Removal and installation the engine (Opel Frontera B)

Removal

Remove the gearbox (see the relevant chapter).

Remove the hood (see the relevant chapter).

Drain the coolant from the engine cooling system.

Disconnect the connector from the engine air temperature sensor located on the air intake tube (1).



Disconnect the resonator hose from the air intake tube (1).

Remove the air intake tube (1) and the air filter housing cover (2) as an assembly.

Disconnect the three connectors (3) from the rear left side of the engine.



Disconnect the connector from the power steering pump pressure sensor.

Disconnect the brake booster vacuum hose from the intake manifold.

Disconnect the changeover vacuum hose from the intake manifold.



Disconnect all ground wires from the engine.

Remove the upper radiator hose.

Remove the V-belt (see the relevant chapter).

Release the wiring harness retaining clips and move the wiring harness to the side so that it does not interfere with engine removal.

Remove the power steering pump (1) from the bracket and, without disconnecting the hoses from it, move it to the side and secure it in the engine compartment.



Remove the air filter resonator (2).



Disconnect the accelerator cable from the throttle body.

Disconnect the wiring harness connector from the generator.

Disconnect the ground wire connector from the right side of the chassis.

Disconnect the cable from the negative battery terminal.



Disconnect the ground wire from the battery support and move it to the side.



Remove the lower radiator hose.

Disconnect the positive battery cable from the fuse block, release the clamps and move the cable to the side.

Disconnect the coolant supply and return hoses from the heater radiator pipes.

Remove the bolts securing the left and right engine mounts to the frame.



Using a lifting mechanism, lift the engine so that its weight is supported by the lifting mechanism.

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

Remove the engine from the engine compartment, being careful not to damage the fuel lines, brake lines, and other components.

Installation

Install the engine into the engine compartment, being careful not to damage the fuel lines, brake lines, and other components.



Screw in the bolts securing the left and right engine mounts to the frame and tighten them to a torque of 41 N·m.



Connect the coolant supply and return hoses to the heater radiator pipes.

Connect the positive battery cable to the fuse box and secure it with clamps.



Install the lower radiator hose.

Use clamps to secure the ground wire to the battery support.

Connect the ground wire to the right side of the chassis.

Connect the wiring harness connector to the generator.

Connect the accelerator cable to the throttle assembly, then adjust the accelerator cable play so that it is within 5.7-6.3 mm.

Install the air filter resonator (2).



Install the power steering pump (1) to the bracket and secure with bolts. Tighten the long bolt to 50 Nm and the short bolt to 25 Nm.





Install the V-belt (see the relevant chapter).

Install the upper radiator hose.

Connect the switching vacuum hose to the intake manifold.

Connect the brake booster vacuum hose to the intake manifold.

Connect the connector to the power steering pump pressure sensor.

Connect the three connectors (3) to the rear left side of the engine.



Install the air filter housing and secure with bolts, tightening them to a torque of 22 N·m.

Install the air intake tube (1) and the air filter housing cover (2). Tighten the air intake pipe mounting nut to the bracket to 16 Nm.



Connect the resonator hose to the air intake tube.



Connect the connector to the engine air temperature sensor located on the air intake tube.

Install the hood (see the relevant chapter).

Install the gearbox (see the relevant chapter).

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