Opel Frontera UBS. Service manual — part 436
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/14.5 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/2.9
lb ft)
Cap nut (M10) 13N·m (1.3 kg·m/9.4 lb ft)
Fuel pipe (M10 apply engine oil) 14 N·m (1.4
kg·m/10 lb ft)
3. Install two way valve.
Torque : 20 N·m (2.0 kg·m/14.5 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 : 80 N·m (8 kg·m/57.9 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
RINSTALLATION
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/20.2 lb ft)
3. Install water hoses and oil pipes.
4. Install heat protector to turbocharger.
Torque : 9 N·m (0.9 kg·m/6.5 lb ft)
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.
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