1998 OPEL FRONTERA Workshop Manual

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Page 5305 of 6000

OPEL FRONTERA 1998 Workshop Manual 6A – 32 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
cylind

Page 5306 of 6000

OPEL FRONTERA 1998 Workshop Manual ENGINE MECHANICAL 6A – 33
INTAKE MANIFOLD
REMOVAL
1. Drain engine coolant and disconnect water hose
from thermostat hosing.
2. Remove intercooler assembly
Refer to “Intercooler” in this ma

ENGINE MECHANICAL 6A – 33
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 Nꞏm (2.0 kgꞏm/14.5 lb ft) for bolt and nut
2. Install the fuel pipe and tighten to the specified
torque.To r q u e :
M16 bolt (apply engine oil) 4 Nꞏm (0.4 kgꞏm/2.9
lb ft)
Cap nut (M10) 13Nꞏm (1.3 kgꞏm/9.4 lb ft)
Fuel pipe (M10 apply engine oil) 14 Nꞏm (1.4
kgꞏm/10 lb ft)
3. Install two way valve.
Torque : 20 Nꞏm (2.0 kgꞏm/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 Nꞏm (8 kgꞏm/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.
2
3
4
1
025RX001
Legend
(1) Intake Manifold
(2) Throttle Valve Assembly
(3) EGR Valve
(4) Gasket

Page 5307 of 6000

OPEL FRONTERA 1998 Workshop Manual 6A – 34 ENGINE MECHANICAL
EXHAUST MANIFOLD
REMOVAL
1. Remove the hose from both turbocharger outlet and
intake manifold inlet side, then remove intercooler
assembly.
2. Loosen belt tensioner

Page 5308 of 6000

OPEL FRONTERA 1998 Workshop Manual ENGINE MECHANICAL 6A – 35
TURBOCHARGER
9875 63
21
4
025RW023
Legend
(1) Exhaust Manifold
(2) Gasket
(3) Turbocharger Assembly
(4) Water Hose(5) Water Hose
(6) Heat Protector
(7) Oil Pipe
(8) Oil Pip

Page 5309 of 6000

OPEL FRONTERA 1998 Workshop Manual 6A – 36 ENGINE MECHANICAL
INSTALLATION
1. Install turbocharger assembly to exhaust manifold,
tighten to the specified torque.
Torque : 27 Nꞏm (2.8 kgꞏm/20.2 lb ft)
2. Install exhaust adapto

Page 5310 of 6000

OPEL FRONTERA 1998 Workshop Manual ENGINE MECHANICAL 6A – 37
CYLINDER HEAD
3
4
1
2
012RW096
Legend
(1) Glow Plug
(2) Plate
(3) Cylinder Head Bolt
(4) Cylinder Head
NOTE:
During disassembly, be sure that the valve train
compon

Page 5311 of 6000

OPEL FRONTERA 1998 Workshop Manual 6A – 38 ENGINE MECHANICAL
1. Cylinder head bolts for damaged threads or
stretching and damaged heads caused by improper
use of tools.
CAUTION: Suspected bolts must be replaced.
2. Cylinder hea

Page 5312 of 6000

OPEL FRONTERA 1998 Workshop Manual ENGINE MECHANICAL 6A – 39
CYLINDER HEAD GASKET
12
13
14
15
1
2
3 7
4
5 6
10
11 9
8
011RW047-1
Legend
(1) Cylinder Head Noise Insulator Cover
(2) Insulator
(3) Bolt and Gasket
(4) Oil Seal
(5) Gasket

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