Opel Frontera UE. Manual - part 271

6A–48

ENGINE MECHANICAL (6VD1 3.2L)

If the engine is assembled in the condition that the
dowels have not been mounted in the specified posi-
tions, the transmission may be damaged the trans-
mission.

012RS009

1. Install engine assembly. Tighten engine mount fixing

bolts to frame to the specified torque.

Torque: 41 N·m (4.2 Kg·m/30 lb ft)

2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to Transmission

section in this manual.

4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two (each

bank) rear exhaust flange nuts then tighten three stud
nuts (each bank) between exhaust manifold and
exhaust pipe, finally tighten rear side nuts to the
specified torque.

Torque:
Nuts: 43 N·m (4.4 Kg·m/32 lb ft)
Stud nuts: 67 N·m (6.8 Kg·m/49 lb ft)

150RX015

Legend

(1) Exhaust Front Pipe RH
(2) O

2

 Sensor

150RX014

Legend

(1) O

2

 Sensor

(2) Exhaust Front Pipe LH

7. Reconnect O

2

 sensor connector.

8. Install cooling fan assembly and tighten bolts/nuts to

the specified torque.

Torque : 22 N·m (2.2 Kg·m/16 lb ft) for fan pulley
and fan bracket.

Torque : 10 N·m (1.0 Kg·m/88.5 lb in) for fan and
clutch assembly.

6A–49

ENGINE MECHANICAL (6VD1 3.2L)

9. Install air conditioner compressor to engine and

tighten to the specified torque.

Torque :
M8 bolts : 22 N·m (2.2 Kg·m/16 lb ft)
M10 bolts : 43 N·m (4.4 Kg·m/32 lb ft)

10. Install power steering pump, tighten fixing bolt to the

specified torque.

Torque :
M8 bolts : 22N·m (2.2 Kg·m/16 lb ft)
M10 bolts : 46 N·m (4.7 Kg·m/34 lb ft)

11. Move drive belt tensioner to loose side using wrench,

then install drive belt to normal position.

850RW001

Legend

(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt

12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.

17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of right

dash panel.

19. Reconnect ground cable between engine and

chassis.

20. Reconnect harness connector to transmission and

install transmission harness bracket on engine left
side.

21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.
24. Install air cleaner assembly.
25. Reconnect air duct.
26. Reconnect accelerator cable and automatic cruise

control cable to throttle valve on common chamber.

035RW007

Legend

(1) Throttle Valve Assembly
(2) Throttle Lever
(3) Idle Air Control Valve
(4) Throttle Position Sensor

27. Install engine hood to the original position.

D

Refer to installation procedure for Body section in
this manual.

28. Install accelerator pedal cable.

6A–50

ENGINE MECHANICAL (6VD1 3.2L)

Cylinder Head

Cylinder Head and Associated Parts

011RW008

Legend

(1) Spark Plug
(2) Cylinder Head Bolt
(3) Camshaft Drive Gear Pulley Fixing Bolt
(4) Camshaft Drive Gear Pulley
(5) Camshaft Bracket Fixing Bolt
(6) Camshaft Bracket
(7) Camshaft Exhaust

(8) Camshaft Intake
(9) Retainer Fixing Bolt

(10) Retainer Assembly

(11) Tappet with Shim

(12) Split Collar
(13) Valve Spring and Spring Upper Seat
(14) Valve

Disassembly

NOTE:

D

During disassembly, be sure that the valve train
components are kept together and identified so that
they can be reinstalled in their original locations.

D

Before removing the cylinder head from the engine
and before disassembling the valve mechanism,
perform a compression test and note the results.

1. Remove camshaft drive gear pulley fixing bolt (3),

then pulley (4).

6A–51

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 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:

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. Install Spark plug and tighten all the spark plugs to

specified torque.

Torque: 18 N·m (1.8 Kg·m/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.