Opel Frontera UE. Manual - part 1420

6A–57

ENGINE MECHANICAL (6VD1 3.2L)

2. Remove camshaft bracket fixing bolt (5), camshaft

bracket (6), then camshaft exhaust (7), and intake
side (8).

3. Remove the cylinder head assembly.
4. Remove tappet with shim (11).
5. 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

6. 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:

D

Do not attempt to weld the cylinder head. Replace
it.

D

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. Reassemble the valve, valve seat, valve spring and

split collars.
Refer to the reassembly procedure for valve spring,
oil controller, valve, valve guide in this manual.

2. Install the cylinder head assembly to cylinder block.

Refer to the installation procedure for cylinder head
in this manual.

3. Install the camshaft assembly.

Refer to the installation procedure for camshaft in this
manual.

4. Install the spark plug and tighten all the spark plugs to

specified torque.

Torque: 18 N·m (1.8 kg·m/13 lb ft)

SECTION

6A–58

ENGINE MECHANICAL (6VD1 3.2L)

Valve Spring, Oil Controller, Valve, Valve Guide

Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts

014RW039

Legend

(1) Camshaft Bracket Fixing Bolts
(2) Camshaft Assembly Inlet
(3) Camshaft Assembly Exhaust
(4) Shim
(5) Tappet
(6) Split Collar

(7) Spring Upper Seat
(8) Valve Spring
(9) Oil Controller

(10) Spring Lower Seat

(11) Valve Guide

(12) Valve

Disassembly

1. Remove camshaft bracket fixing bolts (1).
2. Remove camshaft assembly (intake).

3. Remove camshaft assembly (Exhaust side).
4. Remove shim (4) and tappet (5).

SECTION

6A–59

ENGINE MECHANICAL (6VD1 3.2L)

5. Use 5–8840–2446–0 valve spring compressor and

5–8840–2547–0 valve spring compressor adapter to
remove split collar.

014RW042

6. Remove valve spring.
7. Remove valve.
8. Remove oil controller and spring lower seat.
9. Remove the valve guide using the 5–8840–2442–0

valve guide replacer.

Inspection and Repair

Valve Spring

CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is evident.

1. Measure the free height of the springs. The springs

must be replaced if the free height is below the
specified limit.

Standard : 44.6 mm (1.7559 in)
Limit : 43.6 mm (1.7165 in)

014RS004

2. Measure the valve spring squareness with a steel

square and replace the valve springs if the measured
value exceeds the specified limit.

Limit : 2 mm (0.0787 in)

014RS005

3. Using a spring tester to compress the springs to the

installed height, measure the compressed spring
tension, and replace the springs if the measured
tension is below the specified limit.

At installed height: 35.0 mm (1.38 in)
Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)

014RS006

Valve Guide

CAUTION: Take care not to damage the valve seat
contact surface, when removing carbon adhering to
the valve head. Carefully inspect the valve stem for
scratchs or abnormal wear. If these conditions are
present, the valve and the valve guide must be
replaced as a set.

SECTION

6A–60

ENGINE MECHANICAL (6VD1 3.2L)

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
Intake
Standard : 5.977 mm–5.959 mm

(0.2353 in–0.2346 in)

Limit : 5.90 mm (0.2323 in)
Exhaust
Standard : 5.952 mm–5.970 mm

(0.2343 in–0.2350 in)

Limit : 5.90 mm (0.2323 in)

014RS007

2. Measure the inside diameter of the valve guide with a

micrometer. Subtract the measured outer diameter of
the valve stem from the measured inner diameter of
the valve guide. If the value exceeds the specified
limit, the valve and the valve guide must be replaced
as a set.

Inside Diameter of the Vale Guide
Inlet clearance
Standard : 0.023 mm–0.056 mm

(0.0009 in–0.0002 in)

Limit : 0.20 mm (0.00787 in)
Exhaust clearance
Standard : 0.030 mm–0.063 mm

(0.0012 in–0.0025 in)

Limit : 0.20 mm (0.00787 in)

Valve Guide Replacement

1. Using Valve guide replacer: 5–8840–2442–0, drive

out the valve guide from the combustion chamber
side.

014RS008

2. Apply engine oil to the outside of the valve guide.

Using valve guide replacer 5–8840–2442–0, drive in
a new valve guide from the camshaft side, and check
the valve guide height.

Valve guide upper end height: 13.0 mm (0.5118
in)

(Measured from the cylinder head upper face)

014RW046

3. Check the clearance. If the clearance is less than the

specified value, ream the inside diameter of valve
guide. Using a sharp 6 mm reamer, ream the valve
guide to obtain the specified clearance.

Valve Seat

1. Measure the protrusion of the valve stem when a new

valve is installed in the cylinder head. If the protrusion
of the valve stem exceeds the limit, replace the valve
seat insert or the cylinder head assembly.

Protrusion of valve stem
Intake
Standard: 39.32 mm (1.5480 in)

SECTION