Opel Frontera UBS. Manual - part 2390

6A – 34 ENGINE MECHANICAL

NOTE: Do not scratch the oil seal on the cylinder head
during installation of the high pressure oil pipe.

4. Install the noise insulator and its cover on the

cylinder head cover.

NOTE: Do not catch the injector harness with the noise
insulator cover.

5. Connect the PCV hose.
6. Install the intercooler assembly.

Refer to “Intercooler” in this manual.

7. Install air cleaner cover and air duct.
8. Connect battery ground cable.

ENGINE MECHANICAL 6A – 35

INTAKE MANIFOLD

REMOVAL

1. Drain engine coolant and disconnect water hose

from thermostat hosing.

2. Remove intercooler assembly

Refer to “Intercooler” in this manual.

3. Remove bracket bolt of oil level gauge guide tube.
4. Remove PCV Hose.
5. Remove hoses from EGR, EGR vacuum sensor

and inlet/outlet of heater.

6. Disconnect harness connector form MAP sensor,

EGR vacuum sensor, ETC sensor, water
temperature unit, IAT sensor and EVRV.

7. Remove high pressure oil pipe.
8. Remove the two way valve.
9. Remove fuel pipe from between intake manifold

and high pressure oil pump.

10. Remove fixing bolts and nuts on the intake

manifold, then remove the intake manifold
assembly.

INSTALLATION

1. Install the intake manifold, tighten bolts and nuts to

the specified torque.

Torque : 20 N·m (2.0 kg·m/14 lb ft) for bolt and nut

2. Install the fuel pipe and tighten to the specified

torque.

Torque :

M16 bolt (apply engine oil) 4 N·m (0.4 kg·m/35
lb in)
Cap nut (M10) 13N·m (1.3 kg·m/113 lb in)
Fuel pipe (M10 apply engine oil) 14 N·m (1.4
kg·m/122 lb in)

3. Install two way valve.

Torque : 20 N·m (2.0 kg·m/14 lb ft)

4. Fill with about 300 cc of engine oil from the high

pressure oil pipe installation port of the oil rail using
an oil filler. If assembled without filling the oil rail
with oil, the time for starting the engine will be
longer.

5. Install the high pressure oil pipe immediately and

tighten the sleeve nut to the specified torque.

Torque : 78 N·m (8.0 kg·m/58 lb ft)

6. Reconnect harness connector to MAP sensor, EGR

vacuum sensor, ETC sensor, Water temperature
unit, IAT sensor and EVRV.

7. Connect the hoses to EGR valve, EGR vacuum

sensor, and water inlet/outlet pipe for heater.

8. Connect PCV hose.
9. Install the oil level gauge guide tube and tighten

bracket bolt.

10. Install the intercooler assembly.

Refer to “Intercooler” in this manual.

11. Connect the hose to the thermostat housing and fill

with engine coolant.

For Europe

2

1

3

3

1

4

2

025R200005

Legend

(1)

Intake Manifold

(2)

Throttle Valve Assembly

(3)

EGR Valve

(4)

Gasket

6A – 36 ENGINE MECHANICAL

EXHAUST MANIFOLD

9

5

9

8

For Europe

8

7

5

6

3

2

1

4

7

4

2

1

3

6

025R200004

Legend

(1)

Exhaust Manifold

(2)

Gasket

(3)

Turbocharger Assembly

(4)

Water Hose

(5)

Water Hose

(6)

Heat Protector

(7)

Oil Pipe

(8)

Oil Pipe

(9)

Gasket

REMOVAL

1. Remove the hose from both turbocharger outlet and

intake manifold inlet side, then remove intercooler
assembly.

2. Loosen belt tensioner, remove A/C compressor

assembly.

3. Remove heat protector from turbocharger.
4. Remove water hoses and oil pipes from

turbocharger.

5. Remove turbocharger assembly from exhaust

manifold.

6. Remove exhaust manifold fixing nuts, then remove

exhaust manifold.

ENGINE MECHANICAL 6A – 37

INSTALLATION

1. Install gasket on the exhaust manifold and tighten

to the specified torque.

Torque : 30 N·m (3.1 kg·m/22 lb ft)

2. Install turbocharger on the exhaust manifold.

Torque : 27 N·m (2.8 kg·m/20 lb ft)

3. Install water hoses and oil pipes.
4. Install heat protector to turbocharger.

Torque : 9 N·m (0.9 kg·m/78 lb in)

5. Install A/C compressor assembly and readjust belt

tensioner.

6. Install the intercooler assembly in the normal

position.
Connect both hoses to turbocharger and intake
manifold.