Removal and installation of OHC engine (Opel Frontera A)

Removal

The engine is removed from the car without the gearbox. For this purpose, a mechanism with appropriate lifting capacity is used. It is recommended to use the help of an assistant for this purpose. If you do not have sufficient experience to perform the operation in question, it is recommended that you perform it with the participation of an experienced auto mechanic. Before removing the engine, it is necessary to: prepare the appropriate tool, a container for draining engine oil and coolant, cables, a lifting mechanism and a hook. To carry out the work in question, a site must be selected where the vehicle can be left with the engine removed. In addition, it is necessary to familiarize yourself with the contents of this section.

1. Disconnect the ground cable from the battery and remove the battery to prevent short circuits from occurring while performing work. Removing the battery will also free up the work space for further work.

2. Remove the hood. First, set the hood to a vertical position and disconnect the hose supplying fluid to the windshield washer nozzles. Use a pencil to trace the hinges on the surface of the sheet metal hood so that you can later install the hood in its original position. Loosen the hinge mounting screws. In this case, the assistant must hold the hood. Remove the hood and place it in a well-protected place. Place a thick cloth under the edges of the hood.

3. If the engine is to be disassembled, the engine oil must be drained.



4. Drain the cooling system (Section Filling the cooling system coolant Chapters Routine care and maintenance) and plug the hoses with caps. Remove the radiator completely as described in Cooling and heating systems.

5. Remove the air intake hose.

6. Remove the power steering pump drive belt, remove the pump from the engine or move it to the side.

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7. Disconnect all cables, hoses and lines from the engine. Mark their position.



8. Disconnect the throttle control cable from the intake manifold. Its fastening is shown in the illustration "Connection of the gas control drive to the throttle lever and support".

9. Loosen the bolts connecting the exhaust manifold and the exhaust pipe and move the pipe to the side.

10. Loosen the bolts securing the gearbox to the cylinder block. To do this, first unscrew the bottom six bolts. Disconnect the clutch slave cylinder and hang it on the hose. After this, unscrew the four bolts from the top of the gearbox.



11. View of the right and left engine mounts. Loosen the engine mount bolts on the left and right sides and remove the left engine mount completely.



12. Disconnect the brake booster vacuum hose from the intake manifold. To do this, loosen the clamps and remove the hoses at the points where they connect to the fuel distribution line. Please note that the fuel is under some pressure and the hoses must be disconnected with care. After disconnecting the fuel hoses, close their ends with plugs in the form of a bolt of the appropriate diameter to prevent fuel leakage.

Attention! When opening a pipeline under pressure, fuel is released. Do not place the test lamp nearby under any circumstances. When loosening a connection, it is recommended to put a wrench on it and cover it with a rag on top. After this, slowly unscrew the hollow bolt.

13. Disconnect and unplug all fuel injection system cables.

14. Disconnect the heating hoses from the back of the cylinder block.

15. Disconnect the following electrical connections: distributor or ignition module (pay attention to the method of connection with the ignition cable), oil pressure indicator sensor, oil temperature indicator sensor, piston TDC position sensor, oil level indicator, (if it is installed), coolant temperature gauge sensor, remote thermometer sensor. Not all of the listed instruments are available on every engine. It is important to locate and disconnect all cable connections and carefully move them to the side, ensuring that the engine can be easily removed from the compartment.

16. Remove the bottom protective sheet if present.

17. Attach cables or chains from a lifting device to the eyes on the top of the cylinder head and lift the engine off the suspension so that it is free of the engine mounts.



18. Now lift the engine up. Be careful not to damage any cable connections or pipes, and be careful not to hit the engine against any components in the engine compartment. When performing the described operation, it is recommended to use the help of an assistant.

Installation

The engine is installed in the reverse order of its removal. In this case, the following instructions must be observed, especially regarding the tightening torques of threaded connections.

1. Securely attach the engine to chains or cables on the hoist and carefully lower it into the engine compartment. Be careful not to damage any components in the engine compartment. After installing the engine in place, tighten the engine mounting bolts to the gearbox with a torque of 76 Nm. Fasten the left engine mount to the longitudinal beam with a tightening torque of 52 Nm, and fasten both engine mounts to the suspension beams with a torque of 85 Nm. After this, you can disconnect the engine from the lifting mechanism.

2. Reinstall the exhaust system. Replace gaskets if necessary. Lubricate the bolts that secure the system elements with grease. Tightening torque for threaded connections: 25 Nm.

3. Install new fuel line seals.

4. Tighten the brake booster vacuum hose to a torque of 20 Nm.

When installing the power steering, tighten the bolt on the pulley side to 18 Nm, and the other bolts to 25 Nm.

5. Put on the V-belt (the arrow on the belt should point in the same direction). Tighten the belt as described below.

6. Fill the cooling system with liquid (see chapter Routine care and maintenance). Make sure the drain cock on the radiator is closed.



7. After installing the hood, check that it opens and closes freely and that it is installed correctly.

8. Connect the electrical connections, taking care to ensure correct mating. A connection error may result in a short circuit.