Opel Frontera UBS. Manual - part 393

 

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Opel Frontera UBS. Manual - part 393

 

 

ENGINE MECHANICAL 6A – 45

Cylinder Liner Bore Measurement

Use a cylinder indicator to measure the cylinder liner bore
at measuring point    

   in the thrust       

–      

 and axial      

directions of the crankshaft.
Measuring Point       

20mm (0.79 in)

If the measured value exceeds the specified limit, the cylinder
liner must be replaced.

NOTE:

The inside of the dry type cylinder liner is chrome plated.  It
cannot be rebored or honed.
If the inside of the cylinder liner is scored or scorched, the
cylinder liner must be replaced.

Cylinder Liner Grade Selection

Measure the cylinder body inside diameter and select the
appropriate cylinder liner grade.

If the cylinder liner fitting interference is too small, engine
cooling efficiency will be adversely effected.
If the cylinder liner fitting interference is too large, it will be
difficult to insert the cylinder liner into the cylinder body.

NOTE:

There are two methods by which liners can be selected.

Method I

The cylinder block deck has been marked during production
to indicate the correct liner sizes.  The liner grade (i.e. 1, 2, 3,
4) is indicated in permanent ink.
In the case of a questionable liner marking use the next
method for correct liner selection.

Method II

Cylinder Body Bore Measurement

1)

Take measurements at measuring point (A) across
positions        

–        

,       

–         

,      

–      

, and      

–      

.

Measuring Point (A) 98 mm (3.86 in).

1

2

2

3 3

1

1

1

2

2

3

3

4

4

0.001 – 0.019 (0.0004 – 0.0007)

mm (in.)

Standard Fifting Interference

6A – 46 ENGINE MECHANICAL

Cylinder bore

diameter average

1

Liner outside

diameter

Liner

Grade

97.001-97.010

(3.8189-3.8193)

97.011-97.020

(3.8193-3.8197)

97.021-97.030

(3.8197-3.8201)

97.031-97.040

(3.8201-3.8205)

97.011-97.020

(3.8193-3.8197)

97.021-97.030

(3.8197-3.8201)

97.031-97.040

(3.8201-3.8205)

97.041-97.050

(3.8205-3.8209)

2

3

4

mm (in.)

2)

Calculate the average value of the four measurements
to determine the correct cylinder grade.

3)

Consult the following table with the resultant diameter
for the correct liner application.

Cylinder Liner Installation

1.

Cylinder Liner Installation Using The Special Tool.
1) Use new kerosene or diesel oil to thoroughly clean

the cylinder liners and horse.

2) Use compressed air to blow-dry the cylinder liner

and bore surfaces.

Cylinder Liner Installer : 5-8840-2313-0

NOTE:

All foreign material must be carefully removed from the
cylinder liner and the cylinder bore before installation.

3) Insert the cylinder liner 1 into the cylinder body 2

from the top of the cylinder body.

ENGINE MECHANICAL 6A – 47

4) Set the cylinder liner installer ➂ to the top of the

cylinder liner.
Position the cylinder body so that the installer center
is directly beneath the bench press shaft center ➃.

Cylinder Liner Installer: 5-8840-2313-0

NOTE:

Check that the cylinder liner is set perpendicular to the
bench press and that there is no wobble.

5) Use the bench press to apply a seating force of

4,900 N (500kg/1,102.5 lb) to the cylinder liner.

6) Apply a force of 24,500 N (2,500 kg /5,512.5 lb) to fully

seat the cylinder liner.

7) After installing the cylinder liner, measure the cylin-

der liner projection.

8) After installing the cylinder liner, measure the cylin-

der liner projection.
Refer to “Cylinder Liner Projection Inspection” in
this Section
Measure the cylinder liner bore inside diameter and
select the appropriate piston grade.

CAUTION:

After installed the piston assembly.  Check and see that there
is appropriate clearance between pistons and oil jet pipes by
rotating crankshaft slowly.

16. Crankshaft

Install the main bearings to the cylinder body and
the main bearing caps.

Be sure that they are positioned correctly.

Apply new engine oil to the upper and lower main
bearing faces

Carefully mount the crankshaft.

This illustration 4JG2-T

REASSEMBLY

18. Cylinder Block

17. Piston Cooling Oil Pipe

1) Fix the oil jet pipes with knock pins on the cylinder

block.

2) Install the oil pipe for piston cooling in the cylinder

block, tightening a relief valve 1 and four joint bolts
2 to the specified torque.

Relief valve fixing bolt

29 (3.0/22)

Oil pipe fixing bolts

19 (1.9/14)

8 (0.8/69 lb·in.)

M8

M6

N·m (kg·m/lb·ft)

N·m (kg·m/lb·ft)

6A – 48 ENGINE MECHANICAL

Apply engine oil to the thrust washer.

Assemble the thrust washer to the No. 3 bearing
journal.  The oil grooves must face the crankshaft.

15. Main Bearing Cap Assembly

Apply the recommended liquid gasket or its equiva-
lent to the No. 5 crankshaft bearing cap cylinder
body fiting surfaces at points 1 and 2 shown in the
illustration.

NOTE:

Be sure that the bearing cap fitting surface is completely
free of oil before applying the liquid gasket.
Do not allow the liquid gasket to obstruct the cylinder
thread holes and bearings.

Install the bearing caps with the bearing cap head
arrow mark facing the front of the engine.

Apply engine oil to the crankshaft bearing cap bolts.

Tighten the crankshaft bearing cap bolts to the
specified torque a little at a time in the sequence
shown in the illustration.

NOTE:

Check to see that the crankshaft turns smoothly by rotating
it manually.

Apply the recommended liquid packing or its equiva-
lent to the No. 5 crankshaft bearing cap 3 as shown
in the illustration.
Install the arch packing 4 to the No. 5 bearing cap.

NOTE:

Take care to install the arch packing in the groove of bearing
cap correctly.
Take care not to scratch the arch packing outer surface.

167 (17.0/123)

N·m (kg·m/lb·ft)

 

 

 

 

 

 

 

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