1996 Opel Frontera Sport engine fastener tightening specifications

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Condition	Value

expand_moreAir intake system

expand_moreIntake manifold


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	23.6 lbf⋅ft23.6 lbf⋅ft32 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	19.18 lbf⋅ft19.18 lbf⋅ft26 N⋅m
All Opel gasoline straight-4 2.0 L C 20 NE engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
All Opel gasoline straight-4 2.0 L X 20 SE engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m

expand_moreAuxiliary assemblies

expand_moreAuxiliary drive belt tensioner

expand_moreAll Opel diesel straight-4 2.5 L 25TDS (VM41B) engines


Nuts	50.89 lbf⋅ft50.89 lbf⋅ft69 N⋅m
Screws	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m


All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m
All Opel gasoline straight-4 2.0 L C 20 NE engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Opel gasoline straight-4 2.0 L X 20 SE engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAuxiliary drive belt tensioner


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	34.67 lbf⋅ft34.67 lbf⋅ft47 N⋅m
All Opel gasoline straight-4 2.0 L C 20 NE engines	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m
All Opel gasoline straight-4 2.0 L X 20 SE engines	13.28 lbf⋅ft13.28 lbf⋅ft18 N⋅m

expand_moreAir-conditioning compressor


2.8 TD (53SUD2) with diesel straight-4 2.8 L 111 HP at 3600 RPM, 242 N⋅m at 2100 RPM engine (1995.3–1996.8)	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreAlternator

expand_moreAll Opel diesel straight-4 2.5 L 25TDS (VM41B) engines


Nuts	34.67 lbf⋅ft34.67 lbf⋅ft47 N⋅m
Screws	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreAll Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines


Lock nuts	14.01 lbf⋅ft14.01 lbf⋅ft19 N⋅m

expand_moreScrews


Bottom	29.5 lbf⋅ft29.5 lbf⋅ft40 N⋅m

expand_moreHydraulic lines at the servo-steering pump


2.5 TDS with diesel straight-4 2.5 L 114 HP at 3600 RPM, 260 N⋅m at 1800 RPM engine (1996.9–1998.10)	20.65 lbf⋅ft20.65 lbf⋅ft28 N⋅m

expand_moreServo steering pump


2.8 TD (53SUD2) with diesel straight-4 2.8 L 111 HP at 3600 RPM, 242 N⋅m at 2100 RPM engine (1995.3–1996.8)	27.29 lbf⋅ft27.29 lbf⋅ft37 N⋅m

expand_moreVacuum pump


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	5.16 lbf⋅ft5.16 lbf⋅ft7 N⋅m

expand_moreCarburetion

expand_moreInjection pump drive wheel


2.5 TDS with diesel straight-4 2.5 L 114 HP at 3600 RPM, 260 N⋅m at 1800 RPM engine (1996.9–1998.10)	64.91 lbf⋅ft64.91 lbf⋅ft88 N⋅m

expand_moreInjection hoses


2.5 TDS with diesel straight-4 2.5 L 114 HP at 3600 RPM, 260 N⋅m at 1800 RPM engine (1996.9–1998.10)	16.96 lbf⋅ft16.96 lbf⋅ft23 N⋅m

expand_moreInjection nozzle (injector)


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	50.89 lbf⋅ft50.89 lbf⋅ft69 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	25.81 lbf⋅ft25.81 lbf⋅ft35 N⋅m

expand_moreInjection pump


2.5 TDS with diesel straight-4 2.5 L 114 HP at 3600 RPM, 260 N⋅m at 1800 RPM engine (1996.9–1998.10)	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m

expand_moreInjection pump pulley


2.8 TD (53SUD2) with diesel straight-4 2.8 L 111 HP at 3600 RPM, 242 N⋅m at 2100 RPM engine (1995.3–1996.8)	47.2 lbf⋅ft47.2 lbf⋅ft64 N⋅m

expand_moreCharging

expand_moreTurbo charger


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	23.6 lbf⋅ft23.6 lbf⋅ft32 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	19.18 lbf⋅ft19.18 lbf⋅ft26 N⋅m

expand_moreCooling system

expand_moreCoolant pump


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreCoolant pump pulley


2.5 TDS with diesel straight-4 2.5 L 114 HP at 3600 RPM, 260 N⋅m at 1800 RPM engine (1996.9–1998.10)	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m

expand_moreViscous fan clutch

expand_moreAll Opel diesel straight-4 2.5 L 25TDS (VM41B) engines


Nuts	40.57 lbf⋅ft40.57 lbf⋅ft55 N⋅m
Screws	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m


All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreCylinder head

expand_moreCamshaft bearing


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	17.7 lbf⋅ft17.7 lbf⋅ft24 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	14.01 lbf⋅ft14.01 lbf⋅ft19 N⋅m
All Opel gasoline straight-4 2.0 L C 20 NE engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
All Opel gasoline straight-4 2.0 L X 20 SE engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreCylinder head screws

expand_moreAll Opel diesel straight-4 2.5 L 25TDS (VM41B) engines

expand_moreScrews 1-10

Figure 1. Cylinder head, Cylinder head screws, Opel diesel straight-4 2.5 L 25TDS (VM41B), Screws 1-10.


First stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Use new screws See figure 1.
Second stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Control tensioner
Third stage	70°70°70°
Fourth stage	70°70°70°
Ninth stage	slacken
Tenth stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Eleventh stage	65°65°65°
Twelfth stage	65°65°65°

expand_moreScrews 11 – 18


Fifth stage	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m
Sixth stage	80–90°80–90°80–90°
Thirteenth stage	66.38 lbf⋅ft66.38 lbf⋅ft90 N⋅m


Seventh stage	Warm-up run
Eighth stage	cool down
Fourteenth stage	15°15°15°
Retighten screws after 20 000 kilometers (12 500 miles).

expand_moreAll Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines

Figure 2. Cylinder head, Cylinder head screws, Opel diesel straight-4 2.8 L 28 TDI (4JB1T).


First stage	36.14 lbf⋅ft36.14 lbf⋅ft49 N⋅m
Use new screws. See figure 2.
Second stage	60–75°60–75°60–75°
Third stage	60–75°60–75°60–75°

expand_moreRocker bridge


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	21.39 lbf⋅ft21.39 lbf⋅ft29 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	39.83 lbf⋅ft39.83 lbf⋅ft54 N⋅m

expand_moreValve cover


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	11.8 lbf⋅ft11.8 lbf⋅ft16 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
All Opel gasoline straight-4 2.0 L C 20 NE engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
All Opel gasoline straight-4 2.0 L X 20 SE engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreEngine block

expand_moreConnecting rod bearing

expand_moreAll Opel diesel straight-4 2.5 L 25TDS (VM41B) engines


First stage	21.39 lbf⋅ft21.39 lbf⋅ft29 N⋅m
Second stage	60°60°60°


All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	61.22 lbf⋅ft61.22 lbf⋅ft83 N⋅m

expand_moreAll Opel gasoline straight-4 2.0 L C 20 NE engines


First stage	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
Replace screws and nuts.
Second stage	30°30°30°

expand_moreCrankshaft central screws


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	144.56 lbf⋅ft144.56 lbf⋅ft196 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	137.19 lbf⋅ft137.19 lbf⋅ft186 N⋅m

expand_moreAll Opel gasoline straight-4 2.0 L C 20 NE engines


First stage	95.88 lbf⋅ft95.88 lbf⋅ft130 N⋅m
Use new screw.
Second stage	40–50°40–50°40–50°


Crankshaft pulley	14.75 lbf⋅ft14.75 lbf⋅ft20 N⋅m

expand_moreFlywheel


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	77.44 lbf⋅ft77.44 lbf⋅ft105 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	87.03 lbf⋅ft87.03 lbf⋅ft118 N⋅m

expand_moreAll Opel gasoline straight-4 2.0 L C 20 NE engines


First stage	44.25 lbf⋅ft44.25 lbf⋅ft60 N⋅m
Second stage	30°30°30°
Third stage	15°15°15°

expand_moreMain bearing


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	123.17 lbf⋅ft123.17 lbf⋅ft167 N⋅m

expand_moreAll Opel gasoline straight-4 2.0 L C 20 NE engines


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws and nuts.
Second stage	45°45°45°
Third stage	15°15°15°

expand_moreEngine control

expand_moreCamshaft timing gear

expand_moreAll Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines


Central camshaft screws	47.2 lbf⋅ft47.2 lbf⋅ft64 N⋅m
Flange screws	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m

expand_moreAll Opel gasoline straight-4 2.0 L C 20 NE engines


First stage	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
Replace screws and nuts.
Second stage	60°60°60°
Third stage	15°15°15°

expand_moreDrive belt tensioner device


2.8 TD (53SUD2) with diesel straight-4 2.8 L 111 HP at 3600 RPM, 242 N⋅m at 2100 RPM engine (1995.3–1996.8)	56.05 lbf⋅ft56.05 lbf⋅ft76 N⋅m

expand_moreToothed belt guard


All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	5.9 lbf⋅ft5.9 lbf⋅ft8 N⋅m
All Opel gasoline straight-4 2.0 L C 20 NE engines	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m
All Opel gasoline straight-4 2.0 L X 20 SE engines	2.95 lbf⋅ft2.95 lbf⋅ft4 N⋅m


Toothed belt tensioning roller	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreToothed belt tightener


2.8 TD (53SUD2) with diesel straight-4 2.8 L 111 HP at 3600 RPM, 242 N⋅m at 2100 RPM engine (1995.3–1996.8)	56.05 lbf⋅ft56.05 lbf⋅ft76 N⋅m

expand_moreEngine lubrication

expand_moreOil cooler


2.5 TDS with diesel straight-4 2.5 L 114 HP at 3600 RPM, 260 N⋅m at 1800 RPM engine (1996.9–1998.10)	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m

expand_moreOil cooler lines

expand_more2.5 TDS with diesel straight-4 2.5 L 114 HP at 3600 RPM, 260 N⋅m at 1800 RPM engine (1996.9–1998.10)


Banjo screws	24.34 lbf⋅ft24.34 lbf⋅ft33 N⋅m

expand_moreOil drain plug


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	32.45 lbf⋅ft32.45 lbf⋅ft44 N⋅m
All Opel gasoline straight-4 2.0 L C 20 NE engines	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m
All Opel gasoline straight-4 2.0 L X 20 SE engines	33.19 lbf⋅ft33.19 lbf⋅ft45 N⋅m

expand_moreOil filter housing


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m
All Opel gasoline straight-4 2.0 L C 20 NE engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
All Opel gasoline straight-4 2.0 L X 20 SE engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m

expand_moreOil pump


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	19.91 lbf⋅ft19.91 lbf⋅ft27 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	14.01 lbf⋅ft14.01 lbf⋅ft19 N⋅m

expand_moreOil sump


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	8.11 lbf⋅ft8.11 lbf⋅ft11 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	14.01 lbf⋅ft14.01 lbf⋅ft19 N⋅m
All Opel gasoline straight-4 2.0 L C 20 NE engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Clean the thread and use screw-locking compound.
All Opel gasoline straight-4 2.0 L X 20 SE engines	7.38 lbf⋅ft7.38 lbf⋅ft10 N⋅m
Clean the thread and use screw-locking compound.

expand_moreEngine management

expand_moreGlow plugs


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	11.06 lbf⋅ft11.06 lbf⋅ft15 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m


Knock sensor	9.59 lbf⋅ft9.59 lbf⋅ft13 N⋅m
Lambda sensor	22.13 lbf⋅ft22.13 lbf⋅ft30 N⋅m

expand_moreEngine mounting


2.8 TD (53SUD2) with diesel straight-4 2.8 L 111 HP at 3600 RPM, 242 N⋅m at 2100 RPM engine (1995.3–1996.8)	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m

expand_moreExhaust system

expand_moreExhaust manifold


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	24.34 lbf⋅ft24.34 lbf⋅ft33 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	19.18 lbf⋅ft19.18 lbf⋅ft26 N⋅m
All Opel gasoline straight-4 2.0 L C 20 NE engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Replace screws and nuts.
All Opel gasoline straight-4 2.0 L X 20 SE engines	16.23 lbf⋅ft16.23 lbf⋅ft22 N⋅m
Replace screws and nuts.

expand_moreExhaust pipe


2.8 TD (53SUD2) with diesel straight-4 2.8 L 111 HP at 3600 RPM, 242 N⋅m at 2100 RPM engine (1995.3–1996.8)	49.42 lbf⋅ft49.42 lbf⋅ft67 N⋅m

expand_moreIgnition system


Spark plugs	18.44 lbf⋅ft18.44 lbf⋅ft25 N⋅m

expand_moreStart system

expand_moreStarter


All Opel diesel straight-4 2.5 L 25TDS (VM41B) engines	36.88 lbf⋅ft36.88 lbf⋅ft50 N⋅m
All Opel diesel straight-4 2.8 L 28 TDI (4JB1T) engines	50.89 lbf⋅ft50.89 lbf⋅ft69 N⋅m

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 1996 Opel Frontera Sport user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Opel warranty policy for your region. In some regions DIY service may invalidate your warranty.

Maintenance Items

Engine Fastener Tightening Specifications
Front Suspension Fastener Tightening Specifications
Rear Suspension Fastener Tightening Specifications
Transmission Fastener Tightening Specifications

Service Intervals

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Opel Frontera Sport service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 1996 Opel Frontera Sport you're not only saving money, but also also improving your technical skills and learning something new.

1996 Opel Frontera Sport A facelift Engine Fastener Tightening Specifications

Table of Contents

Conquer your fears and never give up!

Opel Frontera Sport A facelift model years

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