Opel Frontera UBS. Manual - part 1415

 

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Opel Frontera UBS. Manual - part 1415

 

 

6J – 6 INDUCTION

Legend

(1) Pressure gauge
(2) Waste gate control rod

4) Check for cracks or breaks on the hose, if a

problem is found, the hose must be replaced.

CAUTION: Do not apply more than 120 Kpa (900
mmHg / 18.7 PSi) to waste gate actuator.

INSTALLATION

1. Install turbocharger assembly to exhaust manifold,

tighten to the specified torque.

Torque: 27 N·m (2.7 kg·m / 19.5 lb ft)

2. Install exhaust valve assembly to outlet of

turbocharger, tighten bolts to the specified torque.

Torque: 27 N·m (2.7 kg·m / 19.5 lb ft)

3. Install heat protector.
4. Water inlet pipe.

1) Tighten water inlet pipe with new gasket.

Torque: 9 N·m (0.9 kg·m / 6.5 lb ft)

5. Oil drain pipe.

1) Tighten oil drain pipe with new gasket.

Torque: 9 N·m (0.9 kg·m / 6.5 lb ft)

6. Oil inlet pipe.

1) Apply about 100 cc engine oil to turbocharger

housing before installing the oil pipe.

2) Turn the turbine shaft by hand to lubricate the

bearing.

3) Install the oil inlet pipe with a new gasket, tighten

bolt to the specified torque.

Torque: 22 N·m (2.2 kg·m / 15.9 lb ft) For M10 

Torque: 54 N·m (5.5 kg·m / 39.8 lb ft) For M14 

2

1

036RW011

036RW005

036RW006

INDUCTION  6J – 7

7. Water inlet pipe.

1) Install water inlet pipe with a new gasket, tighten

bolts to the specified torque.

Torque: 9 N·m (0.9 kg·m / 6.5 lb ft)

8. Install intercooler assembly.

Refer to “Intercooler” in this manual.

9. Install air cleaner cover with air duct.

10. Fill engine coolant to full level.
11. Install battery and connect battery cable.

036RW005

6J – 8 INDUCTION

INTERCOOLER

REMOVAL

1. Disconnect battery ground cable.
2. Remove air cleaner cover with air duct.
3. Remove intercooler cover.
4. Intercooler assembly.

1) Remove rubber hose from intercooler outlet

side.

2) Remove rubber hose from intercooler inlet side.
3) Remove four fixing bolts and remove intercooler

assembly.

INSPECTION AND REPAIR

1. Visual check for clogs in the fins.
2. Check for brokens on the tube.
3. If any problem on the intercooler is observed during

inspection, clean or replace the intercooler.

INSTALLATION

1. Intercooler assembly.

1) Connect outlet hose to intake manifold.

Tighten hose clamp to the specified torque.

Torque: 4 N·m (0.4 kg·m / 3 lb ft)

2) Connect inlet hose to the turbocharger outlet

side.
Tighten hose clamp to the specified torque.

Torque: 4 N·m (0.4 kg·m / 3 lb ft)

3) Install intercooler assembly, tighten fixing bolts

to the specified torque.

Torque: 20 N·m (2.0 kg·m / 14.5 lb ft)

2. Install intercooler cover.
3. Install air cleaner cover and air duct.
4. Connect battery ground cable.

2

3

1

Legend

(1)

Air Cleaner Cover and Air Duct

(2)

Intercooler Cover

(3)

Intercooler Assembly

036RW012

INDUCTION  6J – 9

REMOVAL

1. Remove intercooler assembly.

Refer to “Intercooler” in this manual.

2. Remove harness connector from motor and ITP

sensor.

3. Loosen the two fixing nuts and remove the throttle

valve assembly.

Legend

(1) Motor
(2) Intake Throttle Valve
(3) ITP sensor

INSPECTION AND REPAIR

1. Check for catching somwhere on the throttle valve.
2. If some problem is discovered during inspection on

the throttle valve, the throttle valve must replace.

INSTALLATION

1. Put gasket on the intake manifold and install throttle

valve.

2. Tighten nuts to the specified torque.

Torque: 20 N·m (2.0 kg·m / 14.5 lb ft)

3. Reconnect harness connector to motor and

ITPsensor.

4. Install intercooler assembly.

1

2

3

025RW032

INTAKE THROTTLE VALVE

 

 

 

 

 

 

 

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