Opel Frontera UBS. Service 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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