Opel Frontera UE. Manual - part 1413

6A–29

ENGINE MECHANICAL (6VD1 3.2L)

Exhaust Manifold RH

Removal

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

2

 sensor connector (5).

6. Remove the 3 stud nuts (6) from the exhaust pipe

flange.

7. Remove the 2 bolts (4) from the rear end of the left

side front exhaust pipe with catalytic converter.

8. Remove the 4 nuts (1) from the front end of the

silencer.

9. Remove the 2 nuts (3) from the rear end of the

silencer.

10. Remove the rubber support (8) from the right-front

exhaust pipe.

11. Move the front exhaust pipe (7), the center exhaust

pipe (9) and the silencer assembly (2) to the rear.

150RY00040

SECTION

6A–30

ENGINE MECHANICAL (6VD1 3.2L)

12. Remove the exhaust gas recirculation (EGR) pipe

fixing bolts from the exhaust manifold.

13. Remove the EGR pipe bracket and bolt from the rear

side of the cylinder head.

14. Loosen the nut between the EGR pipe and the EGR

valve.

F06RY00036

Legend

(1) Pipe Fixing Nut
(2) Bracket and Bolt
(3) Pipe Fixing Bolt

15. Remove the exhaust manifold heat protector.
16. Remove the 8 exhaust manifold fixing nuts and the

exhaust manifold from the engine.

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. Install the EGR pipe between the exhaust manifold

and the EGR valve.
Tighten the fixing nuts and bolts to the specified
torque.

D

Exhaust manifold (2)

Torque: 28 N·m (2.9 kg·m/21 lb ft)

D

Rear cylinder head (1)

Torque: 44 N·m (4.5 kg·m/33 lb ft)

D

EGR pipe and EGR valve.

Torque: 25 N·m (2.5 kg·m/18 lb ft)

4. Fix the front exhaust pipe with catalytic converter to

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

5. Hang the front exhaust pipe with catalytic converter

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

6. Fix the front end of silencer and hand-tighten the 4

nuts.

7. Fix the end of the left side front exhaust pipe and

hand-tighten the bolts.

8. Fix the rear end of the silencer to the rear exhaust

pipe bolts and hand tighten the nuts.

9. Tighten the exhaust pipe flange stud nuts.

Torque: 67 N·m (6.8 kg·m/49 lb ft)

10. Tighten the front end silencer nuts.

Torque: 15 N·m (1.5 kg·m/11 lb ft)

11. Tighten the fixing bolts at the end of the left-side front

exhaust pipe.

Torque: 43 N·m (4.4 kg·m/32 lb ft)

12. Tighten the nuts at the rear of the silencer.

Torque: 43 N·m (4.4 kg·m/32 lb ft)

SECTION

6A–31

ENGINE MECHANICAL (6VD1 3.2L)

Crankshaft Pulley

Removal

1. Disconnect the battery ground cable.
2. Remove the upper fan guide.
3. Remove the serpentine belt.

D

Refer to the removal procedure for Drive Belt
(Serpentine Belt) in this manual.

4. Remove the 4 cooling fan fixing nuts and the cooling

fan with clutch assembly.

5. Remove the fan pulley bracket (2 nuts and 1 bolt) and

the fan pulley bracket.

6. Use the crankshaft holder (J-8614-01), to hold the

crankshaft pulley.

7. Remove the crankshaft center bolt and the pulley.

Installation

1. Use the crankshaft holder (J-8614-01), to hold the

crankshaft pulley.

2. Tighten center bolt to the specified torque.

Torque : 167 N·m (17.0 kg·m/123 lb ft)

3. Install the fan pulley bracket and tighten the nuts and

bolt to the specified torque.

Torque : 22 N·m (2.2 kg·m/16 lb ft)

4. Install the fan with clutch assembly to the fan pulley

bracket.

Torque : 22 N·m (2.2 kg·m/16 lb ft)

5. Use a wrench to force the auto-tensioner pulley

toward the bottom of the engine.
Place the serpentine belt over the pulley.

6. Install the upper fan guide.

SECTION

6A–32

ENGINE MECHANICAL (6VD1 3.2L)

Timing Belt

Removal

1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench

then remove drive belt.

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

5. Remove cooling fan assembly four nuts, then the

cooling fan assembly.

6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.

10. Remove crankshaft pulley assembly using

5–8840–0133–0 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.

11. Remove right side timing belt cover then left side

timing belt cover.

12. Remove lower timing belt cover
13. Remove pusher.

CAUTION: The pusher prevents air from entering
the oil chamber. The rod must always be facing
upward.

014R100020

Legend

(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
(5) Apply a force of 980 N (220 lb) when

compressing the pusher rod.

14. Remove timing belt.

CAUTION:
1. Do not bend or twist the belt, otherwise its core

could be damaged. The belt should not be bent at
a radius less than 30 mm.

2. Do not allow oil or other chemical substances to

come in contact with the belt. They will shorten
the life.

3. Do not attempt to pry or stretch the belt with a

screw driver or any other tool during installation.

4. Store timing belt in a cool and dark place. Never

expose the belt to direct sunlight or heat.

SECTION