How to Repair Using Short-Block the Engine Opel Frontera A

Engine, Repair Using Short Block Engine

Locate engine on Engine Overhaul Stand KM - 412 using KM - 412 - 4.

Drain engine oil.

Visco fan.

Fluid pump together with bracket.

On vehicles with air conditioning:

Screw (A) and V - belt.

Oil pan.

Timing case.

Illustration shows engine in normal position.

Driving gear for high tension distributor.

Flywheel - mark bore for fitting bolt 'P' (arrow).

Oil dipstick guide tube.

Sliding rail of timing chain.

New short block.

Flywheel - note position of fitting bolt 'P', lock with KM - 652.

Coat bolts with Locking Compound 15 10 177 (90 167 347).

Friction disc - edge or identification mark 'Motorseite' (engine side) to face flywheel.

Centre friction disc - KM - 237.

Coat all sliding and bearing surface with Lubricating Paste 19 48 567 (90 006 450).

Sliding rail of timing gear.

Camshaft timing gear support.

Turn crankshaft to TDC, ball on flywheel aligns with pointer (arrow).

Timing chain and camshaft gear - note installation position.

Turn camshaft gear in chain so that when chain runs parallel to runner, mark on camshaft gear aligns with mark of timing gear support (arrowed).

Timing case seals to cylinder block - use grease.

Timing case - note bolt in water pump chamber.

Timing case screws - 15 Nm / 11 lbf ft.

Timing case seal ring - lever out with screwdriver.

New timing case seal ring.

Coat lip of seal ring with grease.

Draw in seal ring up to stop using Ring Installer KM - 289.

Water pump with new seal (A).

Bolt - 15 Nm / 11 lbf ft.

Screw in chain tensioner (B) by a few turns.

Starter.

Apply an approx. 3 mm / 0.19 in. bead of Sealing Compound 15 03 294 (90 001 871) to left and right surfaces between timing case and cylinder block.

Before positioning cylinder head check that valves of first cylinder are closed and those of fourth alternate.

Check marks on camshaft timing gear - camshaft timing gear support.

Cylinder head - use new bolts.

Cylinder head bolts - 60 Nm / 44 lbf ft.

Cylinder head bolts - a further 90° using KM - 470 - A, in same sequence.

Note:

After test run tighten bolts a further 30° to 40°.

Cylinder head to timing case bolts - 25 Nm / 18 lbf ft.

To tighten rear cylinder head bolts shorten Allen Key SW10 as follows:

A = 73 mm.

Tighten left bolt using Allen Key B.

Camshaft sprocket and tighten bolts using Splined Wrench KM - 320.

Cover.

Play between stop surfaces of cover and plastic limitation bolt - use feeler gauge.

Maximum permitted play - 0.1 to 0.2 mm / 0.004 to 0.008 in.

To correct larger play, remove cover and adjust at stop surface with blunt drift.

On vehicles with air conditioning - secure compressor with retainer, if bolts for compressor centre bracket were loosened at bracket, reinsert them with Sealing Compound 15 10 177 (90 167 347).

High tension distributor to timing case.

Ensure that rotor arm (A) points to fastening bolt (B).

When located correctly rotor arm (A) turns towards timing mark (arrow) of No. 1 cylinder.

Visco fan.

Coat separation joints left and right on timing case (arrows) and on rear crankshaft bearing cover with Sealing Compound 15 03 294 (90 001 851).

Oil pan.

Insert rubber seal in groove of oil pan sealing flange, insert bolts finger tight.

Oil pan bolts - 20 Nm / 15 lbf ft.