engine OPEL FRONTERA 1998 Workshop Manual

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

6A – 34 ENGINE MECHANICAL
NOTE: Do not scratch the oil seal on the cylinder head
during installation of the high pressure oil pipe.
4. Install the noise insulator and its cover on the
cylinder head cover.
NOTE: Do not catch the injector harness with the noise
insulator cover.
5. Connect the PCV hose.
6. Install the intercooler assembly.
Refer to “Intercooler” in this manual.
7. Install air cleaner cover and air duct.
8. Connect battery ground cable.

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

6A – 36 ENGINE MECHANICAL
EXHAUST MANIFOLD
9
598 For Europe875 63
21
4
7
4
2
1
36
025R200004
Legend
(1) Exhaust Manifold
(2) Gasket
(3) Turbocharger Assembly
(4) Water Hose(5) Water Hose
(6) Heat Protector
(7) Oil Pipe
(8) Oil Pipe
(9) Gasket
REMOVAL
1. Remove the hose from both turbocharger outlet and
intake manifold inlet side, then remove intercooler
assembly.
2. Loosen belt tensioner, remove A/C compressor
assembly.
3. Remove heat protector from turbocharger.
4. Remove water hoses and oil pipes from
turbocharger.
5. Remove turbocharger assembly from exhaustmanifold.
6. Remove exhaust manifold fixing nuts, then remove
exhaust manifold.

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 – 38 ENGINE MECHANICAL
TURBOCHARGER
9
598 For Europe875 63
21
4
7
4
2
1
36
025R200004
Legend
(1) Exhaust Manifold
(2) Gasket
(3) Turbocharger Assembly
(4) Water Hose(5) Water Hose
(6) Heat Protector
(7) Oil Pipe
(8) Oil Pipe
(9) Gasket

ENGINE MECHANICAL 6A – 39
REMOVAL
1. Remove battery.
2. Drain engine coolant.
3. Remove air cleaner cover with air duct.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove water pipe for turbocharger inlet.
6. Remove oil pipe for turbocharger.
1) Remove eye bolt from turbocharger.
2) Plug oil port on the turbocharger to prevent entry
of foreign materials.
7. Remove oil drain pipe from turbocharger.
8. Remove water outlet pipe.
9. Remove heat protector.
10. Remove exhaust adaptor.
11. Remove turbocharger assembly from exhaust
manifold.
For Europe
025R200006

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