Opel Frontera UBS. Manual - part 2208

6A–22

ENGINE MECHANICAL (6VE1 3.5L)

Common Chamber

Removal

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

013RY00001

Legend

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

3. Disconnect vacuum booster hose from common

chamber.

4. Disconnect connector from manifold absolute

pressure sensor, Ion sensing module, throttle
position sensor, solenoid valve, electric vacuum
sensing valve, and EGR valve.

5. Disconnect vacuum hose on canister VSV and

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

6. Remove ventilation hose from throttle valve and

intake duct and remove water hose.

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

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

9.  Remove two bolts from common chamber rear side

to remove fuel hose bracket.

10. Remove common chamber four bolts and four nuts

then remove the common chamber.

025R200001

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/87 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)

6A–23

ENGINE MECHANICAL (6VE1 3.5L)

7. Connect each connector.
8. Connect vacuum booster hose.
9. Connect the Ion sensing module connectors as

shown in the illustration.

060RY00111

Legend

(1) Green Connector
(2) Blue Connector
(3) Identification Mark (6VE1 Engine Only)

10.  Install air cleaner duct assembly.

013RY00001

Legend

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

6A–24

ENGINE MECHANICAL (6VE1 3.5L)

Exhaust Manifold LH

Removal

1. Disconnect battery ground cable.
2. Remove transfer case skid plate.
3. Remove 3rd crossmember.
4. Disconnect Heated oxygen (O

2

) sensor connector.

5. Remove the three stud nuts from the front exhaust

pipe flange and two nuts from the rear exhaust pipe
flange.

035RX015

Legend

(1) O

2

 Sensors

(2) Exhaust Front Pipe LH
(3) Transfer Case Skid Plate
(4) 3rd Crossmember

6. Remove heat protector two fixing bolts then the heat

protector.

7. 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.

8. Remove exhaust manifold eight fixing nuts and

remove exhaust manifold from the engine.

Installation

1. Install exhaust manifold and gasket and tighten

exhaust manifold fixing nuts to the specified torque
with new nuts.

Torque: 52 N·m (5.2 kg·m/38 lb ft)

2. Install heat protector.
3. Install exhaust front pipe’s three stud nuts and rear

pipe’s two nuts to the specified torque.

Torque : 
Stud nuts: 67 N·m (6.8 kg·m/49 lb ft)
Nuts: (Exhaust front pipe LH–RH): 57 N·m (5.8
kg·m/42 lb ft)
Nuts: (Exhaust front pipe-silencer): 43 N·m (4.4
kg·m/32 lb ft)

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

two bolts to the specified torque.

Torque : 40 N·m (4.1 kg·m/30 lb ft)

5. Reconnect O

2

 sensor connectors.

6. Install 3rd crossmember.
7. Install transfer case skid plate.

6A–25

ENGINE MECHANICAL (6VE1 3.5L)

Exhaust Manifold RH

Removal

035RX016

Legend

(1) Exhaust Front Pipe RH
(2) O

2

 Sensors

(3) Torsion Bar

(4) Front Propeller Shaft
(5) Transfer Case Skid Plate
(6) 3rd Crossmember

1. Disconnect battery ground cable.
2. Remove transfer case skid plate.
3. Remove 3rd  crossmember.
4. Remove torsion bar and front propeller shaft. Refer to

removal procedure in Front Suspension section.

5. Disconnect front Heated oxygen (O

2

) sensor

connectors.

6. Remove front exhaust flange pipe three stud nuts and

two rear flange nuts then disconnect exhaust pipe.

7. Remove heat protector two fixing bolts then the heat

protector.

8. Remove exhaust gas recirculation (EGR) pipe fixing

bolt and nut from exhaust manifold, remove a nut
from EGR valve and a bolt from rear side of cylinder
head for bracket of EGR pipe then remove the EGR
pipe.

9. Remove exhaust manifolds eight fixing nuts and the

exhaust manifold.

Installation

1. Install exhaust manifold and tighten bolts to the

specified torque.

Torque : 52 N·m (5.3 kg·m/38 lb ft)

2. Install the EGR pipe, tighten bolts and nut on exhaust

manifold to specified torque.

Torque : 28 N·m (2.9 kg·m/21 lb ft)

Tighten nut to EGR valve to the specified torque.

Torque : 44 N·m (4.5 kg·m/33lb ft)

Tighten the bolt for EGR pipe bracket to specified
torque.

Torque : 25 N·m (2.5 kg·m/18 lb ft)

3. Install heat protector
4. Install front exhaust flange pipe and tighten three stud

nuts and rear two nuts to the specified torque.

Torque:
Stud nuts: 67 N·m (6.8 kg·m/49 lb ft)