torque OPEL FRONTERA 1998 Workshop Manual

6A – 30 ENGINE MECHANICAL
ENGINE MOUNT (RH)
REMOVAL
1. Disconnect battery ground cable
2. Hang the engine assembly.
3. Rubber engine mount.
1) Remove bolts from chassis frame bracket.
2) Remove nuts from rubber engine mount and
engine mounting bracket.
4. Remove bolt which is fixed between engine and
mounting bracket then remove the engine mounting
bracket.
INSTALLATION
Tighten the fixing bolts to the specified torque.
1. Engine mounting bracket to cylinder block.
Torque : 40 Nꞏm (4 kgꞏm/29 lb ft) (for M10)
127 Nꞏm (13 kgꞏm/94 lb ft) (for M14)
2. Rubber engine mount to chassis frame and engine
mounting bracket.
Torque :40 Nꞏm (4 kgꞏm/29 lb ft)
43
12
022RW018
Legend
(1) Rubber Engine Mount (LH)
(2) Engine Mounting Bracket (LH)
(3) Rubber Engine Mount (RH)
(4) Engine Mounting Bracket (RH)

ENGINE MECHANICAL 6A – 31
ENGINE MOUNT (LH)
REMOVAL
1. Disconnect battery ground cable
2. Hang the engine assembly.
3. Rubber engine mount.
1) Remove bolts from chassis frame bracket.
2) Remove nuts from rubber engine mount and
engine mounting bracket.
4. Remove bolt which is fixed between engine and
mounting bracket then remove the engine mounting
bracket.
INSTALLATION
Tighten the fixing bolts to the specified torque.
1. Engine mounting bracket to cylinder block.
Torque : 40 Nꞏm (4 kgꞏm/29 lb ft) (for M10)
127 Nꞏm (13 kgꞏm/94 lb ft) (for M14)
2. Rubber engine mount to chassis frame and engine
mounting bracket.
Torque :40 Nꞏm (4 kgꞏm/29 lb ft)
43
12
022RW018
Legend
(1) Rubber Engine Mount (LH)
(2) Engine Mounting Bracket (LH)
(3) Rubber Engine Mount (RH)
(4) Engine Mounting Bracket (RH)

6A – 32 ENGINE MECHANICAL
INTERCOOLER
REMOVAL
1. Disconnect the battery ground cable.
2. Remove air cleaner cover and air duct.
3. Remove intercooler cover.
4. Remove intercooler assembly.
1) Remove rubber hose from between intercooler
outlet and intake manifold inlet.
2) Remove rubber hose from between
turbocharger outlet and intercooler inlet.
3) Remove intercooler assembly fixing bolts from
the bracket, remove intercooler assembly.
INSTALLATION
1. Intercooler assembly
1) Connect outlet hose to intake manifold.
Torque : 4 Nꞏm (0.4 kgꞏm/3 lb ft)
2) Connect inlet hose from turbocharger to
intercooler.
Torque : 4 Nꞏm (0.4 kgꞏm/3 lb ft)
3) Install intercooler and tighten fixing bolts to the
specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
2. Install intercooler cover.
3. Install air cleaner cover and air duct.
4. Connect the battery ground cable.
For Europe
2
33
1
135R200003
Legend
(1) Air Cleaner Cover & Air Duct(2) Intercooler Cover
(3) Intercooler Assembly

ENGINE MECHANICAL 6A – 33
CYLINDER HEAD COVER
REMOVAL
1. Disconnect battery ground cable.
2. Remove clip, remove air cleaner cover and air duct.
3. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
4. Remove PCV hose.
5. Remove bolts which fix noise insulator cover then
remove noise insulator cover and insulator.
6. Remove high pressure oil pipe at cylinder head
side.
Take care when removing the injector oil pipe,
because sometimes, during removal, your hand
can be injured by the remaining high pressure oil.
INSTALLATION
1. Cylinder head cover.
1) Install the cylinder head cover gasket to cylinder
head cover.
2) The gasket must be set perfectly with no loose
areas.
3) Apply liquid gasket (TB1207B or equivalent) to
the rubber seal of the camshaft end, injector
harness gasket area and No. 1 camshaft
bracket.4) Tighten cylinder head cover fixing bolts to the
specified torque.
Torque : 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
2. Fill with about 300 cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil rail filler. If assembled without filling the oil rail
with oil, the time for starting the engine will be
longer.
3. Install the high pressure oil pipe immediately and
tighten the sleeve nut to the specified torque.
Torque : 80 Nꞏm (8.1 kgꞏm/57.9 lb ft)
1 7
2
3
4
5 6
010R200006
Legend
(1) Noise Insulator Cover
(2) Insulator
(3) Bolt(4) Oil Seal
(5) Gasket
(6) Cylinder Head Cover
(7) Bolt
3~52~32~33~5
3~5 1~2
012RW119

ENGINE MECHANICAL 6A – 35
INTAKE MANIFOLD
REMOVAL
1. Drain engine coolant and disconnect water hose
from thermostat hosing.
2. Remove intercooler assembly
Refer to “Intercooler” in this manual.
3. Remove bracket bolt of oil level gauge guide tube.
4. Remove PCV Hose.
5. Remove hoses from EGR, EGR vacuum sensor
and inlet/outlet of heater.
6. Disconnect harness connector form MAP sensor,
EGR vacuum sensor, ETC sensor, water
temperature unit, IAT sensor and EVRV.
7. Remove high pressure oil pipe.
8. Remove the two way valve.
9. Remove fuel pipe from between intake manifold
and high pressure oil pump.
10. Remove fixing bolts and nuts on the intake
manifold, then remove the intake manifold
assembly.
INSTALLATION
1. Install the intake manifold, tighten bolts and nuts to
the specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) for bolt and nut
2. Install the fuel pipe and tighten to the specified
torque.To r q u e :
M16 bolt (apply engine oil) 4 Nꞏm (0.4 kgꞏm/2.9
lb ft)
Cap nut (M10) 13Nꞏm (1.3 kgꞏm/9.4 lb ft)
Fuel pipe (M10 apply engine oil) 14 Nꞏm (1.4
kgꞏm/10 lb ft)
3. Install two way valve.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
4. Fill with about 300 cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil filler. If assembled without filling the oil rail
with oil, the time for starting the engine will be
longer.
5. Install the high pressure oil pipe immediately and
tighten the sleeve nut to the specified torque.
Torque : 80 Nꞏm (8 kgꞏm/57.9 lb ft)
6. Reconnect harness connector to MAP sensor, EGR
vacuum sensor, ETC sensor, Water temperature
unit, IAT sensor and EVRV.
7. Connect the hoses to EGR valve, EGR vacuum
sensor, and water inlet/outlet pipe for heater.
8. Connect PCV hose.
9. Install the oil level gauge guide tube and tighten
bracket bolt.
10. Install the intercooler assembly.
Refer to “Intercooler” in this manual.
11. Connect the hose to the thermostat housing and fill
with engine coolant.
For Europe
2
1
3
3 1 42
025R200005
Legend
(1) Intake Manifold
(2) Throttle Valve Assembly
(3) EGR Valve
(4) Gasket

ENGINE MECHANICAL 6A – 37
RINSTALLATION
1. Install gasket on the exhaust manifold and tighten
to the specified torque.
Torque : 30 Nꞏm (3.1 kgꞏm/22 lb ft)
2. Install turbocharger on the exhaust manifold.
Torque : 27 Nꞏm (2.8 kgꞏm/20.2 lb ft)
3. Install water hoses and oil pipes.
4. Install heat protector to turbocharger.
Torque : 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
5. Install A/C compressor assembly and readjust belt
tensioner.
6. Install the intercooler assembly in the normal
position.
Connect both hoses to turbocharger and intake
manifold.

6A – 40 ENGINE MECHANICAL
INSTALLATION
1. Install turbocharger assembly to exhaust manifold,
tighten to the specified torque.
Torque : 27 Nꞏm (2.8 kgꞏm/20.2 lb ft)
2. Install exhaust adaptor.
Torque : 27 Nꞏm (2.8 kgꞏm/20.2 lb ft)
3. Install heat protector.
4. Install water outlet pipe with gasket.
Torque : 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
5. Install turbocharger oil drain pipe.
Torque : 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)6. Install oil supply pipe to turbocharger.
1) Fill with 100 cc engine oil at the turbocharger oil
supply hole before installing the oil pipe.
2) Turn the turbocharger by hand to lubricate
turbocharger shaft.
3) Install oil supply pipe with new gasket to the
turbocharger and tighten oil supply pipe bolts to
the specified torque.
Torque : 22 Nꞏm (2.2 kgꞏm/15.9 lb ft) for M10
54 Nꞏm (5.5 kgꞏm/39.8 lb ft) for M14
7. Install water inlet pipe with new gasket, tighten to
the specified torque.
Torque : 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
8. Install intercooler assembly.
Refer to “Intercooler” in this manual.
9. Install air cleaner cover with air duct, connect both
side hoses.
10. Fill with engine coolant.
11. Install the battery and connect battery cables.
For Europe
025R200007
For Europe
025R200007
For Europe
025R200006

ENGINE MECHANICAL 6A – 41
CYLINDER HEAD
3
4
1
2
012RW096
Legend
(1) Glow Plug
(2) Plate
(3) Cylinder Head Bolt
(4) Cylinder Head
NOTE:
During disassembly, be sure that the valve train
components are kept together and identified so that
they can be re-installed in their original locations.
Before removing the cylinder head from the engine
and before disassembling the valve mechanism, do
a compression test and note the results.
DISASSEMBLY
1. Injector Assy
2. Glow Plug and Glow Plug Connector
3. Cylinder Head Assembly
Refer to “Cylinder Head Gasket”
CLEAN
Cylinder head
Carefully remove all varnish, soot and carbon on
the bare metal. Do not use a motorized wire brush
on any gasket sealing surface.
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
1. Cylinder head gasket and mating surfaces for
leaks, corrosion and blow-by. If the gasket has
failed, determine the cause;
– Improper installation
– Loosen or warped cylinder head
– Insufficient torque on head bolts
– Warped cylinder block surface

6A – 42 ENGINE MECHANICAL
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.
3. Cylinder head deck for corrosion, sand particles in
head and porosity.
CAUTION: Do not attempt to weld the cylinder
head. Replace it.
4. Cylinder head lower surface for flatness.
Use a straight edge and a feeler gauge to measure
the cylinder head lower surface warpage.
If the measured values exceed the specified limit,
the cylinder head must be replaced.
Cylinder Head Lower Face Warpage:
Standard: 0.075 mm (0.0029 in) or less
Limit: 0.2 mm (0.0079 in)
Cylinder Head Height:
Standard: 95 mm (3.740 in)
5. Water jacket sealing plugs seating surfaces.
6. Use a straight edge and a feeler gauge to measure
the manifold cylinder head fitting face warpage.
If the measured values exceed the specified limit,
the manifold must be replaced.
Exhaust Manifold Warpage:
Standard: 0.05 mm (0.0020 in) or less
Limit: 0.20 mm (0.0079 in)
CAUTION: Do not attempt to weld the cylinder
head. Replace it.
REASSEMBLY
1. Cylinder Head
Refer to “Cylinder Head Gasket”.
2. Glow Plug and Glow Plug Connector
Tighten glow plugs.
Torque: 15 Nꞏm (1.5 kgꞏm/11 lb ft)
011RW006
012RW053

ENGINE MECHANICAL 6A – 45
Cylinder head gasket and piston projection mm
CAUTION:
The projection of each piston should be 0.333
mm or more and less than 0.483 mm.
Maximum difference in projection between
pistons should be less than 0.1 mm.
If the piston projection is without standard,
reassemble the engine all over again.
3. Install cylinder head assembly, tighten bolts by
angular tightening method.
To r q u e :
1st step; 49 Nꞏm (4.9 kgꞏm/35.4 lb ft)
2nd step; 60°
3rd step; 60°
CAUTION: The cylinder head bolts cannot be
reused.
4. Install camshaft carrier assembly.
Refer to “Camshaft” in this manual.
5. Install oil rail and injector assembly.
Refer to “Oil rail and injector” in this manual.
6. Install injector harness to connect harness
connector.
Note: Apply liquid gasket (TB 1207B or equivalent) to
the rubber seal of the camshaft end, injector harness
gasket area and No. 1 camshaft bracket. Refer to the
Cylinder head cover.
7. Install cylinder head cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
8. Install glow plug to tighten specified torque.
Torque: 15 Nꞏm (1.5 kgꞏm/11 lb ft) and connectglow plug harness.
9. Install intake manifold.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
10. Install fuel return pipe.
11. Install fuel pipe in between fuel pump and intake
manifold.
12. Install water pipe in between cylinder head and
water pump.
Tighten flange bolt to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
13. Install front plate.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
14. Install camshaft pulley, tighten with angular
tightening method.
1st step 40 Nꞏm (4.0 kgꞏm/29 lb ft)
2nd step 60°
NOTE: Apply engine oil to camshaft pulley bolt.
15. Align timing mark oil pump pulley and camshaft
pulley to front plate then put the timing belt and
tighten tensioner bolt.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) for M8
50 Nꞏm (5.1 kgꞏm/37 lb ft)
16. Install CMP sensor bracket.
17. Install timing belt cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
18. Fill with about 300 cc of engine oil from the high
pressure oil pipe installing port of oil rail using an oil
filler.
If assembled without filling the oil rail with oil, the
time for engine start will be longer.
19. Immediately install high pressure oil pipe to tighten
with specified torque.
Torque: 80 Nꞏm (8 kgꞏm/57.9 lb ft)
20. Install cylinder head noise insulator cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
Grade A Grade B Grade C
011RW042
Grade Piston projectionGasket
thickness
A more 0.333 to less 0.383 1.35
B more 0.383 to less 0.433 1.40
C more 0.433 to less 0.483 1.45