Opel Frontera UBS. Manual - part 446

6A – 74 ENGINE MECHANICAL

CRANKSHAFT

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Legend

(1)

Cylinder Head

(2)

Cylinder Head Gasket

(3)

Flywheel

(4)

Cylinder Block Rear Plate (for A/T) or Flywheel
Housing (for M/T)

(5)

Crankshaft Rear Oil Seal

(6)

Retainer

(7)

Timing Gear Case

(8)

Crankshaft Front Oil Seal

(9)

Timing Gear Case

(10)

Gasket

(11)

Balance Shaft

(12)

Crank Case

(13)

Piston Cooling Oil Pipe

(14)

Main Bearing Cap

(15)

Crankshaft

(16)

Crankshaft Timing Gear

(17)

Piston and Connecting Rod Assembly

(18)

Cylinder Block

ENGINE MECHANICAL 6A – 75

DISASSEMBLY

1. Cylinder Head

1) Refer to “Cylinder head” in this manual.

2. Crankshaft Front Oil Seal

1) Use a plastic hammer and a screwdriver to tap

around the oil seal to free it from the gear case
cover.
Take care not to damage the oil seal fitting
surfaces.

3. Crankshaft Timing Gear
4. Timing Gear Case
5. Flywheel
6. Cylinder Block Rear Plate
7. Crankshaft Rear Oil Seal

1) Use special tool to remove the crankshaft rear

oil seal.
Oil Seal Remover: 5-8840-2360-0

8. Crank Case
9. Piston Cooling Oil Pipe 

10. Piston and Connecting Rod Assembly
11. Main Bearing Cap Assembly
12. Crankshaft

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.

1. Crankshaft Thrust clearance

Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance.
If the thrust clearance exceeds the specified limit,
replace the thrust bearing as a set.

Standard : 0.04 – 0.20 mm (0.0016 – 0.0079 in)
Limit: 0.30 mm (0.0118 in)

2. Main bearing clearance

1) Remove the main bearing caps in the sequence

shown in the illustration.
Arrange the removed main bearing caps in the
cylinder number order.

2) Remove the crankshaft. Remove the main

bearings.

3) Clean the upper and lower bearings as well as

the crankshaft main journal.

4) Check the bearings for damage or excessive

wear.
The bearings must be replaced as a set if
damage or excessive wear is discovered during
inspection.

5) Set the upper bearings and the thrust washers

to their original positions. Carefully install the
crankshaft.

6) Set the lower bearings to the bearing cap

original position.

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6A – 76 ENGINE MECHANICAL

7) Apply plastigage to the crankshaft journal unit as

shown in the illustration.

8) Install the main bearing caps. Apply engine oil to

the bolt threads and the seats. Tighten the bolts
to the specified torque.

Torque: 167 N·m (17 kg·m/123 lb ft)

NOTE: Do not allow the crankshaft to rotate.

9) Remove the main bearing caps.

10) Measure the plastigage width and determine the

oil clearance. If the oil clearance exceeds the
specified limit, replace the main bearings as a
set and/or replace the crankshaft.

11) Clean the plastigage from the bearings and the

crankshaft.
Remove the crankshaft and the bearings.

Standard: 0.031 – 0.063 mm (0.0012 – 0.0025 in)
Limit: 0.11 mm (0.0043 in)

3. Run-out

1) Carefully set the crankshaft on the V-blocks.

Slowly rotate the crankshaft and measure the
runout. If the crankshaft runout exceeds the
specified limit, the crankshaft must be replaced.

Standard: 0.05 mm (0.0020 in) or less
Limit: 0.08 mm (0.0031 in)

Measure the diameter and the uneven wear of
main journal and crank pin.
If the crankshaft wear exceeds the specified
limit, crankshaft must be replaced.

Main journal diameter

Standard: 69.917 – 69.932 mm (2.7526 – 2.7532 in)
Limit: 69.91 mm (2.7524 in)

Crank pin diameter

Standard: 52.915 – 52.930 mm (2.0833 – 2.0839 in)
Limit: 52.90 mm (2.0827 in)

Uneven wear limit

Standard: 0.05 mm (0.0020 in) or less
Limit: 0.08 mm (0.0031 in)

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ENGINE MECHANICAL 6A – 77

Crankshaft inspection

Inspect the surface of the crankshaft journals and crank
pins for excessive wear and damage.
Inspect the oil seal fitting surfaces for excessive wear
and damage.
Inspect the oil ports for obstructions.

Crankshaft tufftriding inspection

1. Use an organic cleaner to thoroughly clean the

crankshaft. There must be no traces of on the
surfaces to be inspected.

2. Prepare a 5 – 10% solution of ammonium cupric

chloride (dissolved in distilled water).

3. Use a syringe to apply the solution to the surface to

be inspected.
Hold the surface to be inspected perfectly
horizontal to prevent the solution from running.

NOTE: Do not allow the solution to come in contact with
the oil ports and their surrounding area (Approximately
10 mm).

Judgment

1. Wait for thirty or forty seconds.

If there is no discoloration after thirty or forty
seconds, the crankshaft is usable.
If discoloration appears (the surface being tested
will become the color of copper), the crankshaft
must be replaced.

2. Steam clean the crankshaft surface immediately

after completing the test.

NOTE: The ammonium cupric chloride solution is highly
corrosive. Because of this, it is imperative that the
surfaces being tested be cleaned immediately after
completing the test.

CRANKSHAFT BEARING SECTION

When installing new crankshaft bearings, refer to the
selection table below.
Select and install the new crankshaft bearings, paying
close attention to the cylinder body journal hole
diameter grade mark and the crankshaft journal
diameter grade mark.

NOTE: Although all upper journal bearings (cylinder
body side) have oil grooves and holes, all lower
bearings (bearing cap side) have no groove and hole.
Play close attention to the distinction during the
installation procedure.

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The portion to be tested
must be held horizontally
so as not to let the test
solution flow.

The sliding surface
of the pin
or journal.

Test liquid should
not be applied to
the area around the
oil port.

Approximately
10mm

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