Opel Frontera UE. Manual - part 869

6A–25

ENGINE MECHANICAL (6VD1 3.2L)

Cylinder Head Cover RH

Removal

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

common chamber.

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3. Disconnect the wires and bonding cables.

D

Exhaust Gas Recirculation (EGR) valve

D

Fuel injectors for right cylinder bank

D

Ignition coils for right cylinder bank

D

Bonding cable

D

Other parts as required

4. Remove the engine harness from the cylinder head

cover.

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Legend

(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies

5. Remove the ignition coil assemblies from the right

cylinder bank.

6. Remove the cylinder head cover assembly.

6A–26

ENGINE MECHANICAL (6VD1 3.2L)

Installation

1. Install the cylinder head cover.

D

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

D

Apply a 2-3 mm bead of sealant (TB-1207B or
equivalent) to the 8 arched areas of the camshaft
bracket.

D

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

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D

Tighten the bolts to the specified torque, using the
tightening sequence shown in the illustration.

Torque : 9 N·m (0.9 kg·m/78 lb in)

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2. Install the ignition coil assemblies and tighten the

fixing bolts to the specified torque.

Torque : 4 N·m (0.4 kg·m/35 lb in)

3. Install the engine harness and tighten the fixing bolts

of the retaining clip and the brackets to the specified
torque.

Torque : 4 N·m (0.4 kg·m/35 lb in)

4. Connect the wires and the bonding cables.
5. Install the engine cover by alining the dowels.

6A–27

ENGINE MECHANICAL (6VD1 3.2L)

Common Chamber

Removal

1. Disconnect the battery ground cable.
2. Drain the engine coolant from the tap at the bottom of

radiator (Approximately 2 liters).

3. Remove the engine cover.
4. Remove the air cleaner duct assembly (3) and the air

cleaner element (4).

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Legend

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

NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before the
air cleaner duct assembly is removed.

5. Disconnect the accelerator pedal cable and the auto

cruise cable from the throttle body and cable bracket.

6. Disconnect the vacuum booster hose from the

common chamber.

7. Disconnect the wires and bonding cables.

D

Manifold absolute pressure (MAP) sensor

D

Vacuum switching valve (VSV) for induction air
control valve (IACV) actuator

D

Fuel injectors

D

Idle air control (IAC) valve

D

Throttle position sensor (TPS)

D

Exhaust gas recirculation (EGR) valve

D

Other parts as required

8. Disconnect the following vacuum hoses.

D

Brake booster

D

VSV for IACV actuator

D

Duty solenoid valve

D

Left cylinder bank PCV

D

Fuel pressure regulator

9. Remove the ventilation hose from the throttle valve

and the intake duct and then remove the water hose.

10. Loosen the clamps securing the 2 rubber hoses to the

fuel pipes (rear side of the transmission).

WARNING: SPILLED GASOLINE IS AN EXTREMELY
DANGEROUS FIRE HAZARD.

D

Plug the rubber hoses leading from the fuel
tank to prevent fuel leakage.

D

Drain residual from the fuel pipes into a
suitable container.

11. Remove the 4 throttle body fixing bolts.

12. Remove the EGR valve assembly fixing nut and bolt

on common chamber together with the pipe fixing nut.

13. Remove the fuel rail with fuel injectors.
14. Loosen the installation bolt to remove the fuel hose

bracket from the lower rear of the left cylinder head.

15.  Remove the 2 bolts from common chamber rear side

to remove the fuel hose bracket.

16. Remove the common chamber 4 nuts and 4 bolts

then remove the common chamber.

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Legend

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

6A–28

ENGINE MECHANICAL (6VD1 3.2L)

Installation

1. Install the common chamber and tighten the nuts and

bolts 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 the fuel hose bracket and tighten the bolts to

the specified torque.

Torque : 10 N·m (1.0 kg·m/87 lb in)

3. Install the fuel rail with fuel injectors.
4. Install the EGR valve assembly and tighten the nuts

and bolts to the specified torque.

Torque : 10 N·m (1.0 kg·m/87 lb in)

5. Tighten the EGR valve pipe nut.

Torque : 44 N·m (4.5 kg·m/33 lb ft)

6. Install the throttle body and tighten the bolts to the

specified torque.

Torque : 25 N·m (2.5 kg·m/18 lb ft)

7. Install the ventilating hose to the throttle valve and

intake duct.

8. Connect the vacuum hoses.

(disconnected during the removal procedure).

Torque : 25 N·m (2.5 kg·m/18 lb ft)

9. Connect the each connector without fail.

10. Connect the vacuum booster hose.

11. Connect the wires and bonding cables.

(disconnected during the removal procedure).

12. Connect the accelerator pedal cable.

Accelerator pedal cable adjustment

1. Loosen the adjusting nut and screw cap.

2. Pull out the outer cable while fully closing the

throttle valve.

3. Tighten the adjusting nut and lock nut temporarily.

4. Loosen the adjusting nut by 3 turns and tighten

the lock nut.
Then manually operating the throttle valve.
Make sure that the valve lever returns up to the
stopper screw.
If it does not reach the stopper screw, repeat from
step 1.

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Legend

(1) Clearance
(2) Lock Nut
(3) Adjusting Nut

13. Install the air cleaner element and air cleaner duct

assembly.
Clip the hose at both ends.