Opel Frontera UBS. Manual - part 2485

6J – 6 INDUCTION

INSPECTION AND REPAIR

Make the necessary adjustments, repairs and part
replacements if excessive wear or damage is
discovered during inspection.
Minor servicing operations are described in this section.
Contact the nearest IHI SERVICE FACILITY for major
repairs and maintenance.
Refer to IHI SERVICE NETWORK at the end of this
section for the location of your area’s IHI SERVICE
FACILITY.
Turbine shaft end play.

1) Set a dial indicator to the turbine shaft end.
2) Apply a force of 11.8 N (1.2 kg / 2.6 lb)

alternately to the compressor wheel and and the
turbine wheel end.

3) Read the dial indicator.

Turbine End Play

Standard: 0.03 – 0.06 mm (0.0012 – 0.0024 in)
Limit: 0.09 mm (0.0035 in)

Turbine shaft and bearing clearance

1) Set a dial indicator to the turbine shaft center

through the center housing oil drain port.

2) Move the turbine shaft from side to side.
3 Read the dial indicator.

Turbine Shaft and Bearing Clearance

Standard: 0.056 - 0.127 mm (0.0022 - 0.0050 in)
Limit: 0.14 mm (0.0055 in)

Waste gate operation 

1) Remove hose from waste gate actuator side and

install pressure gauge (1) to the waste gate
actuator.

2) Operate pump of pressure gauge while engine is

stopped.

3) Read pressure at the control rod (2) move 2mm.

Pressure: 106 – 115 kPa 

(796 – 862 mmHg/ 15.4 – 16.7 PSi)

036RW008

036RW010

036RW009

036RW007

INDUCTION  6J – 7

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 (2.8 kg·m / 20 lb ft)

2. Install exhaust valve assembly to outlet of

turbocharger, tighten bolts to the specified torque.

Torque: 27 N·m (2.8 kg·m / 20 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 / 78 lb in)

5. Oil drain pipe.

1) Tighten oil drain pipe with new gasket.

Torque: 9 N·m (0.9 kg·m / 78 ib in)

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 / 16 lb ft) For M10 

Torque: 54 N·m (5.5 kg·m / 40 lb ft) For M14 

2

1

036RW011

For Europe

025R200007

For Europe

025R200006

6J – 8 INDUCTION

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 / 78 lb in)

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.

For Europe

025R200007

INDUCTION  6J – 9

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 / 35 lb in)

2) Connect inlet hose to the turbocharger outlet

side.
Tighten hose clamp to the specified torque.

Torque: 4 N·m (0.4 kg·m / 35 lb in)

3) Install intercooler assembly, tighten fixing bolts

to the specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

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

For Europe

2

3

3

1

Legend

(1)

Air Cleaner Cover and Air Duct

(2)

Intercooler Cover

(3)

Intercooler Assembly

135R200003