Seat OPEL FRONTERA 1998 Repair Manual

6A – 14 ENGINE MECHANICAL
TIGHTENING TORQUE
Timing Gear Case, Timing Gear
Nꞏm (kgꞏm/lbꞏft)
75(7.6/55)
Apply engine oil to
thread and seat 8(0.8/6)
20(2.0/14.5)
51(5.2/38)
25(2.5/18)
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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)
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6A – 60 ENGINE MECHANICAL
VALVE STEM SEAL, VALVE SPRING AND ADJUSTER
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove the air duct from between air cleaner and
turbocharger.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Disconnect PCV hose.
7. Disconnect EGR vacuum hose.
8. Disconnect harness connectors around the cylinder
head such as the injector, CMP sensor, MAP
sensor, EGR sensor, EVRV, IAT sensor, A/C
compressor, TP stepping motor, TP sensor and fuel
temperature sensor etc.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out drivebelt.
12. Remove heat protector, remove exhaust valve
assembly.
13. Remove water cooling hose and lubrication pipe for
turbocharger.
14. Remove turbocharger assembly.
15. Remove hose between thermostat and radiator.
16. Remove noise insulator cover of cylinder head.
NOTE: Do not damage injector harness.
17. Remove high pressure oil pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner then remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove engine coolant pipe between cylinder
head and water pump.
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2
3
4
5
6
9
10
7
8
011RW031
Legend
(1) Adjuster
(2) Tappet
(3) Split Collar
(4) Spring Seat Upper
(5) Valve Spring(6) Spring Seat Lower
(7) Valve Stem Seal
(8) Valve Guide
(9) Valve Seat
(10) Valve

6A – 62 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)Va l v e G u i d e
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)
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ENGINE MECHANICAL 6A – 63
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.
Va l v e T h i c k n e s s
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°
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6A – 64 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.
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ENGINE MECHANICAL 6A – 65
Valve Seat Insert Installation
1. Carefully place the attachment (1) (having a smaller
outside diameter than the valve seat insert) on the
valve seat insert (2).
Legend
(1) Attachment
(2) Valve Seat Insert
(3) Bench Press
NOTE: The smooth side of the attachment must contact
the valve seat insert.
2. Use a bench press (3) to gradually apply pressure
to the attachment and press the valve seat insert
into place.
Note: Do not apply an excessive amount of pressure
with the bench press. Damage to the valve seat insert
will result.
Valve Seat Insert Correction
1. Remove the carbon from the valve seat insert
surface.
2. Use a valve cutter (15°, 45° and 75° blades) to
minimize scratches and other rough areas. This will
bring the contact width back to the standard value.
Remove only the scratches and rough areas. Do
not cut away too much. Take care not to cut away
unblemished areas of the valve seat surface.
Valve Seat Angle: 45°NOTE: Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.
3. Apply abrasive compound to the valve seat insert
surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat
insert.
6. Check that the valve contract width is correct.
7. Check that the valve seat insert surface is in
contact with the entire circumference of the valve.
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2 1
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150
90
30
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6A – 66 ENGINE MECHANICAL
INSTALLATION
1. Valve stem seal
1) Use the special tool to install the stem seal to the
valve guide.
Stem Seal Installer: 5-8840-2033-0
2. Valve spring.
1) Install the lower valve seat spring, valve spring,
then the upper valve spring seat.
2) Use valve spring compressor to compress the
spring then install the split collar.
Valve spring compressor: 5-8840-2441-0
NOTE: Make sure the split collar installs completely.
3. Install cylinder head assembly.
Refer to “Cylinder Head” in this manual.
4. Install the camshaft carrier with camshaft.
Refer to “Camshaft” in this manual.
5. Install oil rail assembly.
Refer to “Oil rail and injector” in this manual.
6. Install injector assembly.
Refer to “Oil rail and injector” in this manual.
7. Install the injector harness assembly.
Refer to “Injector” in this manual.
8. Reconnect harness connecter to oil pressure
sensor and oil temperature sensor on the oil rail.
9. Reconnect Injector harness connecter to injector.
Refer to “Injector” in this manual.
10. Install cylinder head cover with gasket.
Refer to “Cylinder Head Cover” in this manual.
11. Install glow plug with specified torque.
Torque: 15 Nꞏm (1.5 kgꞏm / 10.8 lb ft)
12. Install the intake manifold assembly.
Refer to “Intake Manifold” in this manual.
13. Install the fuel pipe.14. Install the water pipe between the cylinder head
and water pump.
Torque: 20 Nꞏm (2.0 kꞏm / 14.5 lb ft)
15. Install the front plate.
16. Install the camshaft pulley.
Refer to “Timing Gear” in this manual.
17. Install timing belt and set the tensioner.
Refer to “Timing Belt” in this manual.
18. Install CMP sensor bracket.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
19. Install timing belt cover.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
20. Fill the oil rail with engine oil then immediately
install the high pressure oil pipe with the specified
torque.
Torque: 80 Nꞏm (8.1 kgꞏm / 57.9 lb ft)
21. Install the noise insulator cover.
22. Reconnect hose between thermostat and radiator.
23. Install turbocharger assembly.
Refer to “Turbocharger” in this manual.
24. Install water hose and oil pipe for turbocharger.
Refer to “Turbocharger” in this manual.
25. Install the valve assembly and install heat protector.
26. Install generator and set the fan belts.
27. Install A/C compressor bracket, compressor
assembly and set drive belt.
28. Reconnect harness connector around cylinder
head.
29. Reconnect vacuum hose to EGR valve.
30. Reconnect PCV hose.
31. Install oil level gauge guide assembly.
32. Install intercooler assembly.
Refer to “Intercooler” in this manual.
33. Install the air duct assembly.
34. Fill engine coolant.
35. Connect battery ground cable.
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6A – 76 ENGINE MECHANICAL
7) Apply plastigage to the crankshaft journal unit as
shown in the illustration.
8) Install the main bearing caps. Apply engine oil to
the bolt threads and the seats. Tighten the bolts
to the specified torque.
Torque: 167 Nꞏm (17 kgꞏm/123 lb ft)
NOTE: Do not allow the crankshaft to rotate.
9) Remove the main bearing caps.
10) Measure the plastigage width and determine the
oil clearance. If the oil clearance exceeds the
specified limit, replace the main bearings as a
set and/or replace the crankshaft.
11) Clean the plastigage from the bearings and the
crankshaft.
Remove the crankshaft and the bearings.
Standard: 0.031 – 0.063 mm (0.0012 – 0.0025 in)
Limit: 0.11 mm (0.0043 in)3. Run-out
1) Carefully set the crankshaft on the V-blocks.
Slowly rotate the crankshaft and measure the
runout. If the crankshaft runout exceeds the
specified limit, the crankshaft must be replaced.
Standard: 0.05 mm (0.0020 in) or less
Limit: 0.08 mm (0.0031 in)
Measure the diameter and the uneven wear of
main journal and crank pin.
If the crankshaft wear exceeds the specified
limit, crankshaft must be replaced.
Main journal diameter
Standard: 69.917 – 69.932 mm (2.7526 – 2.7532 in)
Limit: 69.91 mm (2.7524 in)
Crank pin diameter
Standard: 52.915 – 52.930 mm (2.0833 – 2.0839 in)
Limit: 52.90 mm (2.0827 in)
Uneven wear limit
Standard: 0.05 mm (0.0020 in) or less
Limit: 0.08 mm (0.0031 in)
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6A – 80 ENGINE MECHANICAL
3. Piston and Connecting Rod Assembly
1) Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins
and each piston ring and piston.
2) Align the front mark (2) of piston and front mark
(3) of connecting rod then assemble them.
3) The N mark of the piston ring is faced toward the
top, check to see that the piston ring end gap is
correctly positioned.
Legend
(1) 1st piston ring end gap
(2) 2nd piston ring end gap
(3) Oil ring end gap4) Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
The front marks must be facing the front of the
engine.
Piston Ring Compressor: 5-8840-9018-0
5) Match the numbered caps with the numbers on
the connecting rods. Align the punched marks
on the connecting rods and caps.
6) Apply engine oil to the threads and seating faces
of the nuts.
7) Tighten the cap nuts in 2 steps, using angular
tightening method as shown in the following
specifications.
1st step: 29 Nꞏm (3.0 kgꞏm/22 lb ft)
2nd step: 45°– 60°
After tightening the cap nuts, check to see that
the crankshaft rotates smoothly
4. Piston Cooling Oil Pipe
If the piston cooling oil pipe is forcibly assembled,
the end of the oil jet may bend. It could make it
impossible to supply oil to the piston cooling holes,
which will sometimes cause piston seizure.
Sufficient care should be taken to pipe assembly
work.
1) Tighten the bolt and oil jet plug to the specified
torque.
Torque:
M6: 8 Nꞏm (0.8 kgꞏm/6 lb ft)
M8: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
Oiling Jet Plug: 30 Nꞏm (3.1 kgꞏm/22 lb ft)
5. Crank case
1) Refer to “Crank case” in this manual.
6. Apply liquid gasket (TB-1207C or equivalent) to
retainer then install it to rear end of cylinder block
within 5 minutes.
7. Crankshaft Rear Oil Seal
1) Tighten the adapter to the crankshaft rear and
section with 2 bolts.
2) Insert the oil seal into the peripheral section of
the adapter.
3) Insert the sleeve into the adapter and tighten it
with a bolt (M12 x 1.75L = 70) until the adapter
hits the sleeve.
4) Remove the adapter and the sleeve.
5) Check the dimension of the oil seal setting from
rear end of crankshaft.
Standard Dimension = 12.5 ± 0.3 mm
Oil Seal Installer: 5-8840-2359-0
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