Opel Frontera UBS. Manual - part 2067

 

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Opel Frontera UBS. Manual - part 2067

 

 

6A–2

ENGINE MECHANICAL

Piston and Connecting Rod

6A–77

. . . . . . . . . . . . . . . 

Piston, Connecting Rod and Associate
 Parts

6A–77

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Disassembly

6A–77

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection and Repair

6A–78

. . . . . . . . . . . . . . . . . . 

Reassembly

6A–82

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Cylinder Block

6A–85

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Cylinder Block and Associated Parts

6A–85

. . . . . 

Disassembly

6A–85

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection and Repair

6A–86

. . . . . . . . . . . . . . . . . . 

Reassembly

6A–87

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Main Data and Specification

6A–90

. . . . . . . . . . . . . . 

Special Tool

6A–96

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Service Precaution

WARNING: IF SO EQUIPPED WITH 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.

6A–3

ENGINE MECHANICAL

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.

D

A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.

D

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.

D

At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.

D

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.

D

The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.

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:

D

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.

D

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.

D

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 aluminum die–cast casting
for 75

°

V–type six cylinders. It has a rear plate integrated

structure and employs a deep skint. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width of No.3 bearing
on the body side is different in order to support the thrust
bearing. The bearing cap is made of nodular cast iron and
each bearing cap uses four bolts and two side bolts.

Cylinder Head

The cylinder head, made of aluminum alloy casting
employs a pent–roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V–type design. The ports are cross–flow
type.

Valve Train

Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.

Intake Manifold

The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.

Exhaust Manifold

The exhaust manifold is made of nodular cast 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 chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.

Crankshaft and Bearings

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

Engine Lubrication

The oil discharged by a trochoid–type oil pump driven by
the crankshaft is fed through full–flow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.

6A–4

ENGINE MECHANICAL

Engine Diagnosis

Hard Starting

1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.

Condition

Possible cause

Correction

Headlights go out or dim
considerably

Battery run down or under charged

Recharge or replace battery

considerably

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

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

Spark Test
Disconnect an igniton coil from any spark plug. Connect
the spark plug tester 5–8840–0607–0, start the engine,
and check if a spark is generated in the spark plug tester.
Before starting the engine, make sure that the spark plug

tester is properly grounded. To avoid electrical shock, do
not touch the part where insulation of the igniton coil is
broken while the engine is running.

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

3. Trouble In Fuel System

Condition

Possible cause

Correction

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

Fuel tank empty

Fill

occurs but engine does not start.

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

6A–5

ENGINE MECHANICAL

4. Engine Lacks Compression

Condition

Possible cause

Correction

Engine lacks compression

Spark plug loosely fitted or spark
plug gasket defective

Tighten to specified torque or replace
gasket

Valve timing incorrect

Adjust

Cylinder head gasket defective

Replace gasket

Valve incorrectly seated

Lap valve

Valve stem seized

Replace valve and valve guide

Valve spring weakened or broken

Replace

Cylinder or piston rings worn

Overhaul engine

Piston ring seized

Overhaul engine.

Engine Compression Test Procedure

1. Start and run the engine until the engine reaches

normal operating temperature.

2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the

ignition system.

5. Remove the fuel pump relay from the relay and fuse

box.

6. Engage the starter and check that the cranking speed

is approximately 300 rpm.

7. Install cylinder compression gauge into spark plug

hole.

8. With the throttle valve opened fully, keep the starter

engaged until the compression gage needle reaches
the maximum level. Note the reading.

9. Repeat the test with each cylinder.

If the compression pressure obtained falls below the
limit, engine overhaul is necessary.

Limit; 1000 kPa (145 psi)

 

 

 

 

 

 

 

Content   ..  2065  2066  2067  2068   ..