Opel Frontera UBS. Manual - part 407

 

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Opel Frontera UBS. Manual - part 407

 

 

4JG2-NA/4JG2-TURBO ENGINE 6A2 – 49

3.

Cooling Fan Assembly

Remove cooling fan asm fixing nuts, cooling fan
asm, fan pulley and center.

4.

Radiator Assembly

Remove bracket and radiator asm.

5.

Air Cleaner Cover & Air Duct

6.

Intercooler Assembly (4JG2 -T only)

(Refer to Intercooler removal steps in this section)

7.

P/S Pump Drive Belts

Loosen P/S pump fixing bolts and adjusting bolt
and remove two drive belts.

8.

P/S Pump Assembly

Remove two fixing bolts (front side), a fixing nut
(rear side) and support P/S pump asm with oil
hoses by tying to body side.

9.

Engine Ground Cable

Disconnect ground cable from A/C compressor
bracket.

10. AC Generator Harness

Disconnect B terminal and harness connector
from AC generator.

11. A/C Compressor Assembly

Remove A/C compressor fixing bolt (rear under
side of compressor) by using a long extension bar
at under side of wheel arch.

Disconnect magnetic clutch harness connector.

Remove fixing bolts (upper and front lower side
of compressor) and set A/C compressor asm with
pipe lines on battery carrier.

12. Vacuum Hose: Vacuum Pump

Disconnect vacuum hose from vacuum pump.

13. Starter Harness

Disconnect B terminal and put cable harness close
to chassis side.

Disconnect S terminal connector.

14. Engine Harness.

Disconnect engine harness close to engine side.

15. Accelerater Cable

Loosen locking nut at bracket and disconnect
accelerater cable from injection pump control
lever.

16. Fuel Hoses

Disconnect fuel hoses from injection pump side
and take care not to spill fuel and enter dust.

17. Engine Ground Cable

Disconnect ground cable from left rear side of
timing gear case.

6A2 – 50 4JG2-NA/4JG2-TURBO ENGINE

18. Vacuum Hose : Vacuum Tank

Disconnect vacuum hose from vacuum pump
side.

19. Glow Plug Harness

20. Transmission Assembly

Install special tools (engine hangers) in front right
and left rear sides of cylinder head.

Front right side; use the ground cable fixing bolt
on A/C compressor bracket.

Left rear side; fix hanger together with oil cooler
hose clip.
Engine hanger: 5-8840-2032-0

Left engine carefully by using hoist.

21. Engine Mounting

Remove fixing bolts (both left and right side)
using extension bar and box wrench at under side
of wheel arches.

22. Engine Assembly

Install special tools (engine hangers) in left rear
and front right sides of cylinder head.

Lift engine carefully by using hoist.

Lift front part of engine higher than rear part of it.

Take out engine asm taking care not to damage
full pipes, brake pipes and etc.

INSTALLATION

22. Engine Assembly

Position engine mountings by using hoist.

21. Engine Mounting

After all fixing bolts (left: two bolts, rights: two
bolts) were inserted to every holes, and engine
asm and tighten fixing bolts to the specified
torque.

40 (4.1/30)

N·m(Kg·m/lb·ft)

20. Transmission Assembly

Refer to transmission installation steps
in section 7.

19. Glow Plug Harness

18 Vacuum Hose: Vacuum Tank

17. Engine Ground Cable

16. Fuel Hose

15. Accelerator Cable

Refer to accelerater cable installation steps in
section 6C.

4JG2-NA/4JG2-TURBO ENGINE 6A2 – 51

14. Engine Harness.

13. Starter Harness

12. Vacuum Hose: Vacuum Pump

11. A/C Compressor Assembly

Tighten temporarily fixing bolts (upper and front
lower sides of compressor).

Tighten fixing bolt (rear under side of
compressor) to the specified torque by using
along extension bar and torque wrench at under
side of wheel arch.

Tighten fixing bolts (front upper and lower sides
of compressor) to the specified torque.

40 (4.1/30)

N·m(Kg·m/lb·ft)

6A2 – 52 4JG2-NA/4JG2-TURBO ENGINE

6.

Intercooler Assembly (4JG2-T Only)

Refer to intercooler installation steps in  this
section.

5.

Air Cleaner Cover & Duct

4.

Radiator Assembly

Install cushion rubber in under left and right part
of radiator and position radiator.

Fix radiator by bracket.

3.

Cooling Fan Assembly

Install cooling fan asm and tighten fixing bolts to
the specified torque.

2.

Fan Shroud

1.

Radiator Hose

Connect upper and lower hose to engine side.

Pour coolant in to radiator.

Install battery.

Connect window washer hose.

10. A.C. Generator Harness

9.

Engine Ground Cable

Attached ground cable to A/C compressor bracket.

8.

P/S Pump Assembly

Install P/S pump asm in engine and tighten
temporarily fixing nut.

7.

P/S Pump Drive Belt

Install drive belts adjust belt tension by adjusting
bolt and tighten locking bolt to the specified
torque.

Refer to “Drive Belt Adjustment” in section 6B.

8 (0.8/69)

N·m(Kg·m/lb·in)

40 (4.1/30)

N·m(Kg·m/lb·ft)

 

 

 

 

 

 

 

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