Opel Frontera UE. Manual - part 1412

6A–25

ENGINE MECHANICAL (6VD1 3.2L)

Cylinder Head Cover RH

Removal

1. Disconnect battery ground cable.
2. Remove engine cover from the dowele on the

common chamber.

F06RY001

3. Disconnect ventilation hose from cylinder head cover.
4. Disconnect three ignition coil connectors from ignition

coils and remove harness bracket bolts on cylinder
head cover then remove ignition coil fixing bolts on
ignition coils and remove ignition coils.

5. Disconnect fuel injector harness connector then

remove fuel injector harness bracket bolt.

6. Remove eight fixing bolts then the cylinder head

cover.

010RW002

Installation

1. Install cylinder head cover.

D

Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely. 

Apply sealant (TB-1207B or equivalent) bead
(diameter 2-3 mm) at eight places of arched areas
of camshaft bracket on front and rear sides.

D

The cylinder head cover must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.

D

Tighten bolts to the specified torque.

Torque : 9 N·m (0.9 kg·m/78 lb in)

014RW019

2. Tighten fuel injector harness bracket bolts to

specified torque then reconnect fuel injector harness
connector.

Torque : 7.8 N·m (0.8 kg·m/5.7 lb ft)

3. Connect ignition coil connector and tighten ignition

coil fixing bolts to specified torque.

Torque : 4 N·m (0.4 kg·m/35 lb in)

4. Connect ventilation hose to cylinder head.
5. Install engine cover mating with the dowels.

SECTION

6A–26

ENGINE MECHANICAL (6VD1 3.2L)

Common Chamber

Removal

1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.

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Legend

(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Flow Sensor

3. Disconnect vacuum booster hose from common

chamber.

4. Disconnect connector from manifold absolute

pressure sensor, Ion sensing module, throttle
position sensor, solenoid valve, electric vacuum
sensing valve, and EGR valve.

5. Disconnect vacuum hose on canister VSV and

positive crankcase ventilation hose, fuel rail
assembly with pressure control valve bracket.

6. Remove ventilation hose from throttle valve and

intake duct and remove water hose.

7. Remove the four throttle body fixing bolts.
8. Remove exhaust gas recirculation valve assembly

fixing bolt and nut on common chamber and remove
EGR valve assembly.

9.  Remove two bolts from common chamber rear side

for remove fuel hose bracket.

10. Remove common chamber four bolts and four nuts

then remove the common chamber.

025R100011

Legend

(1) Common Chamber
(2) Throttle Valve Assembly
(3) Bolt

Installation

1. Install common chamber and tighten bolts and nuts to

the specified torque.

Torque :
Bolt : 25 N·m (2.5 kg·m/18 lb ft)
Nut : 25 N·m (2.5 kg·m/18 lb ft)

2. Install fuel hose bracket and tighten bolts to specified

torque.

Torque : 10 N·m (1.0 kg·m/89 lb in)

3. Install exhaust gas recirculation valve assembly and

tighten bolt and nut to the specified torque.

Torque : 25 N·m (2.5 kg·m/18 lb ft)

4. Install throttle body and tighten bolts to the specified

torque.

Torque : 10 N·m (1.0 kg·m/89 lb in)

5. Install ventilating hose to throttle valve and intake

duct.

6. Connect vacuum hoses on canister VSV and positive

crankcase ventilation hose. Tighten bolts for fuel rail
assembly with pressure control valve bracket.

Torque : 25 N·m (2.5 kg·m/18 lb ft)

7. Connect each connector without fail.

SECTION

6A–27

ENGINE MECHANICAL (6VD1 3.2L)

8. Connect vacuum booster hose.
9. Connect the Ion sensing module connectors as

shown in the illustration.

060RY00003

Legend

(1) Green Connector
(2) Blue Connector

10.  Install air cleaner duct assembly.

013RY00001

Legend

(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Mass Air Flow Sensor

SECTION

6A–28

ENGINE MECHANICAL (6VD1 3.2L)

Exhaust Manifold LH

Removal

1. Disconnect the battery ground cable.
2. Raise the vehicle and support it with chassis stands.
3. Remove the left side wheel and tire assembly.
4. Remove the mud fender skirt.
5. Disconnect the O

2

 sensor connector.

6. Remove the 3 stud nuts from the exhaust pipe flange.
7. Remove the 2 bolts from the rear end of the front

exhaust pipe with catalytic converter.

8. Remove the front exhaust pipe with catalytic

converter rubber support.

9. Move the front exhaust pipe with catalytic converter to

the rear.

150RY00039

Legend

(1) Exhaust Front Pipe LH
(2) Bolt
(3) Rubber Support
(4) Stud Nut
(5) O

2

 Sensor

10. Remove the exhaust manifold heat protector.

11. Remove the 8 exhaust manifold fixing nuts and the

exhaust manifold from the engine.

027RY00006

Legend

(1) Exhaust Manifold Heat Protector
(2) Exhaust Manifold

Installation

1. Install the exhaust manifold and exhaust manifold

gasket.

D

Do not reuse the old exhaust manifold nuts.

Use new nuts and tighten to the specified torque.

Torque: 57 N·m (5.8 kg·m/42 lb ft)

2. Install the exhaust manifold heat protector.
3. Fix the front exhaust pipe with catalytic converter to

the exhaust manifold flange stud bolts and
hand-tighten the nuts.

4. Hang the front exhaust pipe with catalytic converter

on the chassis (pipe to rubber support/rubber support
to chassis).

5. Hand-tighten the 2 bolts at the rear end of the front

exhaust pipe.

6. Tighten the exhaust pipe flange stud nuts.

Torque : 67 N·m (6.8 kg·m/49 lb ft)

7. Tighten the 2 bolts at the rear end of the front exhaust

pipe.

Torque : 43 N·m (4.4 kg·m/32 lb ft)

8. Connect the O

2

 sensor connector.

9. Install the mud fender skirt.

10. Install the left side wheel and tire assembly.

SECTION