Removal and installation the engine (Opel Frontera B)

Warning! All connectors, wires and other removable parts when dismantling the engine must be laid and secured in the same way as they were located before their disconnection.

Removal

Disconnect the cable from the negative battery terminal.

Remove the lower engine compartment protection.

Remove the gearbox (see the relevant chapter).

Disconnect the exhaust pipe from the turbocharger.

Remove the hood (see the relevant chapter).

Remove the radiator (see the relevant chapter).

Remove the air filter assembly (1).



Disconnect the hose from the intake manifold that connects it to the intercooler.

Disconnect the hose from the turbocharger (2) connecting it to the intercooler.

Disconnect the hoses from the power steering drive and drain the fluid from the power steering hydraulic drive into a suitable container.

Remove the power steering fluid reservoir (2).



Discharge the refrigerant from the air conditioning system, then disconnect the pipe (1) from the partition and move it to the side.



Disconnect the connectors (3) from the vacuum valves.



Remove the vacuum valves along with the hoses attached to them, then remove the bracket from the inner fender and secure it over the engine.

Disconnect the hose from the cylinder head that comes from the expansion tank.

Remove the expansion tank.

Disconnect the coolant supply and return hoses to the heater from the pipes on the engine compartment bulkhead.

Disconnect the positive battery cable from the fuse box, release it from all clamps and secure it above the engine.

Disconnect the negative battery cable from the battery support and move it to the side.

(Text copied from an internet website: OpelBook.ru)

Disconnect the brake booster vacuum hose from the vacuum pump.

Remove the turbocharger thermal protective casing.

Remove the bolts securing the engine mounts to the chassis brackets.

Check that all electrical connectors, hoses, tubes and wire harnesses are disconnected from the engine.

Attach the lifting gear to the lifting eyes, lift the engine and remove it from the engine compartment, being careful not to damage the fuel lines, brake lines, etc.

Installation

Using a lifting mechanism, position the engine in the engine compartment, being careful not to damage the fuel lines, brake lines, or the turbocharger/exhaust pipe connection.

Align the engine mounts with the brackets and secure with bolts, tightening them to a torque of 42 N·m.

Connect the brake booster vacuum hose to the vacuum pump.

Connect the coolant supply and return hoses to the heater ports on the engine compartment bulkhead.

Connect the air conditioning pipe to the fitting on the engine compartment bulkhead.

Install the expansion tank.

Connect the expansion tank hose to the cylinder head.

Install the vacuum valve bracket.

Connect the connectors to the vacuum valves.

Install the power steering fluid reservoir.

Connect the hoses to the power steering drive and fill with fluid.

Connect the hose to the turbocharger that connects it to the intercooler.

Connect the hose to the intake manifold that connects it to the intercooler.

Install the air filter assembly.

Install the radiator (see the relevant chapter).

Connect the exhaust pipe to the turbocharger and secure with nuts, tightening them to a torque of 65 Nm.



Install the turbocharger thermal protective casing.

Install the gearbox (see the relevant chapter).

Install the hood (see the relevant chapter).

Connect the positive battery cable to the fuse block.

Connect the negative battery cable to the battery post.

Install the lower engine compartment protection.

Charge the air conditioning system with refrigerant.

Fill the engine cooling system with coolant, bleed the cooling system and check the cooling system for leaks (see the relevant chapter).