Opel Frontera UBS. Manual - part 240

 

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Opel Frontera UBS. Manual - part 240

 

 

6A–27

ENGINE MECHANICAL

Exhaust Manifold RH

Removal

1. Disconnect battery ground cable.
2. Remove torsion bar. Refer to removal procedure in

Front Suspension section.

3. Remove exhaust front pipe three stud nuts and two

nuts then disconnect exhaust front pipe.

150RW061

Legend

(1) Exhaust Front Pipe RH
(2) O

2

 Sensor (for IGM)

4. Remove heat protector two fixing bolts then the heat

protector.

5. 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.

056RW001

Legend

(1) Exhaust Gas Recirculation (EGR) Valve
(2) EGR Pipe

6. Remove exhaust manifold eight fixing nuts then the

exhaust manifold.

Installation

1. Install exhaust manifold and tighten bolts to the

specified torque.

Torque : 57 N·m (5.8 Kg·m/42 lb ft)

2. Install the EGR pipe, tighten bolt 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/33 lb 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 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)

5. Install the torsion bar and readjust the vehicle height.

Refer to installation and vehicle height adjustment
procedure for Front Suspension.

6A–28

ENGINE MECHANICAL

Crankshaft Pulley

Removal

1. Disconnect battery ground cable.
2. Remove air cleaner 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 radiator upper fan shroud from radiator.
4.  Move serpentine belt tensioner to loose side using

wrench then remove serpentine belt.

850RW001

Legend

(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Serpentine Belt

5. Remove cooling fan assembly four fixing nuts, then

the cooling fan assembly.

6. Remove crankshaft pulley assembly using J-8614-01

crankshaft holder, hold crankshaft pulley then
remove center bolt and pulley.

Installation

1. Install crankshaft pulley using J-8614-01 crankshaft

holder, hold the crankshaft pulley and tighten center
bolt to the specified torque.

Torque : 167 N·m (17.0 Kg·m/123 lb ft)

2. Install cooling fan assembly and tighten bolts/nuts to

the specified torque.

Torque : 22 N·m (2.2 Kg·m/16 lb ft) for fan pulley
and fan bracket.

Torque : 10 N·m (1.0 Kg·m/88.5 lb in) for fan and
clutch assembly.

3. Move serpentine belt tensioner to loose side using

wrench, then install serpentine belt to normal
position.

4. Install radiator upper fan shroud.
5. Install air cleaner assembly.

6A–29

ENGINE MECHANICAL

Timing Belt

Removal

1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench

then remove drive belt.

850RW001

Legend

(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt

5. Remove cooling fan assembly four nuts, then the

cooling fan assembly.

6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.

10. Remove crankshaft pulley assembly using

5–8840–0133–0 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.

11. Remove right side timing belt cover then left side

timing belt cover.

12. Remove lower timing belt cover
13. Remove pusher.

CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.

014RW011

Legend

(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin

14. Remove timing belt.

CAUTION:
1. Do not bend or twist the belt, otherwise its core

could be damaged. The belt should not be bent at
a radius less than 30 mm.

2. Do not allow oil or other chemical substances to

come in contact with the belt. They will shorten
the life.

3. Do not attempt to pry or stretch the belt with a

screw driver or any other tool during installation.

4. Store timing belt in a cool and dark place. Never

expose the belt direct sunlight or heat.

6A–30

ENGINE MECHANICAL

Installation

NOTE: For correct belt installation, the letter on the belt
must be able to be read as viewed from the front of the
vehicle.

014RY00042

Legend

(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley

014RY00043

Legend

(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt
(9) Alignment Mark (notch) on Crankshaft Timing

Pulley.

(10) Alignment Mark (groove) on Crankshaft Timing

Pulley.

014RW006

Legend

(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side

1. Install timing belt.

1. Align the mark (notch) of crankshaft timing pulley

(2) with mark on oil pump (1).
Align the mark (groove) on the crankshaft timing
pulley (3) with alignment mark (white dots line) on
the timing belt (4).

NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.

014RW003

Legend

(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt

 

 

 

 

 

 

 

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