Opel Frontera UBS. Manual - part 1273

 

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Opel Frontera UBS. Manual - part 1273

 

 

ENGINE MECHANICAL 6A – 25

CRANKSHAFT

DISASSEMBLY

1.

Cylinder Head

Refer to “Cylinder head” in Section 6A2.

2.

Camshaft Timing Gear

Refer to “Camshaft” in Section 6A2.

3.

Crankshaft Timing Gear

4.

Crankshaft Front Oil Seal

5.

Timing Gear Case

6.

Flywheel

7.

Cylinder Block Rear Plate

6A – 26 ENGINE MECHANICAL

8.

Crankshaft Rear Oil Seal

With the oil seal pushed in deep, install the special
tool as shown in the illustration and remove the oil
seal.

Oil Seal Remover : 5-8840-2362-0

9.

Crankcase Assembly

Refer to “Crankcase” in Section 6A2.

10. Oil Pump Assembly

11. Piston Cooling Oil Pipe

12. Piston and Connecting Rod Assembly

13. Main Bearing Cap

14. Crankshaft

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered
during inspection.

1.

Crankshaft

Thrust clearance
Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance.
If the thrust clearance exceeds the specified limit, re-
place the thrust bearing as a set.

Standard

Limit

mm(in)

0.10 (0.0039)

0.30 (0.0118)

167 (17/123)

N·m(kg·m/lb·ft)

2.

Main bearing clearance

1) Remove the main bearing caps in the sequence

shown in the illustration
Arrange the removed main bearing caps in the
cylinder number order.

2) Remove the crankshaft.  Remove the main

bearings.

3) Clean the upper and lower bearings as well as the

crankshaft main journal.

4) 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.

5) Set the upper bearings and the thrust washers to

their original positions.  Carefully install the
crankshaft.

6) Set the lower bearings to the bearing cap original

position.

7) Apply plastigage to the crankshaft journal unit as

shown in the illustration.

8) Install the main bearing caps.  Apply engine oil to

the bolt threads and the seats.  Tighten the bolts
to the specified torque.

ENGINE MECHANICAL 6A – 27

NOTE:

Do not allow the crankshaft to rotate.

9) Remove the main bearing caps.

10) 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.

11) Clean the plastigage from the bearings and the

crankshaft.
Remove the crankshaft and the bearings.

3.

Run-out

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.

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.

Standard

Limit

mm(in.)

0.031 – 0.063

(0.0012 – 0.0025)

0.11 (0.0043)

Standard

Limit

mm(in)

0.05 (0.0020)

or less

0.08 (0.0031)

Run-Out

Standard

Limit

mm(in)

Main journal
diameter

69.91

(2.7524)

69.917-69.932
(2.7526-2.7532)

Crank pin
diameter

52.90

(2.0843)

52.915-52.930
(2.0833-2.0839)

Uneven

wear limit

0.05

(0.0020)

or less

0.08

(0.0031)

6A – 28 ENGINE MECHANICAL

Crankshaft inspection

Inspect the surface of the crankshaft journals 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.

Crankshaft tufftriding inspection

The portion to be tested must be held horizontally so as
not to let the test solution flow.
Test liquid should not be applied to the area around the
oil port.
The sliding surface of the pin or journal.
Approximately 10mm

NOTE:

To increase crankshaft strength,Tufftride Method (Soft
nitriding) has been applied.  Because of this, it is not
possible to regrind the crankshaft surfaces.

1.

Use an organic cleaner to thoroughly clean the crank-
shaft.  There must be no traces of oil the surfaces to be
inspected.

2.

Prepare a 5 - 10% solution of ammonium cupric chloride
(dissolved in distilled water).

3.

Use a syringe to apply the solution to the surface to be
inspected.
Hold the surface to be inspected perfectly horizontal to
prevent the solution from running.

NOTE:

Do not allow the solution to come in contact with the oil
ports and their surrounding area.

Testing

1.

Wait for thirty to forty seconds.
If there is no discoloration after thirty or forty seconds,
the crankshaft is usable.
If discoloration appears (the surface being tested will
become the color copper), the crankshaft must be re-
placed.

2.

Steam clean the crankshaft surface immediately after
completing the test.

NOTE:

The ammonium cupric chloride solution is highly corrosive.
Because of this, it is imperative that the surfaces being
tested be cleaned immediately after completing the test.

 

 

 

 

 

 

 

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