main Data and Specifications ........................ 6A - 72
Special Tools ................................................. 6A - 77

SECTION

6A–2

ENGINE MECHANICAL (X22SE 2.2L)

Service Precaution

WARNING:  THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO  THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON  OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR  THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS  COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.

CAUTION:  Always use the correct fastener in the
proper location. When you replace a fastener,  use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal.  ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use  supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally,  such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners,  use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage  to parts
and systems.

General Description

Engine Cleanliness And Care

An automobile engine is a combination of many 
machined, honed, polished and lapped surfaces with 
tolerances that are measured in the thousandths of a 
millimeter (ten thousandths of an inch). Accordingly, 
when any internal engine parts are serviced, care and 
cleanliness are important. Throughout this section, it 
should be understood that proper cleaning and 
protection of machined surfaces and friction areas is 
part of the repair procedure. This is considered 
standard shop practice even if not specifically stated.

• A liberal coating of engine oil should be applied to all 

friction areas during assembly to protect and 
lubricate the surfaces on initial operation.

• Whenever valve train components, pistons, piston 

rings, connecting rods, rod bearings, and crankshaft 
journal bearings are removed for service, they should 
be retained in order.

• At the time of installation, they should be installed in 

the same locations and with the same mating 
surfaces as when removed.

• Battery cables should be disconnected before any 

major work is performed on the engine. Failure to 
disconnect cables may result in damage to wire 

harness or other electrical parts.

• The four cylinders of this engine are identified by 

numbers; cylinders 1, 2, 3 and 4, as counted from 
crankshaft pulley.

General Information on Engine Service

The following information on engine service should be 
noted carefully, as it is important in preventing damage 
and contributing to reliable engine performance:

• When raising or supporting the engine for any 

reason, do not use a jack under the oil pan. Due to 
the small clearance between the oil pan and the oil 
pump strainer, jacking against the oil pan may cause 
damage to the oil pick up unit.

• The 12–volt electrical system is capable of damaging 

circuits. When performing any work where electrical 
terminals could possibly be grounded, the ground 
cable of the battery should be disconnected at the 
battery.

• Any time the intake air duct or air cleaner is removed, 

the intake opening should be covered. This will 
protect against accidental entrance of foreign 
material into the cylinder which could cause 
extensive damage when the engine is started.

Cylinder Block

The cylinder block is made of cast iron. The crankshaft 
is supported by five bearings. The bearing cap is made 
of nodular cast iron.

Cylinder Head

The cylinder head is made of aluminum alloy casting 
with a spark plug in the center.

Valve Train

Valve system is direct–acting invertered bucket tappet.
The valves clearance adjustment are hydraulic.
Hydraulic valve lash adjustment, no adjustment 
necessary.

Intake Manifold

The intake manifold is made of aluminum alloy.

Exhaust Manifold

The exhaust manifold is made of high Si–Mo nodular 
iron.

Pistons and Connecting Rods

Aluminum pistons are used after selecting the grade 
that meets the cylinder bore diameter. Each piston has 
two compression rings and one oil ring. The piston pin is 
made of case–harded steel. The connecting rods are 
made of cast iron. The connecting rod bearings are 
made of steel backed with babbitt metal.

ENGINE MECHANICAL (X22SE 2.2L)

6A–3

Crankshaft and Bearings

The crankshaft is made of nodular cast iron. Pins and 
journals are graded for correct size selection for their 
bearing.

Balance Shaft

Type is lanchester (twin counter–rotating shafts). The 
balance shafts are made of cast iron and gears are hard 
faced. The housing is made of cast iron. Backlash 
adjustment method is shim–balancer housing to block 
(selective fit).

6A–4

ENGINE MECHANICAL (X22SE 2.2L)

Engine Diagnosis

Hard Starting

1. Starting Motor Does Not Turn Over

Trouble Shooting Procedure

Turn on headlights and starter switch.

2. Ignition Trouble — Starting Motor Turns Over But 
Engine Does Not Start

Spark Test

Disconnect a high tension cable from any spark plug. 
Connect the spark plug tester J–26792 (ST–125), crank 

the engine, and check if a spark is generated in the 
spark plug tester.  Before cranking the engine, make 
sure that the spark plug tester is properly grounded. To 
avoid electrical shock, do not touch the high tension 
cable while the engine is running.

3. Trouble In Fuel System

Condition

Possible cause

Correction

Headlights go out or dim 
considerably

Battery run down or under charged

Recharge or replace battery

Terminals poorly connected

Clean battery posts and terminals 
and connect properly

Starting motor coil circuit shorted

Overhaul or replace

Starting motor defective

Overhaul or replace

Condition

Possible cause

Correction

Spark jumps across gap

Spark plug defective

Clean, adjust spark gap or replace

Ignition timing incorrect

Refer to Ignition System

Fuel not reaching fuel injector(s) or 
engine

Refer to item 3 (Trouble in fuel 
system)

Valve timing incorrect

Adjust

Engine lacks compression

Refer to item 4 (Engine lacks 
compression)

No sparking takes place

Ignition coil disconnected or broken

Connect properly or replace

Electronic Ignition System with 
module

Replace

Poor connections in engine harness

Correct

Powertrain Control Module cable 
disconnected or defective

Correct or replace

Condition

Possible cause

Correction

Starting motor turns over and spark 
occurs but engine does not start.

Fuel tank empty

Fill

Water in fuel system

Clean

Fuel filter clogged

Replace filter

Fuel pipe clogged

Clean or replace

Fuel pump defective

Replace

Fuel pump circuit open

Correct or replace

Evaporative Emission Control 
System circuit clogged

Correct or replace

Multiport Fuel Injection System 
faulty

Refer to “Electronic Fuel Injection" 
section