Opel Frontera UBS. Manual - part 2399

6A – 70 ENGINE MECHANICAL

(For example)
If you find identification marking “A”, “RA” and “2”
on the injector, you can use injector grade “A”. (The
“RA” is sometimes printed, but can be ignored)

Legend

(1) Part Number
(2) Two Alphabet Letter
(3) Serial Number
(4) Bar Code
(5) One Alphabet Letter
(6) One Numeral Letter

13. Remove harness connector from each injector.
14. Loosen nuts and bolts for oil rail.
15. Remove injector fixing bolts.
16. Remove injector clamp.
17. Remove injector assembly.

NOTE: Do not drop O-ring

INSTALLATION

1. Install oil rail, tighten temporarily
2. Install injector assembly.

NOTE: Do not forget to install O-ring between injector
and oil rail.

3. Apply oil and install injector fixing bolts, tighten

temporarily.

4. Apply oil and install injector clamp, tighten nut

temporarily.

5. Tighten injector bolts to the specified torque.

Torque: 7 N·m (0.7 kg·m / 61 lb in)
6. Tighten injector clamp nut to the specified torque

with special method.

Torque: 30 N·m (3.1 kg·m / 22 lb ft) then loose a
time again tighten as following torque.

Torque: 25 N·m (2.5 kg·m / 18 lb ft)
7. Tighten oil rail to the specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)
8. Install injector harness assembly, reconnect

harness connecter to injector.

9. Record the identification marking of injector for

each cylinder that is indicated on the upper portion
of injector.

Legend

(1) Part Number
(2) Two Alphabet Letter
(3) Serial Number
(4) Bar Code
(5) One Alphabet Letter
(6) One Numeral Letter

10. Install cylinder head assembly.

Refer to “Cylinder Head” in this manual.

11. Fill with about 300cc of engine oil from the high

pressure oil pipe at the high pressure oil pipe
installation port on the oil rail using an oil filler.
If assembled without filling the oil rail with oil, the

055RW021-1

Identification

One Alphabet One Numeral

Marking

Letter

Grade

ENGINE MECHANICAL 6A – 71

time for engine starting will be longer.

12. Immediately install high pressure oil pipe and

tighten to specified torque.

Torque: 78 N·m (8.0 kg·m / 58 lb ft)
13. Install cylinder head noise insulator cover.

Refer to “Cylinder Head” in this manual.

14. Install intercooler assembly.

Refer to “Intercooler” in this manual.

15. Install air cleaner cover and air duct.
16. Use TECH2 to rewrite injector data to ECM.

For rewriting method refer to section “Data
Programming in Case of ECM Change” of 6E 4JX1
engine driveability and emissions in this manual.

NOTE:

1) On completion of servicing, bleed air from the

engine inside fuel passage by means of the priming
pump. (The priming pump should be operated more
times than in the case of conventional engines.)

2) As air is in the oil rail, it takes more time to start the

engine. Rough idling may occur while the air is
being bled completely after starting the engine, but
it does not indicate trouble.
The air will be bled and normal engine status will be
reached while the vehicle is driven for about 5 km
or engine is operated for about 5 minutes at 1500 to
2000 rpm.

3) The injector spare part will be provided for group

number B1, B2 and B3 only.

6A – 72 ENGINE MECHANICAL

CRANK CASE

REMOVAL

1. Drain engine oil.
2. Remove transmission assembly.
3. Remove crankshaft damper pulley.
4. Remove timing belt cover, timing belt, pulley and

front plate.

5. Remove timing gear case cover.
6. Remove timing gears.

NOTE: Do not forget to set lock bolt for idle gear A and
lock pin for idle gear C.

7. Remove timing gear case.
8. Remove oil level gauge guide assembly.
9. Remove flywheel assembly.

CAUTION:

1) The flywheel heavy; be careful not to drop it.

2) Be careful no to let it slip because the hexagon

of the bolt is thin.

10. Remove rear plate (for A/T) or flywheel housing (for

MT).

11. Remove retainer.

NOTE:

1) Be careful not to damage the oil seal; it can be

reused.

2) Inspect installation portion for distortion and flow on

the slinger; also inspect for flow on the oil seal lip.

3) If there is some flow oil seal/slinger, replace a set.

12. Remove bolts from thrust plate of balance shaft LH

then remove balance shaft.

13. Loosen crank case fixing bolts.
14. Use seal cutter to take off the liquid gasket.

Seal cutter: 5-8840-2153-0

15. Remove crank case assembly.

CAUTION:
Do not give shock to crank case for prevention take
off applied vibration insulation material on the
crank case.

012RW029

Legend

(1)

Crank Case

(2)

Oil Pan

(3)

Drain Plug

ENGINE MECHANICAL 6A – 73

INSTALLATION

1. Install relief valve (if it was removed).

Torque: 30 N·m (3.1 kg·m / 22 lb ft)

2. Apply oil and insert O-ring to strainer, install strainer

and tighten to specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

3. Apply liquid gasket (TB1207B or equivalent) to

surface of oil pan and tighten bolt to the specified
torque.

Torque: 22 N·m (2.2 kg·m / 16 lb ft)

4. Apply engine oil to the balance shaft (left) and insert

it into crank case.

NOTE:

•

Do not damage bearing when inserting the balance
shaft.

•

Make sure it rotates smoothly.

5. Tighten thrust plate of balance shaft LH.

Torque: 25 N·m (2.5 kg·m / 18 lb ft)

6. Set O-ring port of oil gallery on the cylinder block.
7. Apply liquid gasket (TB1207C or equivalent) to

crankcase fixing surface then tighten bolts to the
specified torque.

Torque: 24 N·m (2.4 kg·m / 17 lb ft)

NOTE: Make sure there is no oil, dust or scratches on
the surface coated with liquid gasket and mount within
five minutes of gasket application.

8. Install retainer with oil seal.
9. Install rear plate (A/T) or flywheel housing (MT),

tighten bolt to the specified torque.

Torque: 97 N·m 9.9 kg·m / 72 lb ft)
10. Install flywheel assembly with applied engine oil to

the bolt, tighten the bolt using angular tightening
method.

1st step: 59 N·m (6.0 kg·m / 43 lb ft)
2nd step: 60° to 90°
3rd step: 60° to 90°
11. Install oil level gauge guide assembly.
12. Install timing gear case.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)
13. Install timing gears

Refer to “Timing Gear” in this manual.

14. Remove lock bolt from idle gear A and remove lock

pin from idle gear C.

15. Install timing gear case cover.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)
16. Install oil pump pulley.

Torque: 10 N·m (1.0 kg·m / 87 lb in)
17. Install camshaft pulley tighten bolt with angular

tightening method.

Torque:
1st step: 40 N·m (4.1 kg·m / 30 lb ft)
2nd step: 60° to 90°
18. Install timing belt and belt tensioner.

Refer to “Timing Gear” in this manual.

19. Install crankshaft damper pulley.

Torque: 216 N·m (22 kg·m / 159 lb ft)
20. Fill engine oil.

2~2.5mm

Apply liquid gasket around inside
of the bolt hole

Bolt hole

Inside

Outside

F06HX00001

2~2.5mm

Apply liquid gasket around inside
of the bolt hole

Bolt hole

Inside

Outside

F06HX00001

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