Opel Frontera

Since 1992 of release

Repair and car operation



Opel of Frontera
+ Cars of mark Opel Frontera
+ Current leaving and service
- The engine
   Removal and engine OHC installation
   Removal and engine DOHC installation
   Engine dismantling
   Engine assemblage
   Head of cylinders and valves
   Pistons and rods
   The block of cylinders
   Cranked shaft and bearings of a cranked shaft
   Camshaft drive
   Engine mounts
   Compression check
   Greasing system
   Works with system of greasing of engine OHC/DOHC of 2.0 l
   Works with greasing system on the engine of 2.4 l
   The oil filter
   Oil radiator (if it is established)
   Pressure and oil temperature
+ Cooling and heating systems
+ The power supply system and release
+ Engine electric equipment
+ Coupling
+ Manual box of a gear change
+ Kardannye shaft, the main transfer
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
+ Controls and operation
+ Electric equipment schemes



Works with system of greasing of engine OHC/DOHC of 2.0 l

THE GENERAL DATA

Removal and pallet installation картера on the engine till the end of 1996 of release

The pallet картера can act in film without engine removal if, for example, it is necessary to replace a lining картера. Work labour-consuming enough, as it is necessary to lower all beam of the forward bridge to take out the pallet картера. Corresponding works are described in the Head the Suspension bracket and a steering. Besides, the engine should be lifted by means of any load-lifting device to disconnect support.

PERFORMANCE ORDER
1. Remove the bottom protective sheet (a pallet guard картера) under a forward part of the car.
2. Substitute capacity under the pallet картера and turn out a drain stopper from картера. Impellent oil should be warm, but not hot.
3. Remove the cross-beam of a suspension bracket which is under the pallet картера.
4. Lower the forward bridge as it is described in corresponding section.
5. Turn away bolts and remove the working cylinder of a drive of coupling (Coupling see the Head).
6. Turn away bolts of fastening of arms and remove them from a transmission and the block of cylinders. The engine should be thus fixed on the load-lifting mechanism (for example, on тали or on the manual crane). At engine DOHC remove engine support between a transmission and the block of cylinders.
7. According to иллюстр. Remove маслопровод (1), having disconnected the holder (2). Remove also маслоуспокоительный sheet. At engine DOHC fastening of considered details corresponds to the right part иллюстр. At the left – for the engine of 2,0 l.

Pallet installation картера is carried out in sequence, to return its removal:

PERFORMANCE ORDER
1. Carefully clear an interfaced surface of the block of cylinders and put a hermetic quantity on block corners. At the left on иллюстр. Hermetic drawing is shown for the oil pump, on the right for a bearing cover (till the end of 1996 of release).
2. Establish маслоуспокоительный sheet on a new lining. If маслоуспокоительный the sheet is replaced, it is necessary to mean that it is established with the new vulcanized lining.
3. Attach маслопровод to the oil pump and fix its collar. Bolts grease with means for fixing of carving connections "Loctite". Carving apertures can be passed a tap to remove the rests old "Loctite". Bolts of fastening of a bringing branch pipe tighten the moment of 8 Nanometers, the screw of fastening of a collar the moment of 6 Nanometers.
4. Establish the pallet картера with a new lining on the block of cylinders. Fastening bolts screw on hermetic. Find out, what hermetic is for this purpose applied in firm Opel repair trucks. Installation it is necessary to execute within 10 minutes Carving apertures in the block of cylinders it is possible to pass a tap to remove the rests of old hermetic. Tighten bolts the moment of 15 Nanometers.
5. Establish engine support, the working cylinder of a drive of coupling, a cross-beam and a pallet guard картера in sequence, return to removal. The inhaling moments are equal.
6. In conclusion of assemblage screw in the pallet картера and tighten a drain stopper (55 Nanometers). Fill in oil in the engine.
7. Start the engine and check up tightness of connection of the pallet картера.

The oil pump – removal and installation

PERFORMANCE ORDER
1. Remove a gear belt and a back protective cover of a belt. The piston of the first cylinder thus should be in ВМТ. To familiarise with corresponding instructions. The cover of a gear belt has two fixing bolts from above and two from below.
2. Remove the pallet картера.
3. Turn away bolts and remove a reception pipe of the oil pump in the bottom part of the block of cylinders (иллюстр.).
4. Remove filtering element.
5. Find the gauge of the index of pressure of oil and расстыкуйте it штекерное connection.
6. Take out from a cranked shaft flat-nose pliers segment шпонку.
7. Remove the oil pump from the block of cylinders, having turned away bolts. The place of fastening of the pump is shown on иллюстр. The lining is between oil pumps the block of cylinders. If it is necessary, check up the oil pump according to the instructions resulted in following subsection or replace with the new. The epiploon can be established both before, and after pump installation. Interfaced surfaces of the pump and the block of cylinders should be carefully cleared.
8. Establish a new lining on the block of cylinders (for fastening grease with its small amount консистентной greasings) put the pump. Watch to damaging at all an epiploon if it is already established. Bolts tighten the moment of 6 Nanometers. An interfaced surface between the oil pump and the block of the cylinders, adjoining to the pallet картера, grease with hermetic.
9. Fix bolts a pipe маслоприемника to the oil pump and the block of cylinders. At the pump the moment of 8 Nanometers, at the block of cylinders the moment of 6 Nanometers. The bolts rolled in the pump, grease "Loctite".
10. Join штекерное connection of the gauge of the index of pressure of oil.
11. Establish in the pump a new filtering element (the moment of an inhaling of 15 Nanometers).
12. Establish the pallet картера.
13. Again establish a back protective cover of a gear belt and a gear belt. Adjust a belt tension as it is described in corresponding section.
14. Fill the engine with necessary quantity of impellent oil. Apply the impellent oil recommended by firm Opel.
After installation of the oil pump before engine start-up spend the works described above.
15. Pull a gear belt.
16. Check up mechanism adjustment газораспределения.

Repair of the oil pump

The oil pump шестеренный, with gear wheels of internal gearing. The pump has редукционный the valve. For valve removal turn out a stopper.
Attention

The stopper is under the pressure of a spring and can jump out. Be careful. It is necessary to replace a sealing ring. The piston beat out from a valve aperture.


PERFORMANCE ORDER
1. Turn away bolts and uncover the pump (иллюстр.). Take out both gear wheels from the pump.

Instructions

The reduktsionnyj valve can be replaced without pump removal. It is on the right side of the pump, looking at the engine, near to a pulley.


The greasing system has перепускной the valve. It is in a head of cylinders. For its replacement it is necessary to remove a head of cylinders for what the special tool is required. In the presence of complexities with its replacement it is necessary to address in a repair truck. The head of cylinders for this purpose acts in film.
2. Cautiously оправкой beat out an epiploon of a cranked shaft.
3. Carefully clear all details and check up visually their deterioration. Wear tracks on a pump cover in most cases specify in a pump exit out of operation. If details look well, their further control is carried out as follows:
4. Insert gear wheels into the case of the pump and put from above a steel ruler, as is shown in иллюстр. Measure щупом a backlash between a ruler and gear wheels. It should make 0.03-0.10 mm. If the backlash leaves for the specified limits, gear wheels or all pump are replaced.
5. Measure щупом a backlash between two any teeths of gear wheels, as is shown in иллюстр. It should make 0.175 – 0.225 mm. If the backlash leaves for the specified limits, are replaced in the complete set of a gear wheel or all pump.
6. The zolotnik редукционного the valve should not have wear tracks. The spring should be serviceable.

Pump assemblage is carried out in sequence, return dismantling. Gear wheels before installation plentifully grease. Bolts of fastening of a cover grease with hermetic. The reduktsionnyj valve (balance of assembly: a zolotnik, a spring and a stopper) establish on a new lining. A stopper tighten the moment of 30 Nanometers.
Establish a sealing ring now or at pump installation.

The perepusknoj valve in a head of cylinders

The valve working as safety, is under a carving stopper and consists of a steel ball with a spring. There is a possibility of dismantle of the specified stopper (drill an aperture, screw саморез and take out a stopper flat-nose pliers). However it is possible to replace a valve saddle. It is taken only by means of a stripper. Installation of a carving stopper demands skill. Therefore it is recommended to carry out this work in the conditions of a repair truck.

Removal and pallet installation картера the car since 1997 of release


Kind of the so-called bearing pallet картера for the engine since 1997 of release.


By arrows places where in a groove of a back base plane hermetic is put are shown.
1 - the Pallet картера;
2 - the Lining;
3 - the Bolt, 20 Nanometers;
4 - the Drain stopper.
 

As well as on cars of earlier release, it is necessary to lower a beam of the forward bridge. The basic changes are made in a pallet design картера. For pallet removal картера establish on supports a forward part of the car.

PERFORMANCE ORDER
1. Remove the bottom protective sheet (a pallet guard картера).
2. Substitute under the pallet картера capacity and turn out from картера a drain stopper. Impellent oil should be warm, but not hot.
3. Remove the beam of a suspension bracket which is under the pallet картера.
4. Lower the forward bridge as it is described in corresponding section.
5. Turn away bolts and disconnect the hydrocylinder of a drive of coupling from a transmission (look the Head Coupling).
6. Turn away bolts and disconnect the pallet картера from the oil pump and the block of cylinders. Pallet fastening картера is shown on иллюстр. Above

The pallet картера in the following sequence is established:

PERFORMANCE ORDER
. 1. Carefully clear an interfaced surface of the block of cylinders and put a hermetic small amount on block corners as it is shown on иллюстр. Too most make concerning an interfaced surface of the oil pump on the right at a cover of bearings and at the left at the oil pump. Put also the hermetic platen in grooves of back plugs of the pallet картера.
2. Establish the pallet картера (1), as is shown in иллюстр. Above, with a new lining (2) on the block of cylinders and the oil pump also screw bolts. Bolts tighten the moment of 20 Nanometers.
3. Establish the working hydrocylinder of a drive of coupling, a cross-beam and protective sheet of the pallet картера in sequence, return to removal.
The inhaling moments, see Specifications.
4. In summary screw a drain stopper in the pallet картера and tighten its moment of 45 Nanometers. Fill the engine with impellent oil.
5. Start the engine and check up tightness of the received connections.

The oil pump – removal and installation (release since 1997)

Installation and removal of the oil pump is carried out also, as at the engine till 1997 of release. The difference consists in pallet removal картера. This operation is carried out also as it is described in last subsection. The soaking up pipe of the oil pump is placed on the right side, as is shown in иллюстр. Point 7. Pump repair also corresponds to the description resulted above.

The perepusknoj valve in a head of cylinders (release since 1997)


The valve working as safety, is under a carving stopper and consists of a steel ball with a spring. For it the description resulted concerning the valve of earlier release is fair. For this purpose it is necessary to remove a head of cylinders.

The reduktsionnyj valve (all engines)

The reduktsionnyj valve can be replaced without engine removal. The pallet guard картера should be removed.

PERFORMANCE ORDER
1. In the presence of the conditioner remove the pump of the hydraulic booster of a steering, at cars without the conditioner remove the generator.
2. Turn out a bolt (1) screwed in a face plane of the oil pump and shown on иллюстр. The bolt is under the influence of effort of a spring.
3. Take out in the order of a detail and store them as installation.
4. Establish the new valve in return sequence. A stopper tighten the moment of 30 Nanometers.

The podshipnikovyj bridge and маслоуспокоительный sheet

PERFORMANCE ORDER
1. The block of cylinders looks like, shown on иллюстр. The Podshipnikovyj bridge (1) is fixed by bolts to the bottom party of the block of cylinders and covers of radical bearings of a cranked shaft, forming thus rigid communication. Maslouspokoitelnyj sheet (2) is connected by bolts with the bottom part подшипникового the bridge (3). At pallet removal картера at engines of the given type to remove маслоуспокоительный sheet it is not necessary.
Removal of a reception pipe of the oil pump and маслоуспокоительного sheet is carried out according to иллюстр. Point 1 here.