Opel Frontera

since 1992 of release

Repair and car operation



Fronter's Opel
+ Opel Frontera brand Cars
+ Current leaving and service
- Engine
   Removal and OHC engine installation
   Removal and DOHC engine installation
   Engine dismantling
   Engine assembly
   Head of cylinders and valves
   Pistons and rods
   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 the OHC/DOHC engine of 2.0 l
   Works with greasing system on the engine of 2.4 l
   Oil filter
   Oil radiator (if it is established)
   Pressure and oil temperature
+ cooling and heating Systems
+ Power supply system and release
+ engine Electric equipment
+ Coupling
+ Manual box of gear shifting
+ Driveshafts, main transfer
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
+ Governing bodies and operation
+ electric equipment Schemes



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

GENERAL INFORMATION

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

The pallet of a case can act in film without engine removal if, for example, it is necessary to replace case laying. Work rather labor-consuming, as it is necessary to lower all beam of the forward bridge to take out the case pallet. The corresponding works are described in 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 leaf (a guard of the pallet of a case) under a forward part of the car.
2. Substitute capacity under the pallet of a case and turn out a drain stopper from a case. Impellent oil should be warm, but not hot.
3. Remove the cross-piece of a suspension bracket being under the pallet of a case.
4. Lower the forward bridge as it is described in appropriate section.
5. Unscrew bolts and remove the working cylinder of a drive of coupling (see. Head Coupling).
6. Unscrew 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 a waist or on the manual crane). At the DOHC engine remove engine support between a transmission and the block of cylinders.
7. According to иллюстр. remove an oil pipeline (1), having disconnected the holder (2). Remove also maslouspokoitelny leaf. At the DOHC engine fastening of considered details corresponds to the right part иллюстр. At the left – for the engine of 2,0 l.

Installation of the pallet of a case is carried out in sequence, return to 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. drawing of hermetic is shown for the oil pump, on the right for a bearing cover (till the end of 1996 of release).
2. Establish a maslouspokoitelny leaf on new laying. If the maslouspokoitelny leaf is replaced, it is necessary to mean that it is established with the new vulcanized laying.
3. Attach an oil pipeline to the oil pump and fix it a collar. Bolts grease with means for fixing of carving connections of "Loctite". Carving openings can be passed a tap to remove the remains of 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 case pallet with new laying on the block of cylinders. Bolts of fastening screw on hermetic. Find out, what hermetic is for this purpose applied in Opel firm repair trucks. Installation is necessary for executing within 10 minutes. Carving openings can be passed in the block of cylinders a tap to remove the remains of old hermetic. Tighten bolts the moment of 15 Nanometers.
5. Establish engine support, the working cylinder of a drive of coupling, a cross-piece and a guard of the pallet of a case in sequence, return to removal. The moments of an inhaling are equal.
6. In conclusion of assembly screw in the pallet of a case and tighten a drain stopper (55 Nanometers). Fill in oil in the engine.
7. Start the engine and check tightness of connection of the pallet of a case.

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 VMT. To familiarize with the corresponding instructions. The cover of a gear belt has two fixing bolts from above and two from below.
2. Remove the case pallet.
3. Unscrew bolts and remove a reception pipe of the oil pump in the lower part of the block of cylinders (иллюстр.).
4. Remove filtering element.
5. Find the sensor of the index of pressure of oil and расстыкуйте its shtekerny connection.
6. Take out from a cranked shaft flat-nose pliers a segment shponka.
7. Remove the oil pump from the block of cylinders, having unscrewed bolts. The place of fastening of the pump is shown on иллюстр. Laying is between oil pumps the block of cylinders. If it is necessary, check the oil pump according to the instructions provided in the 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 new laying on the block of cylinders (for fixing grease it with a small amount of konsistentny greasing) 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, adjacent to the case pallet, grease with hermetic.
9. Fix bolts a pipe of a maslopriyemnik 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 shtekerny connection of the sensor 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 case pallet.
13. Again establish a back protective cover of a gear belt and a gear belt. Adjust a belt tension as it is described in appropriate section.
14. Fill the engine with necessary amount of impellent oil. Apply the impellent oil recommended by Opel firm.
After installation of the oil pump before start-up of the engine carry out the works described above.
15. Pull a gear belt.
16. Check adjustment of the mechanism of a gazoraspredeleniye.

Repair of the oil pump

The oil pump shesterenny, with gear wheels of internal gearing. The pump has the reduktsionny valve. For removal of the valve 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 opening.


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

Instruction

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


The system of greasing has perepuskny the valve. It is in a head of cylinders. For its replacement it is necessary to remove a head of cylinders what needs the special tool. In the presence of difficulties with its replacement it is necessary to address in a repair truck. The head of cylinders for this purpose acts in film.
2. Carefully opravky beat out an epiploon of a cranked shaft.
3. Carefully clear all details and check visually their wear. Wear tracks on a pump cover in most cases indicate 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 shchupy a gap between a ruler and gear wheels. It should make 0.03 - 0.10 mm. If the gap leaves out of the specified limits, gear wheels or all pump are replaced.
5. Measure shchupy a gap between two any teeths of gear wheels, as is shown in иллюстр. It should make 0.175 – 0.225 mm. If the gap leaves out of the specified limits, are replaced in a set of a gear wheel or all pump.
6. The zolotnik of the reduktsionny valve should not have wear tracks. The spring should be serviceable.

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

Perepuskna the 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 opening, 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 installation of the pallet of a case of the car from 1997 of release


Type of the so-called bearing pallet of a case for the engine since 1997 of release.


Shooters showed places where in a groove of the back base plane hermetic is put.
1-Case pallet;
2-Laying;
3-Bolt, 20 Nanometers;
4-Drain stopper.
 

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

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

The case pallet in the following sequence is established:

PERFORMANCE ORDER
. 1. Carefully clear an interfaced surface of the block of cylinders and put a small amount of hermetic 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 roller in grooves of back plugs of the pallet of a case.
2. Establish the pallet of a case (1), as is shown in иллюстр. above, with new laying (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-piece and a protective leaf of the pallet of a case in sequence, return to removal.
The inhaling moments, see. Specifications.
4. In summary screw a drain stopper in the pallet of a case and tighten it the moment of 45 Nanometers. Fill the engine with impellent oil.
5. Start the engine and check 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 removal of the pallet of a case. This operation is carried out also as it is described in the 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 provided above.

Perepuskna the 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 provided concerning the valve of earlier release is fair. For this purpose it is necessary to remove a head of cylinders.

Reduktsionny valve (all engines)

The Reduktsionny valve can be replaced without engine removal. The guard of the pallet of a case 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 the 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.

Podshipnikovy Bridge and maslouspokoitelny leaf

PERFORMANCE ORDER
1. The block of cylinders looks like, shown on иллюстр. Podshipnikovy 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. The Maslouspokoitelny sheet (2) is connected by bolts with the lower part of the bearing bridge (3). At removal of the pallet of a case at engines of this type to remove a maslouspokoitelny leaf it is not necessary.
Removal of a reception pipe of the oil pump and maslouspokoitelny leaf is carried out according to иллюстр. point 1 here.