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



Pistons and rods

THE GENERAL DATA

Removal

ENGINE OHC

Pistons and rods can be removed without engine removal, for example, for replacement of any piston or шатунного the bearing. In this case it is necessary to remove a head of cylinders and the pallet картера as it is described in corresponding section.
Turn away bolts and remove soaking up branch pipe of the oil pump and маслоуспокоительный sheet. If more considerable repair is required, the engine is necessary for removing.
Pistons and rods are squeezed out upward by the hammer handle. After that covers and loose leaves шатунных bearings can be removed. Before carrying out of the specified works it is necessary to familiarise with the instructions resulted more low, concerning marks, directions of installation and other features:

PERFORMANCE ORDER
1. Each shatunno-piston group should have marks of the corresponding cylinder. It is better put a paint on the piston bottom (иллюстр.). Here it is necessary to put an arrow specifying in a forward part of the engine. The piston bottoms have marks. However because of their deposit it to can not be visible. Besides, they can be damaged in the course of deposit removal.
2. At removal of the piston from a rod it is necessary to pay attention to a direction of installation of a cover шатунного of the bearing. Before cover removal it is necessary to mark with cylinder number on the one hand a rod and a cover (иллюстр.). It is better to make кернером (the cylinder №1 with one blow кернера, the cylinder №2 two blows etc.). The rod and a cover шатунного the bearing should gather so that ledges on the rods, shown by arrows on иллюстр., looked towards coupling if the arrow or a label looks at the piston bottom towards a drive of the mechanism of distribution.
3. Loose leaves шатунного the bearing are marked according to a rod and a cover. Marks are put by a paint on undersides of the top and bottom loose leaves of bearings.
4. If the piston was disconnected from a rod replacement of all elements of assemblage-piston, a piston finger and a rod is necessary. Pistons act in film as follows. Thus means that the engine the head of cylinders, the pallet картера and a reception pipe of the oil pump is removed and removed:
5. Remove covers of bearings and take out loose leaves. Squeeze out piston groups upward as it has been described earlier. If it is necessary, remove шабером a deposit in the top part of cylinders.
6. Check up piston group as it is described more low on this page. At detection of deterioration or any damages all group is replaced.
7a. In need of replacement only piston rings, they act in film special nippers one after another through the piston bottom. Nippers are established on a piston ring, as is shown in иллюстр. 7a, and the ring is moved apart until it does not leave a flute. If rings are used again, it is necessary to mark them.
7b. If special nippers for removal of rings are not present, under rings it is possible to establish steel strips, as is shown in иллюстр. 7b. One strip is established necessarily towards the end of a ring to exclude piston damage. Assemblage of pistons and rods for different types of engines is described separately.

THE ENGINE OF 2.0 L OHC FROM THE MIDDLE OF 1995 OF RELEASE

The krivoshipno-shatunnyj mechanism of this engine completely is taken from the previous engine. Therefore concerning this engine fairly above-stated description.

THE ENGINE OF 2.4 L OHC


Works are spent to similarly above described scheme, including marks of the bottom of pistons, rods, etc. the Arrow or a label on the piston bottom should be turned forward. The ledge on a rod should be turned back. The piston finger is kept by lock rings.

ENGINE DOHC


The instructions resulted concerning engine OHC are valid and for engine DOHC if it concerns removals. Differences are available at dismantling of shatunno-piston group as in this case group details can be replaced independently from each other. It is necessary to pay attention also to a pallet design картера of the engine till the end of 1997 of release and further. Details are described in corresponding section.

PERFORMANCE ORDER
1. Each shatunno-piston group mark in the collected kind. In the middle of a rod cover there is mechanically processed inflow. The edge of this inflow should specify towards a flywheel.
2. Выпрессуйте a piston finger, preliminary having removed lock rings. Sample around an aperture under a finger allows to use for removal of lock rings оправку, as is shown in иллюстр. A finger выпрессовывается with application corresponding оправки. Watch to damaging the piston. If necessary the piston can be heated up a little.
3. Piston rings act in film, as was described above (иллюстр. 7a). Rings store in an order of their installation on the piston if they are established further again. Before installation of a piston ring they should be checked up. Backlashes on height between piston rings and flutes and backlashes in the lock are thus checked. If the new piston should be established and new piston rings is established.

Measurement of diameter of cylinders

The present instructions concern engines of all types.
Diameter of cylinders is measured micrometric нутромером in three belts and in two directions (иллюстр.). The top and bottom belts are located accordingly on 10 mm below the top and bottom edge of the cylinder. In general 6 measurements for each cylinder are carried out. The received values should be written down and compared to the values resulted in Specifications. Thus it is necessary to mean a difference in values for various types of engines.
If values of diameters of one of cylinders fall outside the limits set, it is necessary to chisel all cylinders of the engine. The deviation in 0.04 mm from a preset value of diameter is admissible. In Specifications diameters of repair cylinders are resulted.
Diameter расточки the cylinder is defined as the sum диметра the piston measured in section at right angle to the bottom, and a backlash in interface of the piston to the cylinder. Besides, it is necessary to consider the allowance of 0.02 mm left on хонингование. Considered operation should be carried out, of course, in the conditions of a specialised repair truck. Its description is resulted here only for the information.
For backlash check their diameters as it is described above are measured in interface of the piston to the cylinder. The difference of diameters represents a backlash. In case of its exit for limits admissible, cylinders should be ground.

Check of pistons and rods


All details carefully check up. At presence задиров, deep scratches or detail wear tracks are replaced. Considered details are subject to the following check:

PERFORMANCE ORDER
1. Measure щупом backlashes on height between piston rings and flutes, having inserted rings into corresponding flutes (иллюстр.). In case of excess of a preset value of a backlash, the piston ring or the piston are worn out.
2. One after another insert all rings into the block of cylinders. The piston turned upside down advance rings downwards on 15 mm.
3. Щупом measure a backlash in the ring lock (иллюстр.). The ring is under the bottom edge of cylinders. Measurement can be executed as well снижней the cylinder parties. Compare the received values to the data in Specifications. Backlashes should not leave for a deterioration limit.
4. At too small backlash (for example, at new rings where the backlash also should be measured) the ends of rings can be запилены a file. For this purpose the file with a small notch is clamped in a vice, and rings запиливаются in such position. At too big backlash it is necessary to replace a ring.
5. Check up a piston finger and расточку under it in a rod on presence of deterioration and задиров (only in the event that details will be again will be applied). In the presence of defects in one of details, both are replaced in the complete set.
6. Check up in the special adaptation rods on a warp and непараллельность axes of heads of a rod.
7. Shatunnye bolts are always replaced. Again they are not applied.

Backlash measurement in шатунных bearings

This operation is described more low in subsection "Check of details of a cranked shaft".

Assemblage of shatunno-piston group


THE ENGINE OF 2.0 L OHC


At replacement of pistons all of them are established one size.

PERFORMANCE ORDER
1. Before assemblage of shatunno-piston group the rod head should be нагрета to temperature 280 With for what it is possible to use, for example, a cooker with a temperature regulator. It is desirable to have also a colour core for the heating control.

Owing to the specified complexities it is recommended to make assemblage of shatunno-piston group of a repair truck. If the engine is removed from the car, it is recommended to hand over also in a repair truck the block of cylinders correctly to pick up pistons.

Attention

If the piston finger was not possible запрессовать as it is described above from the first, or the direction of installation of the piston or a rod is mixed, the shatunno-piston group is subject to replacement. Certainly, such situation should be excluded.
It is necessary to mean also that all rods should be replaced in the complete set as they steal up on weight only in the complete set.


THE ENGINE OF 2.4 L OHC

In the considered engine fixing of a piston finger is made by lock rings. Therefore assemblage in this case is carried out just as for engine DOHC (look more low).

ENGINE DOHC


The piston with a rod of the given engine easily gathers after heating of a head of a rod. It is necessary to watch correct orientation of the piston and a rod. Ledges on a rod and a bearing cover should be on the same party, as a platform at inflow for a piston finger.

PERFORMANCE ORDER
1. Plentifully grease a piston finger (1), enter a rod into the piston and insert a finger through the piston and a rod head. Keeping the piston, as is shown in иллюстр., press a finger so that it has rested against a lock ring on an opposite side. After that put the second lock ring. Check up reliability of an arrangement of rings in grooves.

FOR ALL ENGINES

PERFORMANCE ORDER
1. By means of special nippers establish one after another all piston rings in flutes (see иллюстр. 7а). Kompressionnye rings can be mixed. Therefore it is necessary to pay attention to their marks. Marks should be visible from outside the piston bottoms.

Installation of shatunno-piston group

ENGINE OHC


PERFORMANCE ORDER
1. Plentifully oil walls of cylinders.
2. Spread out shatunno-piston group according to marks and the instructions resulted above.

THE ENGINE OF 2.0 L

PERFORMANCE ORDER
1. Arrows should specify in the bottom of pistons in a forward part of the engine.

THE ENGINE OF 2.4 L

PERFORMANCE ORDER
1. At this engine of the marksman or the label should specify in the piston bottom forward. Inflow on the piston should specify back.

AT THE ENGINE OF 2.0 L

PERFORMANCE ORDER
1. Locks компрессионных rings should settle down at an angle 180 under the relation to each other. Locks маслосъемного rings should be displaced on 25 - 50 mm to the right and to the left concerning the lock of average компрессионного rings. Locks are displaced by turn of rings. The second ring has marks "TOP" which after ring installation should be visible from above.

AT THE ENGINE OF 2.4 L

PERFORMANCE ORDER
1. The top and bottom rings have marks "TOP". Both marks should be turned upward. The lock маслосъемного rings should be turned on 180 rather компрессионного rings.
2. Clasp the piston a steel tape, as is shown in иллюстр., also press rings into the piston. Check up reliability обжимания rings and a direction of installation of the piston.
3. Turn a cranked shaft so that two of шатунных necks have appeared below.
4. Insert a rod from above into the cylinder. For this purpose the engine put on one side so that the rod could be directed on a neck of a cranked shaft, and walls of the cylinder and шатунный the bearing were not damaged. The loose leaf шатунного the bearing should be in a rod and to be inserted a ledge into sample on a rod.
5. The piston enter into the cylinder so that piston rings, and a heel of a rod of village on a neck of a cranked shaft have smoothly entered. Check up at once that the arrow specified in the piston bottom in a direction of the mechanism of distribution.
6. Insert into a cover of the bearing the second loose leaf, plentifully having greased it. Establish on the loose leaf a cover, and slightly strike on it. Pay attention to, that of marks (иллюстр.) have been turned into one party.
7. Screw and tighten new шатунные bolts.

AT THE ENGINE OF 2.0 L OHC

PERFORMANCE ORDER
1. Tighten шатунные bolts alternately the moment of 35 Nanometers. From this position tighten bolts on 45 and then once again on 45 .

AT THE ENGINE OF 2.4 L

PERFORMANCE ORDER
1. Tighten шатунные bolts at the left and on the right the moment of 45 Nanometers.

ALL ENGINES

PERFORMANCE ORDER
1. After rod installation turn some times a cranked shaft and reveal resistance if those are available.
2. Establish into place two others shatunno-piston groups for what in appropriate way turn a cranked shaft.
3. Once again check up marks of all rods according to иллюстр. Ledges (1) on covers шатунных bearings should be turned towards a flywheel. Check up also a direction of installation of pistons (see иллюстр. 1).
4. Measure щупом a backlash between lateral surfaces of a rod and cheeks of a cranked shaft, as is shown in иллюстр. The axial backlash should not exceed 0.20 - 0.40 mm.
5. Cover with hermetic interfaced surfaces of the oil pump and a back cover of the bearing of a cranked shaft. Establish new маслоотбойный sheet and tighten fastening bolts.
6. Establish on the block of cylinders маслоприемный a branch pipe. At first tighten bolts of fastening of a branch pipe to the oil pump the moment of 8 Nanometers (a carving grease "Loctite"), then fix the holder to the block of cylinders the moment of 6 Nanometers.
7. Other works on assemblage are carried out in sequence, return dismantling, i.e. heads of cylinders etc. are established the pallet картера,

ENGINE DOHC

Installation of shatunno-piston groups on this engine is carried out also, as on engine OHC of 2.0 l. An arrangement of piston rings here too similarly. Follow the instructions operating concerning the engine of 2.0 l. It concerns by the time of an inhaling шатунных bolts.
Pallet installation картера will be executed according to the instructions resulted in corresponding section since this operation has the differences depending on year of release of the engine. (Before and after 1997г.).