Opel Frontera UBS. Service manual — part 2486

6J – 10 INDUCTION

REMOVAL

1. Remove intercooler assembly.

Refer to “Intercooler” in this manual.

2. Remove harness connector from motor and ITP

sensor.

3. Loosen the two fixing nuts and remove the throttle

valve assembly.

Legend

(1) Motor
(2) Intake Throttle Valve
(3) ITP sensor

INSPECTION AND REPAIR

1. Check for catching somwhere on the throttle valve.
2. If some problem is discovered during inspection on

the throttle valve, the throttle valve must replace.

INSTALLATION

1. Put gasket on the intake manifold and install throttle

valve.

2. Tighten nuts to the specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft)

3. Reconnect harness connector to motor and

ITPsensor.

4. Install intercooler assembly.

1

2

3

025RW032

INTAKE THROTTLE VALVE

INDUCTION 6J – 11

INTAKE MANIFOLD

REMOVAL

1. Drain engine coolant and remove water hose from

thermostat housing

2. Remove intercooler assembly.
3. Remove bracket fixing bolt of oil level gauge guide

tube.

4. Remove PCV hose.
5. Remove hoses from EGR valve, EGR vacuum

sensor and outlet of heater unit.

6. Disconnect harness connector from MAP sensor,

EGR vacuum sensor, ETC sensor, Water
temperature unit, IAT sensor and EVRV.

7. Remove high pressure oil pipe.
8. Remove two way check valve.
9. Remove fuel pipe.

10. Remove fixing bolts and nuts of intake manifold,

remove intake manifold assembly.

Legend

(1) Intake manifold
(2) Fixing portion of throttle valve
(3) EGR passage
(4) EGR valve

For Europe

2

1

3

3

1

4

2

Legend

(1)

Intake Manifold

(2)

Throttle Valve Assembly

(3)

EGR Valve

(4)

Gasket

025R200005

3

1

2

4

025RW031

6J – 12 INDUCTION

INSPECTION AND RAPAIR

1. Visually check for cracks/clogs inside intake

manifold.

2. If foreign material is observed, it should be taken

out, and if there are some cracks on the intake
manifold, it must be replaced.

INSTALLATION

1. Install the intake manifold assembly, tighten bolts

and to the specified torque.

Torque: 20 N·m (2.0 kg·m / 14 lb ft) for bolt
Torque: 20 N·m (2.0 kg·m / 14 lb ft) for nut

2. Install fuel pipe.

Torque: 4 N·m (0.4 kg·m / 35 lb in) for M16 nut

(Apply engine oil)

Torque: 13 N·m (1.3 kg·m / 113 lb in) for M10 cap
nut

Torque: 14 N·m (1.4 kg·m / 122 lb in) for M10

(Apply engine oil)

3. Install two way check valve.

Torque: 20 N·m (2.0 kg·m / 14 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 engine starting will be longer.

5. Install high pressure oil pipe, then tighten sleeve nut

to the specified torque.

Torque: 29 N·m (3.0 kg·m / 22 lb ft)

6. Reconnect harness connector to MAP sensor, EGR

vacuum sensor, ETC sensor, Water thermo unit,
IAT sensor and EVRV sensor.

7. Install hoses to EGR valve, EGR vacuum sensor

and Water outlet of heater.

8. Connect PCV hose.
9. Install oil level gauge guide and fix it.

10. Install intercooler assembly.

Refer to “Intercooler” in this manual.

11. Install water hose to thermostat housing and fill with

engine coolant.

Model of Turbocharger

IHI RHF5

Turbine Maximum Speed

180,000 rpm

Maximum Inlet Gas Temperature

800 °C (1472 °F)

Vibration Peak (G) criteria

Maximum 4 (G) at Turbine Rotor Speed 140,000 rpm

Tolerance Limit of Compressor Blade Height

Less then 0.5 mm (0.0197 in)

MAIN DATA AND SPECIFICATIONS

INDUCTION 6J – 13

IHI SERVICE NETWORK

For inquiries relating to turbochargers, please contact your ISUZU distributor or the nearest IHI Turbocharger Service
Facility.

HEADQUARTERS

ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD. (IHI)

General Machinery Division
Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku
Tokyo 100-0005 JAPAN

TEL: 81-(3)-3286-2405 to 2407 (3 lines)
FAX: 81-(3)-3286-2430

CHINA

IHI BEIJING OFFICE
Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue
Beijing, People’s R epublic of CHINA
TEL: 86-(1)-505-4997, 0408
FAX: 86-(1)-505-4350
TLX: 210343 IHIPK CN

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Room 1202, Chia Hsin Building, No. 96 Chung Shan
North Road, Section 2, Taipei, TAIWAN
TEL: 886-(2)-542-5520, 5521, 5523
FAX: 886-(2)-542-4362
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TEL: 66-(2)-236-3490, 7356, 9099
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