1998 OPEL FRONTERA torque

6A–53
ENGINE MECHANICAL
2. Remove camshaft bracket fixing bolt (5), camshaft
bracket (6), then camshaft exhaust (7), and intake
side (8).
3. Remove tappet with shim (11).
4. Use the 5–8840–2446–0 valve spring compressor
and 5–8840–2547–0 valve spring compressor
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).
014RW042
5. Remove spark plug (1).
CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.
Inspection and Repair
1. Cylinder head gasket and mating surfaces for leaks,
corrosion and blow–by. If the gasket has failed,
determine the cause.
– Insufficient torque on head bolts.
– Improper installation
– Loose or warped cylinder head
– Missing dowel pins
– Warped case surface
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.
Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and exhaust
manifold mating surfaces for flatness. These
surfaces may be reconditioned by milling. If the
surfaces are “out of flat” by more than specification,
the surface should be ground to within specifications.
Replace the head if it requires machining beyond the
repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362 in)
011RW019
5. Water jacket sealing plugs seating surfaces.
Reassembly
1. Install Spark plug and tighten all the spark plugs to
specified torque.
Torque: 18 Nꞏm (1.8 Kgꞏm/13 lb ft)
2. Tighten sub gear setting bolt.
1. Use 5–8840–2443–0 gear spring lever to turn sub
gear to right direction until the M5 bolt aligns with
the hole between camshaft driven gear and sub
gear.

6A–54
ENGINE MECHANICAL
2. Tighten the M5 bolt to a suitable torque to prevent
the sub gear from moving .
014RW025
3. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)
4. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the specified
torque.
1. Apply engine oil to camshaft journal and bearing
surface of camshaft bracket.
2. Align timing mark on intake camshaft (one dot for
right bank, two dots for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).
014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust
014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin

6A–55
ENGINE MECHANICAL
014RW024
Legend
(1) Right Bank
(2) Left Bank(3) Alignment Mark on Camshaft Drive Gear
(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer
3. Tighten twenty bolts in numerical order on one
side bank as shown in the illustration.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)
014RW031
5. Tighten bolt for camshaft drive gear assembly pulley
to the specified torque.
Torque: 98 Nꞏm (10.0 Kgꞏm/72 lb ft)

6A–65
ENGINE MECHANICAL
Runout
Limit : 0.1 mm (0.0039 in)
014RW044
4. Measure the camshaft journal oil clearance.
1. Measure the camshaft bracket housing inside
diameter.
NOTE: Tighten camshaft bracket (2) to specified torque
before measuring the camshaft bracket inside diameter.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
014RW031
2. Subtract the camshaft outside diameter from the
camshaft bracket housing inside diameter.
Oil Clearance
Standard : 0.027 mm–0.078 mm
(0.0011 in–0.0031 in)
Limit : 0.11 mm (0.0043 in)
014RW037
5. Replace the cylinder head and/or camshaft if the
measured oil clearance exceeds the specified limit.
1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
2. Install camshaft assembly and camshaft brackets
(2), tighten twenty bolts (1) on one side bank to
the specified torque.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)
014RW031
3. Measure the camshaft thrust clearance with a dial
indicator. Replace the camshaft and/or the
cylinder head if the camshaft thrust clearance
exceeds the specified limit.
Camshaft thrust Clearance
Standard : 0.03 mm–0.08 mm
(0.0012 in.–0.0031 in.)

6A–66
ENGINE MECHANICAL
Limit : 0.12 mm (0.0047 mm)
014RW035
Reassembly
1. Install camshaft drive gear assembly and tighten
three bolts to specified torque.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)
2. Tighten sub gear setting bolt.
1. Use 5–8840–2443–0 to turn sub gear to right
direction until the M5 bolt hole aligns between
camshaft driven gear and sub gear.
2. Tighten M5 bolt suitable torque for prevent
moving the sub gear.
014RW041
3. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the specified
torque.
1. Apply engine oil to camshaft journal and bearing
surface of camshaft bracket.2. Align timing mark on intake camshaft (one dot for
right bank, two dots for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).
014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discerning Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust

6A–67
ENGINE MECHANICAL
014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin
014RW024
Legend
(1) Right Bank
(2) Left Bank(3) Alignment Mark on Camshaft Drive Gear
(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer
3. Tighten twenty bolts in numerical order on one
side bank as shown in the illustration.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)

6A–68
ENGINE MECHANICAL
014RW031
4. If the oil seal requires replacement, use the
5–8840–2445–0 to install the oil seal.
014RW034
5. Tighten bolt for camshaft drive gear pulley to the
specified torque using the 5–8840–2447–0 universal
holder.
Torque: 98 Nꞏm (10.0 Kgꞏm/72 lb ft)
014RW060

6A–70
ENGINE MECHANICAL
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8).
Refer to “Piston, Piston Ring and Connecting Rod” in
this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).
Inspection and Repair
1. Crankshaft
Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance. If the thrust
clearance exceeds the specified limit, replace the
thrust bearings as a set.
Thrust Clearance
Standard : 0.06 mm–0.24 mm
(0.0024 in–0.0094 in)
Limit : 0.30 mm (0.0118 in)
015RS003
Main Bearing Clearance
1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.
Arrange the removed main bearing caps in the
cylinder number order.
Remove the main bearings.
015RS004
3. Remove the crankshaft.
Remove the main bearings.
4. Clean the upper and lower bearings as well as the
crankshaft main journal.
5. Check the bearings for damage or excessive wear.
The bearings must be replaced as a set if damage or
excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to their
original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8. Apply plastigage to the crankshaft journal unit as
shown in the illustration.
NOTE: Do not set the plastigage on the oil hole.
015RS005
9. Install main bearing caps, oil gallery and crank case
bolts in the order shown, and tighten each bolt to the
specified torque.