Turbocharger — removal and installation (Opel Frontera B)

Removal

Disconnect the cable from the negative battery terminal.

Loosen the clamps (1) and disconnect the three air intake pipes (2) from the turbocharger.



Loosen the nut (1) and remove the mounting bracket from the cylinder block.



Loosen the clamps, disconnect the air intake pipe (1) from the air flow meter (3) and remove the air intake pipe from the engine.



Remove 3 bolts (1) and move the expansion tank to the side and disconnect the connector (2) from the tank.







Remove 3 bolts and remove the engine cover.

Using special pliers KM-717, disconnect the connectors (1) from the glow plugs and move them to the side.



Remove 3 bolts (1) and remove the turbocharger heat shield.



Remove 2 bolts and heat shield from exhaust manifold.





Disconnect the vacuum hose (1) from the turbocharger pipe.



Loosen the clamp (4) and disconnect the intercooler hose (2) (intercooler) from the turbocharger.

Disconnect the engine oil supply pipe (3) with two sealing washers from the turbocharger.

Remove 2 bolts (1), remove gaskets and disconnect engine oil return pipe (2) from turbocharger. To prevent dirt from getting in, close the opening in the turbocharger with the appropriate plug.



Remove 2 bolts (1 and 2) and remove the exhaust manifold support bracket.







Remove 2 bolts (1 and 2) and remove the exhaust manifold support bracket.



Remove 3 bolts, disconnect the front exhaust pipe (1) from the turbocharger (2) and remove the gasket.



Remove 3 bolts (1), disconnect the turbocharger from the bypass manifold and remove the gasket.





Unscrew 10 nuts (1), remove the exhaust manifold with the turbocharger and remove the gasket.



Remove 3 bolts (1) and remove the turbocharger from the exhaust manifold. To prevent dirt from getting in, close the opening in the turbocharger with the appropriate plug.

Installation

Install the turbocharger onto the exhaust manifold and secure with 3 bolts, tightening them to a torque of 30 Nm.



Install the new gasket and exhaust manifold with turbocharger, then secure with 10 nuts, tightening them to a torque of 22 N·m.



Install a new gasket, connect the bypass manifold to the turbocharger and secure with 3 bolts, tightening them to a torque of 30 Nm.

Warning: When connecting the front exhaust pipe, it is necessary to follow the correct tightening sequence of the bolts. Failure to tighten the bolts in the correct sequence may result in damage to the parts being connected.

Attach the front exhaust pipe (1) to the turbocharger (2) and secure with bolts. Loosely tighten the bolts securing the front exhaust pipe to the turbocharger, tighten the bolts to 30 Nm, then, starting with the first bolt, check that the bolts are securely tightened.





Attach the second exhaust manifold support bracket to the transmission and secure with bolt (1), tightening it to 70 N·m.



Attach the second exhaust manifold support bracket to the front exhaust pipe and secure with bolt (2), tightening it to 24 Nm.

Install the exhaust manifold support bracket and secure with 2 bolts (1 and 2), tightening them to a torque of 25 N·m.





Connect the engine oil return pipe (2) with a new gasket to the turbocharger and secure with 2 bolts, tightening them to a torque of 8 Nm.





Remove the plug, connect the engine oil supply pipe (3) with two new sealing washers to the turbocharger and secure with the bolt, tightening it to a torque of 20 Nm.



Connect the intercooler hose (2) (intercooler) to the turbocharger and secure it with a clamp (4). Make sure that the hose is connected to the turbocharger tightly.

Connect the vacuum hose (1) to the turbocharger pipe.

Install the exhaust manifold heat shield and secure with 2 bolts.



Install the turbocharger heat shield (1) and secure with 3 bolts, tightening them to 8 Nm.

Using special pliers KM-717, connect the connectors (1) to the glow plugs.



Install the engine cover and secure with 3 bolts, tightening them to 8 Nm.

Connect the connector (2) to the expansion tank, install the tank and secure with 3 bolts (1).





Install the air intake pipe on the engine, connect the air intake pipe (1) to the air flow meter (3) and secure with a clamp (2).



Install the mounting bracket onto the cylinder block and secure with the nut (1).



Connect the three air intake pipes (2) to the turbocharger and secure with clamps (1).



Connect the cable to the negative terminal of the battery.

Reprogram the memory of electronic control units.