Opel Frontera UBS. Manual - part 405

4JG2-NA/4JG2-TURBO ENGINE 6A2 – 41

19 (1.9/14)

N·m(Kg·m/lb·ft)

•

After tightening the bolts, make sure that the
crankshaft rotates smoothly.

167 (17.0/123)

N·m(Kg·m/lb·ft)

13. Connecting Rod Caps

•

The cap number must be same as connecting rod
number.

•

Apply engine oil to the thread and sealing surface
of each nut.

•

Tighten nuts to the specified torque.

•

After tightening the nuts, make sure that the
crankshaft rotates smoothly.

12. Rear Plate

•

Tighten bolts to the specified torque.

82 (80/61)

N·m(Kg·m/lb·ft)

11. Flywheel

•

Tighten bolts to the specified torque.

118 (12.0/87)

N·m(Kg·m/lb·ft)

10. Gear Case

•

Tighten fixing bolts to the specified torque.

19 (1.9/14)

N·m(Kg·m/lb·ft)

9.

Crankcase

•

Remove oil from oil pan mounting surface, and
dry the surface.

•

Apply a proper wide bead of sealant (TB1207C or
equivalent) to the crankcase mounting surface.
The bead must be continuous.

•

Crankcase must be installed within 5 minutes
after sealant application.

•

Tighten fixing bolts and nuts to the specified
torque.

Bolts

1st step 29 (3.0/22)     2nd step 45°  – 60°

N·m(Kg·m/lb·ft)

6A2 – 42 4JG2-NA/4JG2-TURBO ENGINE

8.

Camshaft Timing Gear

1)

Install the camshaft timing gear to the camshaft.
The timing gear mark ("Y - Y") must be facing out-
ward.

2)

Tighten the timing gear to the specified torque.

Nuts

6.

Idler Gear

1)

Apply engine oil to the idler gear and the idler gear
shaft.
The idler gear shaft oil hole must be facing up.

2)

Position the idler gear setting marks "X" and "Y" so
that they are facing the front of the engine.

3)

Align the idler gear "X" setting mark with the crank-
shaft timing gear 1 "X - X" setting mark.

4)

Align the idler gear "Y" setting mark with the cam-
shaft timing gear 2 "Y - Y" setting mark.

5)

Install the thrust collar and bolts to the cylinder body
through the shaft.
The thrust collar oil hole must be facing up, and the
thrust collar chamfered must be outward.

6)

Tighten the idler gear bolt to the specified torque.

64 (6.5/47)

N·m(Kg·m/lb·ft)

19 (1.9/14)

N·m(Kg·m/lb·ft)

5.

Idler Gear "B" and Shaft

1)

Apply engine oil to the idler gear and the idler gear
shaft.

2)

Align the idler gear "B" 3 "Z" setting mark with the
idler gear "A" 4 "Z - Z" setting mark.

3)

Tighten the idler gear bolt to the specified torque.

76 (7.7/56)

N·m(Kg·m/lb·ft)

24 (2.4/18)

N·m(Kg·m/lb·ft)

4JG2-NA/4JG2-TURBO ENGINE 6A2 – 43

7.

Injection Pump

1)

Install the O-ring 1 to the injection pump flange 2.

2)

Install the injection pump to the timing gear case.
Align the idler gear "B" 3 "V - V" mark with the
injection pump timing gear 4 "V" mark.

3)

Temporarily tighten the six injection pump nuts 5.
The injection pump nuts will be finally tightened after
the injection pump rear bracket bolts.

7)

Tighten the injection pump bracket bolts 8 to the
specified torque.

4.

Timing Gear Oil Pipe

1)

Install the oil pipe to the timing gear case and idler
gear "A".

2)

Tighten the oil pipe eye bolt 1 and bolt 2 to the
specified torque.

4)

Install the injection pump rear bracket 6 and the rear
bracket bolts 7 to the cylinder body.

5)

Install the rear bracket bolts 8 to the injection pump
bracket 9.
Do not tighten the bolts.
The rear bracket bolts 7 and 8 will be finally tight-
ened to the specified torque after the injection pump
nuts.

13 (1.3/9)

N·m(Kg·m/lb·ft)

6)

Tighten the infection pump bracket bolts 7  to the
specified torque.

20 (2.0/15)

N·m(Kg·m/lb·ft)

40 (4.1/30)

N·m(Kg·m/lb·ft)

6A2 – 44 4JG2-NA/4JG2-TURBO ENGINE

3.

Timing Gear Case Cover

1)

Align the gear case with the timing gear case knock
pin and then install the timing gear case cover.

2)

Tighten the gear case cover bolts to the specified
torque.

2.

Crankshaft Damper Pulley

Tighten the crankshaft damper pulley bolt to the specified
torque.

NOTE:

Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper
pulley.

1.

Engine Assembly

8 (0.8/69)

N·m(Kg·m/lb·in)

206 (21.0/152)

N·m(Kg·m/lb·ft)