height OPEL FRONTERA 1998 Owner's Guide

6A – 6 ENGINE MECHANICAL
SERVICE STANDARD
Enginemm (in)
Parts Items Service standard Service limit Remarks
Cylinder Head
Va l v e S p r i n g
Valve and
Valve guide
Camshaft0.075 (0.0030) or less
95.0 (3.740)
45.7 (1.8)
—
241 (54.2)
6.959 – 6.977
(0.27 – 0.272)
6.692 – 6.970
(0.271 – 0.272)
0.023 – 0.056
(0.0009 – 0.0022)
0.03 – 0.063
(0.0011 – 0.0024)
8.0 (0.312)
1.1 (0.0433)
1.2 (0.0472)
1.2 (0.0472)
45°
2.1 (0.0827)
2.1 (0.0827)
0.08 (0.00314)
46.67 (1.8374)
46.77 (1.8413)
29.939 – 29.960
(1.167 – 1.168)
0.02 (0.0008) or less
0.40 – 0.082
(0.0016 – 0.0032)0.50 (0.0197)
—
44.8 (1.765)
1.6 (0.063)
210 (47.22)
6.92 (0.270)
6.90 (0.269)
0.19 (0.0074)
0.20 (0.0079)
—
1.6 (0.0630)
1.1 (0.0433)
1.1 (0.0433)
—
2.6 (0.1024)
2.6 (0.1024)
2.0 (0.00797)
46.57 (1.8335)
46.67 (1.8374)
29.84 (1.1748)
0.10 (0.0039)
0.12 (0.0047)Cannot be
reground Cylinder head lower surface for flatness
Cylinder head height
Free height
Squareness
Spring tension (when assembled) N(lb)
Diameter of Valve stem IN
EX
Valve and valve guide clearance IN
EX
Valve guide upper end height
(Measured from the Cylinder head upper
face)
Valve guide margin
Valve thickness IN
EX
Valve seat contact surface angle
Valve seat contact width IN
EX
End play
Cam lobe height IN
EX
Journal diameter
Runout
Camshaft oil clearance

6A – 38 ENGINE MECHANICAL
1. Cylinder head bolts for damaged threads or
stretching and damaged heads caused by improper
use of tools.
CAUTION: Suspected bolts must be replaced.
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: 0.50 mm (0.0197 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”.
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
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
1. Camshaft Journal diameter
1) Use a micrometer to measure each camshaft
journal diameter in two directions (1) and (2). If
the measured value is less than the specified
limit, the camshaft must be replaced.
Standard: 29.939 – 29.96 mm (1.1787 – 1.1795 in)
Limit: 29.84 mm (1.17 in)
2. Cam Height
1) Measure the cam height (H) with a micrometer.
If the measured value is less than the specified
limit, the camshaft must be replaced.
Standard: IN 46.62 mm (1.8354 in)
EX 46.72 mm (1.8394 in)
Limit: IN 46.57 mm (1.8335 in)
EX 46.67 mm (1.8374 in)3. Cam Run-Out
1) Mount the camshaft on V-blocks.
2) Measure the cam height (H) with a micrometer.
If the measured value is less than the specified
limit, the camshaft must be replaced.
Standard: 0.02 mm (0.0008 in) or less
Limit: 0.10 mm (0.0039 in)
4. Camshaft oil clearance
1) Clean the camshaft, camshaft bracket and
camshaft carrier.
2) Put camshaft carrier on the cylinder head.
3) Put camshaft on the camshaft carrier.
4) Put plastigauge on the camshaft journal.
5) Install camshaft bracket to original position and
tighten bolts to specified torque in the numerical
order shown in the illustration.
Torque: A; 21.6 Nꞏm (2.2 kgꞏm/15.9 lb ft)
B; 38.0 Nꞏm (3.9 kgꞏm/28.2 lb ft)
C; 21.6 Nꞏm (2.2 kgꞏm/15.9 lb ft)
D; 38.0 Nꞏm (3.9 kgꞏm/28.2 lb ft)
(1)Ft Rr
(2)
014RW179
H
012RW059
014RW171
CC
D
B
CC
B
CC
D
CC
B
C
A AA A A A
AAAA
110RW035

ENGINE MECHANICAL 6A – 57
24. Remove fuel pipe between fuel pump and intake
manifold.
25. Remove fuel return pipe from rear of cylinder head.
26. Remove intake manifold assembly.
27. Disconnect glow plug harness and remove glow
plug.
28. Remove cylinder head cover.
29. Remove injector harness connector.
30. Disconnect harness connector from oil pressure
sensor and oil temperature sensor on the oil rail.
31. Remove injector harness assembly.
32. Remove injector clamp.
33. Remove injector is fixed bolts.
34. Remove injector assembly.
35. Remove oil rail.
36. Remove camshaft carrier assembly with camshaft.
37. Remove cylinder head assembly.
38. Disassemble valve spring according to the following
method.
1) Use valve spring compressor then remove split
collars.
2) Valve spring compressor: 5-8840-2441-0
NOTE: Put removed valve spring in order of cylinder
number.
39. Valve stem seal.
1) Use a screwdriver or pliers to remove valve
stem seal.
NOTE: Do not reuse removed valve stem seal.
INSPECTION AND REPAIR
Make the necessary adjustments, repairs and part
replacements if excessive wear or damage is
discovered during inspection.
Va l v e s p r i n g
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is
evident.
1. Free height
1) Measure the free height of the springs. The
springs must be replaced if the height is below
the specified limit.
Standard: 45.85 mm (1.8051in)
Limit: 43.9 mm (1.7283 in)
2. Squareness
1) Measure the valve spring squareness with a
steel square.
2) Replace the valve springs if the measured value
exceeds the specified limit.
Limit: 1.6 mm (0.063 in)
014rw042
014rs004
014rs005

6A – 58 ENGINE MECHANICAL
3. Spring tension
1) Use a spring tester to compress the springs to
the installed height. Measure the compressed
spring tension.
2) Replace the springs if the measured tension is
below the specified limit.
Standard: 236.0 N (24 kg/53 lb)
Limit: 205.0 N (21 kg/46 lb)Valve Guide
CAUTION: Taking care not to damage the valve seat
contact surface, when removing carbon adhering to
the valve head.
Carefully inspect the valve stem for scratching or
abnormal wear. If these conditions are present, the
valve and the valve guide must be replaced as a set.
1. Valve Guide Clearance
1) Measure the valve stem diameter with a
micrometer.
If the valve stem diameter is less than the
specified limit, the valve and the valve guide
must be replaced as a set.
Diameter of Valve stem:Inlet
Standard: 6.959 – 6.977 mm (0.2740 – 0.2747 in)
Limit: 6.92 mm (0.2724 in)
Diameter of Valve stem:Exhaust
Standard: 6.952 – 6.97 mm (0.2737 – 0.2744 in)
Limit: 6.90 mm (0.2717 in)
2) Measure the inside diameter of the valve guide
with a micrometer.
3) Subtract the measured outer diameter of the
valve stem from the measured inner diameter of
the valve guide.
If the valve exceeds the specified limit, the valve
and the valve guide must be replaced as a set.
Inlet clearance
Standard: 0.023 – 0.053 mm (0.0009 – 0.0021 in)
Limit: 0.19 mm (0.0075 in)
Exhaust clearance
Standard: 0.03 – 0.063 mm (0.0012 – 0.0025 in)
Limit: 0.20 mm (0.0079 in)
014RS006
014RS007

ENGINE MECHANICAL 6A – 59
Valve Guide Replacement
1. Using the special tool, drive out the valve guide
from the combustion chamber side.
Valve guide replacer: 9-8523-1212-0
2. Apply engine oil to the outside of the valve guide.
Using the special tool, drive in a new valve guide
from cylinder head upper face side, and check the
valve guide height.
Valve guide replacer: 9-8523-1212-0
Height: 8.0 mm (0.315 in)
NOTE: If the valve guide has been removed, both the
valve and the valve guide must be replaced as a set.
Valve Thickness
1. Measure the valve thickness.
2. If the measured value is less than the specified
limit, the valve and the valve guide must be
replaced as a set.
Inlet
Standard: 1.2 mm (0.0472 in)
Limit: 1.1 mm (0.0433 in)
Exhaust
Standard: 1.2 mm (0.0472 in)
Limit: 1.1 mm (0.0433 in)
Contact surface angle on valve seat on
valve
1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace
valve, valve guide and valve seat as a set.
Standard: 68°
011RW001
012RW052
012RW060
014RW018

6A – 60 ENGINE MECHANICAL
Valve Depression
1. Measure the valve stem height from the upper
surface of the cylinder head as shown in the
illustration.
Standard:
Intake side 35.59 mm (1.4012 in)
Exhaust side 35.49 mm (1.3972 in)
Limit:
Intake side 35.74 mm (1.4071 in)
Exhaust side 35.64 mm (1.4031 in)
Legend
(1) Intake Side
(2) Exhaust Side
Valve Contact Width
1. Check the valve contact faces for roughness and
unevenness. Make the valve contact surfaces
smooth.
2. Measure the valve contact width.
If the measured value exceeds the specified limit,
the valve seat insert must be replaced.
Inlet
Standard: 2.1 mm (0.0827 in)
Limit: 2.6 mm (0.1024 in)
Exhaust
Standard: 2.0 mm (0.0787 in)
Limit: 2.5 mm (0.0984 in)
Valve Seat Insert Replacement
Valve Seat Insert Removal
1. Arc weld the entire inside circumference of the
valve seat insert.
2. Allow the valve seat insert to cool for a few minutes.
This will invite contraction and make removal of the
valve seat insert easier.
3. Use a screwdriver to pry the valve seat insert free.
Take care not to damage the cylinder head.
4. Carefully remove carbon and other foreign material
from the cylinder head insert bore.
12
011RW044
014RS015

INDUCTION 6J – 11
INSPECTION AND RAPAIR
1. Visually check for cracks/clogs inside intake
manifold.
2. If foreign material is observed, it should be taken
out, and if there are some cracks on the intake
manifold, it must be replaced.
INSTALLATION
1. Install the intake manifold assembly, tighten bolts
and to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft) for bolt
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft) for nut
2. Install fuel pipe.
Torque: 4 Nꞏm (0.4 kgꞏm / 2.9 lb ft) for M16 nut
(Apply engine oil)
Torque: 13 Nꞏm (1.3 kgꞏm / 9.4 lb ft) for M10 cap nut
Torque: 14 Nꞏm (1.4 kgꞏm / 10 lb ft) for M10
(Apply engine oil)
3. Install two way check 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 engine starting will be longer.
5. Install high pressure oil pipe, then tighten sleeve nut
to the specified torque.
Torque: 29 Nꞏm (3.0 kgꞏm / 21.7 lb ft)
6. Reconnect harness connector to MAP sensor, EGR
vacuum sensor, ETC sensor, Water thermo unit,
IAT sensor and EVRV sensor.
7. Install hoses to EGR valve, EGR vacuum sensor
and Water outlet of heater.
8. Connect PCV hose.
9. Install oil level gauge guide and fix it.
10. Install intercooler assembly.
Refer to “Intercooler” in this manual.
11. Install water hose to thermostat housing and fill with
engine coolant.
Model of Turbocharger IHI RHF5
Turbine Maximum Speed 180,000 rpm
Maximum Inlet Gas Temperature 800 °C (1472 °F)
Vibration Peak (G) criteria Maximum 4 (G) at Turbine Rotor Speed 140,000 rpm
Tolerance Limit of Compressor Blade Height Less then 0.5 mm (0.0197 in)
MAIN DATA AND SPECIFICATIONS

7A–50
AUTOMATIC TRANSMISSION (4L30–E)
36. Separate second (40) and third clutch (41)
assemblies.
37. Remove thrust washer (42).
38. Remove reverse clutch plates (43 and 44) and
reverse clutch pressure plate (45).
39. Remove bearing (46) and washer (47).
40. Remove planetary carrier assembly (48).
41. Remove thrust bearing (49).
42. Remove reaction sun gear (50)
43. Remove needle bearing (51).
44. Remove brake drum (52).
45. Remove brake band (53).
46. Remove thrust bearing (54).
242RS003
47. Rotate case to horizontal position, valve body side
facing up.
Remove spring pin (55), using cutting pliers, then
remove parking lock and selector lever assembly
(56).NOTE: Insert wire in the center of the spring pin to
prevent it from collapsing during removal. Be aware of pin
height. Protect machined face of main case.
48. Remove parking lock and range selector lever 17 mm
nut (57).
49. Remove parking lock and range selector lever (56),
and actuator assembly.
50. Remove selector shaft (58).
NOTE: Inspect the shaft for burrs before removing to
prevent damaging seal. If necessary, remove burrs by
lightly sanding with an oilstone.
249RS004
Reassembly
1. Inspect selector shaft seal, and replace it if
necessary.
NOTE: Use a seal installer when replacing the seal.
Install selector shaft.
NOTE: Spring pin groove must be positioned inside the
case.
2. Install spring pin. Be sure the selector shaft can move
freely. Do not push the pin flush with the case surface.
Leave enough height for removal.
3. Install actuator assembly (1).
4. Install parking lock and range selector lever (2) and
new 17 mm nut. Tighten the nut to the specified
torque.
To r q u e : 2 2 N
m (2.2 kgꞏm/16 lb ft)

7A–192 AUTOMATIC TRANSMISSION (AW30-40LE)
248RY00024
248RY00025
248RY00026
248RY00027
Using vernier calipers, measure the distance between the
sun gear input drum and direct clutch drum as shown in the
figure.
If the values are nonstandard, check for an improper
installation.
Coat the assembled bearing and race with petroleum jelly
and install it onto the forward clutch.
19. Second coast brake piston assembly
Coat the oil seal ring with ATF and install it to the second
coast brake piston.
Install the washer, spring and piston to the piston rod.
Install the E–ring.
(1): Second coast brake piston
(2): Oil seal
(3): Piston rod
20. Snap ring
Coat two new oil seals with ATF and install them to the
piston cover.
Install the spring, second coast brake piston assembly and
piston cover to the case.
Using snap ring pliers, install the snap ring.mm (in.)
Height9.8 – 11.8
(0.386 – 0.465)
Assembled bearing and race diameter (Reference)
mm (in.)
Inside Outside
Bearing
and race33.7 (1.327) 47.8 (1.882)