Opel Frontera UBS. Manual - part 2072

6A–22

ENGINE MECHANICAL

16. Remove timing belt covers for right bank side.
17. Reomve timing belt covers for right bank side.

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Legend

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

18. Remove ignition coil assemblies for the right side

bank.

19. Remove cylinder head cover assembly.

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.

D

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

D

The cylinder head cover must be installed within 5
minutes after sealant application before the sealant
hardens.

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D

Tighten bolts in turn to the specified torque.

Torque : 8.8 N·m (0.9 Kg·m/78 lb in)

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2. Install 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 timing belt cover and tighten the fixing bolts and

nut to the specified torque.

Torque : 19 N·m (1.9 Kg·m/14 lb ft)

4. Install crankshaft pulley and tighten the fixing bolt

using 5–8840–0133–0 crankshaft holder to the
specified torque.

Torque : 167 N·m (17 Kg·m/123 lb ft)

5. Install auto tensioner assembly and tighten the fixing

bolts to the specified torque.

Torque :
Shorter Bolt : 20 N·m (2.0 Kg·m/14.8 lb ft)
Longer Bolt : 39 N·m (4.0 Kg·m/28.8 lb ft)

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.

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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) 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.

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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.

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Legend

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

10.  Install 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 Cleaner Element.
(5) Mass Air Flow Sensor