Opel Frontera UBS. Manual - part 1124

6A–23

ENGINE MECHANICAL

6. Install idle pulley assembly and tighten the fixing bolt

to the specified torque.

Torque : 52 N·m (5.3 Kg·m/38.4 lb ft)

7. Install fan pulley and bracket assembly and tighten

the fixing bolts and nut to the specified torque.

Torque : 22 N·m (2.2 Kg·m/16.2 lb ft)

8. Install drive belt by pushing down the auto tensioner

using spanner as shown in the removal step of drive
belt.

9. Install cooling fan clutch assembly and tighten the

fixing bolts to the specified torque.

Torque : 10 N·m (1.0 Kg·m/88.5 lb in)

10. Install upper fan guide and clip both side and tighten

the fixing bolts to the specified torque.

Torque : 4 N·m (0.4 Kg·m/35.4 lb in)

11. Install engine harness and tighten the fixing bolts of

the retaining clip and brackets to the specified torque.

Torque : 4 N·m (0.4 Kg·m/35.4 lb in)

12. Connect radiator upper and lower hoses and clip

them securely.

13. Connect wiring connectors and bonding cable of

those which were disconnected in the removal step.

14. Install air cleaner element and air cleaner duct

assembly, and the clip both end securely.

15. Connect MAF sensor connector, IAT sensor

connector and PCV hose.

16. Install engine cover mating with the dowels.

6A–24

ENGINE MECHANICAL

Common Chamber

Removal

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

130RW001

Legend

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

3. Disconnect accelerator pedal cable from throttle body

and cable bracket.

4. Disconnect vacuum booster hose from common

chamber.

5. Disconnect connector from manifold absolute

pressure sensor, idle air control valve, throttle
position sensor, solenoid valve, electric vacuum
sensing valve, and EGR valve.

6. Disconnect vacuum hose on canister VSV and

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

7. Remove ventilation hose from throttle valve and

intake duct and remove water hose.

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

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

10.  Remove two bolts from common chamber rear side

for remove fuel hose bracket.

11. Remove common chamber four bolts and four nuts

then remove the common chamber.

025RW001

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 : 25 N·m (2.5 Kg·m/18 lb ft)

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.
8. Connect vacuum booster hose.
9. Connect accelerator pedal cable.

Accelerator pedal cable adjustment

1. Loosen the adjusting nut and screw cap.

2. Pull outer cable while fully closing the throttle

valve.

6A–25

ENGINE MECHANICAL

3. Tighten adjusting nut and lock nut temporarily.

4. Loosen adjusting nut by three turns and tighten

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.

035RW004

Legend

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

10.  Install air cleaner duct assembly.

130RW001

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

6A–26

ENGINE MECHANICAL

Exhaust Manifold LH

Removal

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

130RW001

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

3. Remove exhaust front pipe three stud nuts from

exhaust side and two nuts from rear end of exhaust
front pipe.

150RW062

Legend

(1) Exhaust Front Pipe LH

4. Remove heat protector two fixing bolts then the heat

protector.

5. Remove a bolt on engine LH side for air conditioner

(A/C) compressor bracket and loosen two bolts for
A/C compressor then move A/C compressor to front
side.

6. Remove exhaust manifold eight fixing nuts and

remove exhaust manifold from the engine.

Installation

1. Install exhaust manifold and tighten exhaust manifold

fixing nuts to the specified torque with new nuts.

Torque: 57 N·m (5.8 Kg·m/42 lb ft)

2. Install heat protector.
3. Install exhaust front pipe and tighten three stud nuts

and two nuts to the specified torque.

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

150RW062

Legend

(1) Exhaust Front Pipe LH

4. Set A/C compressor to normal position and tighten

two bolts and a bolt to the specified torque.

Torque : 40 N·m (4.1 Kg·m/30 lb ft)

5. Install air cleaner duct assembly.