Opel Frontera UBS. Manual - part 398

4JG2-NA/4JG2-TURBO ENGINE 6A2 – 13

26 (2.7/20)

N·m(Kg·m/lb·ft)

INSTALLATION

13. Turbocharger Assembly (4JG2-T Only)

•

Install the turbocharger asm with gasket in exh.
manifold and tighten fixing nuts to the specified
torque.

12. Exh. Adapter (4JG2-T Only)

•

Install exh. adapter and tighten bolts to the
specified torque.

11. Heat Protector (4JG2-T Only)

10. Exh. Pipe: Ft

•

Install exh. pipe and tighten bolts to the specified
torque.

9.

Water Outlet Pipe: Turbo (4JG2-T Only)

•

Install water outlet pipe with new gasket to the
specified torque.

26 (2.7/20)

N·m(Kg·m/lb·ft)

67 (6.8/49)

N·m(Kg·m/lb·ft)

8(0.8/6)

N·m(Kg·m/lb·ft)

6A2– 14 4JG2-NA/4JG2-TURBO ENGINE

8.

Oil Return Pipe: Turbo (4JG2-T Only)

•

Install oil return pipe with new gasket in
turbocharger and tighten joint bolt to the
specified torque.

7.

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

•

Apply about 100 cc engine oil to oil feed hose of
turbocharger housing before installing oil feed
pipe.

•

Lubricate turbocharger securely by rotating
turbine shaft by hand.

•

Install oil feed pipe with new gasket and tighten
joint bolt to the specified torque.

6.

Water Inlet Pipe: Turbo (4JG2-T Only)

•

Install water inlet pipe with new gasket and
tighten joint bolt to the specified torque.

4.

Engine Ground Cable

3.

P/S Pump Drive Belts

•

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

•

Refer to drive belt adjustment steps in section 6B.

2.

Intercooler Assembly (4JG2-T Only)

•

Refer to intercooler installation steps in this
section.

1.

Air Cleaner Cover & Air Duct (4JG2-T Only)

•

Connect inlet and outlet connecting hoses and
tighten stay fixing bolts.

•

Install right front tire.

•

Fill coolant

•

Install battery and connect battery cables.

5.

A/C Compressor Assembly

•

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

•

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

•

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

8(0.8/6)

N·m(Kg·m/lb·ft)

1 23 (2.3/17) 2 29 (3.0/22)

N·m(Kg·m/lb·ft)

8(0.8/6)

N·m(Kg·m/lb·ft)

37 (3.8/27)

N·m(Kg·m/lb·ft)

4JG2-NA/4JG2-TURBO ENGINE 6A2 – 15

TIMING GEAR

REMOVAL

Preparation:

•

Disconnect battery ground cable.

•

Drain coolant.

1.

P/S Pump Drive Belt

•

Loosen P/S pump mounting bolt and adjust bolt,
and remove the drive belt.

2.

AC Generator Drive Belt

•

Loosen AC Generator mounting bolt (under side)
and adjust plate lock bolt, and remove the drive
belt.

3.

Cooling Fan Assembly

•

Remove clamp nut, and remove cooling fan asm,
distant pipe, and fan pulley.

4.

Crankshaft Damper Pulley

5.

Upper Noise Shield Cover

6.

Lower Noise Shield Cover

7.

Noise Cover Spacer.

8.

Timing Gear Case Cover

9.

Oil Pipe

10. Idler Gear “B” and Shaft

1)

Measure the camshaft timing gear backlash and the
crenkshaft timing gear backlash before removing the
idler gear.

6A2 – 16 4JG2-NA/4JG2-TURBO ENGINE

2)

Measure the idler gear end play before removing the
idler gear.

NOTE:

Refer to the following items for details on the backlash
and end play measurement procedures.

Timing Gear Backlash Measurement

1)

Set a dial indicator to the timing gear to measured.
Hold both the gear to be checked and the adjoining
gear stationary.

2)

Move the gear to be checked as far as possible to
both the right and the left.
Take the dial indicator reading.
It the measured value exceeds the specified limit, the
timing gear must be replaced.

Idler Gear "A" End Play Measurement

Insert a feeler gauge between the idler gear and the thrust
collar to measure the gap and determine the idler gear
end play.
If the measued value exceeds the specified limit, the the
thrust collar must be replaced.

Standard

mm (in)

Timing Gear Backlash

0.10-0.17 (0.0039-0.0067)

Limit

0.30 (0.012)

11. Idle Gear

12. Injection Pump

1)

Remove the six injection pump bracket bolts 1 from
the timing gear case.

Standard

mm (in)

Idler Gear End Play

0.07 (0.0028)

Limit

0.2 (0.0079)