engine OPEL FRONTERA 1998 Workshop Manual

ENGINE MECHANICAL 6A – 13
VALVE CLEARANCE ADJUSTMENT
1. Install 2.80 mm valve adjuster (shim) first when
reassembling the engine.
Thickness mark faces down.
2. Measure the valve clearance after installing cam
carrier assy with camshafts.
3. Change the adjuster using a special tool when the
clearance is out of tolerance.
Valve Clearance Adjusting Tool: 5-8840-2590-0
VALVE CLEARANCE (When cold condition)
Inlet 0.15 ± 0.05 mm
Exh 0.25 ± 0.05 mm
COMPRESSION PRESSURE
MEASUREMENT
1. Start the engine and allow it to idle until the coolant
temperature reaches 70 – 80°C (158 – 176°F).
2. Remove the following parts.
Glow plugs
Fuel cut solenoid connector
QOS (Quick-On Start System) fuse in the fuse
box.
3. Set the adapter and compression gauge to the No.
1 cylinder glow plug hole.
Compression Gauge
(with Adapter): 5-8840-2008-0
4. Turn the engine over with the starter motor and take
the compression gauge reading.
Compression Pressure at 200 rpm
Standard: 3040 kPa (31 kg/cm
2/441 psi)
Limit: 2160 kPa (22 kg/cm
2/313 psi)
5. Repeat the procedure (Steps 3 and 4) for the
remaining cylinders.
QUICK-ON START 4 SYSTEM
Quick-On Start System Inspection Procedure
1. Disconnect the ECT-sensor connection around the
thermostat outlet pipe.
2. Turn the starter switch to the “ON” position.
If the Quick-On Start 4 System is operating
properly, the glow relay will make a clicking sound
within seven seconds after the starter switch is
turned on.
3. Measure the glow plug terminal voltage with a
circuit tester immediately after turning the starter
switch to the “ON” position.
Glow Plug Terminal Voltage: approx. 12V
NOTE: Electrical power to the quick-on start system will
be cut after the starter has remained in the “ON”
position for twenty seconds.
Turn the starter switch to the “OFF” position and back
to the “ON” position.
This will reset the Quick-On Start 4 System.
014RW150

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)
020RW00001

ENGINE MECHANICAL 6A – 15
Cylinder Head, Flywheel, Crank Case, Oil Pan
Nꞏm (kgꞏm/lbꞏft)
012RW121
1st
49N•m(5.0kg•m/36 Ib ft)
167(17.0/123)
8(0.8/5.8)
20(2.0/14.5)
20(2.0/14.5)
30(3.1/22)
25(2.5/18)
2nd
60
1st
59N•m(6kg•m/43 Ib ft)
2nd
60-90
1st
29N•m(3.0kg•m/22 Ib ft)
2nd
45-60
3rd
60
19(1.9/14)

6A – 16 ENGINE MECHANICAL
Intake / Exhaust Manifold
Nꞏm (kgꞏm/lbꞏft)
025R200003
For Europe
For Europe 20(2.0/14.5)
20(2.0/14.5)
20(2.0/14.5)
22(2.2/16)
22(2.2/16)
30(3.1/22)
30(3.1/22)
20(2.0/14.5)

ENGINE MECHANICAL 6A – 17
Timing Pulley
Nꞏm (kgꞏm/lbꞏft)
020RW024
20(2.0/14.5)
40(4/29) 60
-90
1st 2nd
10(1.0/7.2)
20(2.0/14.5)
50(5.1/37)
20(2.0/14.5)
9(0.9/6.5)
9(0.9/6.5)

6A – 18 ENGINE MECHANICAL
Engine Electricals
Nꞏm (kgꞏm/lbꞏft)
060R200263
A
A
15(1.5/11)
94(9.6/69)
40(4.1/29.7)
40(4.1/29.7)
24(2.4/17.4)
19(19/13.7)

ENGINE MECHANICAL 6A – 19
Injector
Nꞏm (kgꞏm/lbꞏft)
E06R200022
With
spacer type
Without
spacer type
20Nꞏm(2.0kgꞏm/14 Ib ft)
7Nꞏm(0.7kgꞏm/61 Ib in)
Recheck tightening torque
after tighten the oil rail
Apply engine oil on the
thread of stud bolts
20Nꞏm(2.0kgꞏm/14 Ib ft)
Tighten 30Nꞏm(3.1kgꞏm/22 Ib ft)
Then loosen it again tighten with
24Nꞏm(2.4kgꞏm/17 Ib ft)
Apply engine oil
both side

6A – 20 ENGINE MECHANICAL
High Pressure Oil Pipe
Nꞏm (kgꞏm/lbꞏft)
80(8.1/57.9)
80(8.1/57.9)
80(8.1/57.9)
80(8.1/57.9)
052R200002

ENGINE MECHANICAL 6A – 21
Air Duct and Intercooler (For General Export)
Nꞏm (kgꞏm/lbꞏft)
3.0(0.3/2.2)
4.0(0.4/3)
20(2.0/14.5)
4.0(0.4/3)
20(2.0/14.5)
135R200002

6A – 22 ENGINE MECHANICAL
Air Duct and Intercooler (For Europe)
Nꞏm (kgꞏm/lbꞏft)
4.0(0.4/3)
4.0(0.4/3)
3.0(0.3/2.2) 20(2.0/14.5)
135R200001