Opel Frontera UBS. Manual - part 1287

4JG2-NA/4JG2-TURBO ENGINE 6A 2– 29

23. Rocker Arm Shaft Assembly

•

Loosen all adjusting screws.

•

Align fixing bolts to not of rocker arm shaft and
tighten them to the specified torque.

•

Valve clearance adjustment.

•

Refer to valve clearance adjustment steps in
section 00.

22. Fuel Leak Off Pipe

•

Install fuel leak off pipe with new copper gasket
and tighten joint bolts to the specified torque.

54 (5.5/40)

N·m (kg·m/lb·ft)

21. Injection Pipe

•

Install injection pipes and sleeve nuts securely and
tighten them to the specified torque.

29 (3.0/22)

N·m (kg·m/lb·ft)

29 (3.0/22)

N·m (kg·m/lb·ft)

20. Glow Plug Harness
19. Cylinder Head Cover

•

Apply engine oil to the rocker arms and the valve
spring.

•

Install the cylinder head cover gasket to the
cylinder head cover.

•

Tighten the cylinder head cover nuts to the
specified torque in the numerical order shown in
the illustration.

18. Fuel Leak Off Hose
17. Front Exh. Pipe

•

Install front exhaust pipe and tighten fixing bolts to
the specified torque.

13 (1.3/113)

N·m (kg·m/lb·in)

19 (1.9/14)

N·m (kg·m/lb·ft)

16. Exh. Manifold W/turbo  (4JG2-T Only)

•

Install manifold gasket in cylinder head.

•

Insert exh. manifold into studs on cylinder head a
little.

•

Under this condition, insert oil return pipe frange
into studs on crankcase.

•

Tighten exh. manifold fixing bolts and nut to
specified torque.

26 (2.7/20)

N·m (kg·m/lb·ft)

15. Oil Cooler Hose
14. Oil Return Pipe: Turbo (4JG2-T Only)

•

Tighten joint bolt to the specified torque.

8 (0.8/69)

N·m (kg·m/lb·in)

6A2 – 30 4JG2-NA/4JG2-TURBO ENGINE

13. Oil Feed Pipe: Turbo (4JG2-T Only)

•

Tighten joint bolts (cylinder block and turbo
charger side) to the specified torque.

12. Water Outlet Hose: Turbo (4JG2-T Only)

•

Connect to water inlet pipe of engine.

11. Water Inlet Hose: Turbo (4JG2-T Only)

•

Connect to water outlet pipe.

10. Water Bypass Hose

•

Water bypass hose connect to water inlet pipe.

9.

Heater Hose

•

Connect to heater pipe.

8.

Engine Harness

•

Connect five harness connecters to units on
thermostat housing.

7.

Water Hose: CSD

6.

A/C Compressor

•

Tighten temporarily fixing bolts (upper and front
lower sides of compressor.)

•

Tighten fixing bolt (rear under side of compressor)
to the specified torque by using a long extension
bar and torque wrench at under side of wheel arch.

•

Tighten fixing bolts (front upper and lower sides of
compressor) to the specified torque.

5.

P/S Pump Drive Belt

•

Install drive belts adjust belt tension by adjusting
bolt and tighten locking bolt to the specified
torque.

•

Refer to “Drive Belt Adjustment” in section 6B.

4.

Oil Level Gauge Guide Tube

•

Tighten guide tube to the specified torque.

23 (23/17)

N·m (kg·m/lb·ft)

37 (3.8/27)

N·m (kg·m/lb·ft)

40 (4.1/30)

N·m (kg·m/lb·ft)

19 (1.9/14)

N·m (kg·m/lb·ft)

3.

Intercooler Assembly (4JG2-T Only)

•

Refer to “Drive Belt Adjustment” in section 6B.

2.

Intake Air Duct (4JG2-T Only)

1.

Radiator Hose Upper

•

Connect to water outlet pipe.

4JG2-NA/4JG2-TURBO ENGINE 6A2 – 31

CRANKCASE

REMOVAL

Preparation

•

Disconnect battery ground cable.

•

Lift up car.

•

Drain engine oil.

NOTE

•

Install drain plug with new gasket.

1. Transmission Housing Bolt

•

Remove six fixing bolts from under side of hous-

ing.

2. Oil Return Pipe: Turbo (4JG2 -T only)

•

Remove return pipe fixing nuts and set return pipe
frange from stud on crankcase.

3. Oil Pipe Clip Bolt: Vaccum Pump

4. Oil Level Gauge Guide Tube

•

Remove two guide tube stay fixing bolts.

•

Disconnect blow by hose and remove oil level
gauge guide tube.

6A2 – 32 4JG2-NA/4JG2-TURBO ENGINE

5. Vacuum Hose

6. Crankcase

•

Remove crankcase fixing bolts two fixing bolts for
rear oil seal arch parts on crankcase could be
removed extention universal joint box wrench.

•

Remove crankcase by using crankcase seal cutter
to shear sealant off and remove crankcase.
Oil seal cutter: 5-8840-2153-0

NOTE

•

Don’t ply crankcase or you may distort sealing
surface.

•

Distorted or damaged crankcase should not by
used.

INSTALLATION

6.

Crankcase

•

Completely remove all sesidual sealant, lubricant
and moisture from the sealing surface of
crankcase and cylinder block.

•

Apply a correct width bead of sealant (TB-1207C or
its equivalent) to contact surface of crankcase
there must be no gaps in the bead.

•

Install crankcase with cylinder-block, and tighten
fixing bolts to the specified torque.

5. Vacuum Hose

4. Oil Level Gauge Guide Tube

•

Install guide tube to the specified torque.

•

Connect blow by hose to guide tube.

3. Oil Pipe Clip Bolts: Vacuum Pump

•

Tighten oil pipe clip fixing bolts to the specified
torque.

2. Oil Return Pipe: Turbo.

•

Tighten fixing nuts to crankcase to the specified
torque.

1. Transmission Housing Bolts

•

Pour engine oil into engine.

•

Install battery ground cable.

•

Start the engine and check for oil leakage from
crankcase.

19 (1.9/14)

N·m (kg·m/lb·ft)

19 (1.9/14)

N·m (kg·m/lb·ft)

19 (1.9/14)

N·m (kg·m/lb·ft)

8 (0.8/69)

N·m (kg·m/lb·in)