Opel Frontera UBS. Manual - part 1328

 

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Opel Frontera UBS. Manual - part 1328

 

 

6A – 62 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 N·m (1.5 kg·m / 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 N·m (2.0 k·m / 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 N·m (2.0 kg·m / 14.5 lb ft)

19. Install timing belt cover.

Torque: 9 N·m (0.9 kg·m / 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 N·m (8.1 kg·m / 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.

014RW042

ENGINE MECHANICAL 6A – 63

VALVE CLEARANCE ADJUSTMENT

NOTE: 

1. Valve clearance should be inspected and adjusted

while the engine is cool.

2. The tightening of the camshaft bearing cap and

camshaft carrier assembly should be checked
before inspecting and adjusting valve clearance.

INSPECTION

1. Remove cylinder head noise insulator cover and

cylinder head cover.
Refer to “Cylinder Head” in this manual.

2. Disconnect all harness connecters of the injector

and remove harness assembly.

3. Drain oil from oil rail assembly.
4. Remove injector clamp nuts and fixing bolts to take

out injector assembly.

5. Loosen oil rail bolts, remove oil rail assembly.
6. Set cylinder No.1 to the TDC at the compression

stroke. Make sure that there is play in cylinder No.1
tappets on inlet and exhaust sides and that there is
no play in cylinder No.4 tappets.

7. Measure valve clearance at No.1 TDC (Refer to the

black circles indicated in the illustration).

Standard Valve clearance:

Intake valve:

0.15 mm (0.0059 in) ± 0.05 mm (0.0020 in)

Exhaust valve: 0.25 mm (0.0098 in) ± 0.05 mm (0.0020 in)

8. Turn the crankshaft one turn to set No.4 cylinder

TDC at the compression stroke.

9. Measure valve clearance at No.4 TDC (Refer to the

black circles indicated in the illustration).

Standard Valve clearance:

Intake valve:

0.15 mm (0.0059 in) ± 0.05 mm (0.0020 in)

Exhaust valve: 0.25 mm (0.0098 in) ± 0.05 mm (0.0020 in)

10. If measured value is outside standard value,

readjust the valve clearance.

ADJUSTMENT

For valve clearance adjustment, follow the procedure
given below.

1. Set cylinder No.1 or No.4 to the TDC at the

compression stroke.
Set the valve clearance adjusting tool on the tappet
requiring adjustment.
After making sure of the correct setting of the
special tool, depress the tappet by turning the bolt.
Valve Clearance Adjusting Tool: 5-8840-2590-0

NOTE: Before depressing the tappet, set the tappet
notch in the direction where adjuster can be easily
taken out.

2. Take out the adjuster using a small screw driver and

finger magnet.

No.1

Ft

No.2

No.1 TDC

No.3

No.4

EXH

IN

011RW045

No.1

Ft

No.2

No.4 TDC

No.3

No.4

EXH

IN

011RW046

014RW150

6A – 64 ENGINE MECHANICAL

3. Determine the thickness of the adjuster as follows.

1) Measure the thickness of the removed adjuster

with a micrometer.

2) Calculate the thickness of a new adjuster.

Calculation
TA: Thickness of new adjuster
M:  Valve clearance measurement.
TO: Thickness of the removed adjuster
For intake side:

TA=TO+(M–0.15) mm

For exhaust side:

TA=TO+(M–0.25) mm

Select a new adjuster whose thickness is as
close to the estimated value as possible.

4. Install oil rail and tighten it temporarily.
5. Install injector assembly.

NOTE:

1) Do not forget to insert the O-ring between injector

and oil rail.

2) Install the injector to the same position as before

removal.

6. Install the injector fixing bolts and temporarily

tighten.

7. Install the injector clamp and tighten temporarily.
8. Tighten injector fixing bolts to the specified torque.

Torque: 6.5 N·m (0.7 kg·m / 5.1 lb ft)

9. Tighten injector clamp nut to the specified torque

with special method.

Torque: loosen one turn and tighten again to
specified torque.

Torque: 25 N·m (2.4 kg·m / 17.4 lb ft)
10. Tighten oil rail to the specified torque.

Torque: 20 N·m (2.0 kg·m / 14.5 lb ft)
11. Install injector harness and reconnect connector.
12. Install cylinder head cover.

Refer to”Cylinder Head” in this manual.

13. Fill with about 300cc of engine oil at the high

pressure oil pipe installation port on the oil rail using
an oil filler.
If assembled without filling the oil rail with oil, the
time for engine starting will be longer.

14. Immediately install high pressure oil pipe to tighten

with specified torque.

Torque: 80 N·m (8.1 kg·m / 57.9 lb ft)
15. Install cylinder head noise insulator cover.

Refer to “Cylinder Head” in this manual.

ENGINE MECHANICAL 6A – 65

OIL RAIL AND INJECTOR

REMOVAL

Prior to removal, be sure to confirm and record the
group code of the injector installed using Tech2.

1. Disconnect battery ground cable.
2. Remove air cleaner cover and air duct.
3. Remove intercooler.

Refer to “Intercooler” in this manual.

4. Remove PCV hose and pipe.
5. Remove cylinder head noise insulator cover.
6. Remove high pressure oil pipe.

CAUTION:

1) Sleeve nut should be loosened with cloth tied

around it to prevent oil from spurting due to the
remaining pressure.

2) The high pressure pipe should be disconnected

with a cloth tied around the intake manifold
glow plug to prevent oil from flowing out of the
oil rail.

7. Loosen eye bolt of fuel pipe at fuel pump side.

NOTE: Cloth should be put around the loosened eye
bolt to prevent fuel from flowing out.

8. Remove fuel return hose at chassis side.
9. Remove PCV hose to cylinder head cover.

10. Remove cylinder head cover.
11. Drain the oil from oil rail assembly.
12. Record the identification marking of injector for

each cylinder which is indicated on the upper
portion of injector.
There are nine kinds of identification marking
available, one alphabet letter and one numeral
letter.
In case three kinds of markings are given, one
alphabet letter (sometimes printed) and one
numeral letter, top priority is given to the one
alphabet letter and one numeral letter.

1

6

2

7

3

5

4

012RW102-1

Legend

(1)

Injector Clamp

(2)

Injector Assembly

(3)

Oil Rail Assembly

(4)

Camshaft Bracket

(5)

Camshaft

(6)

O-Ring

7)

Drain Plug

 

 

 

 

 

 

 

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