fuel filter location OPEL FRONTERA 1998 Workshop Manual

6A–3
ENGINE MECHANICAL
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.
Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance:
When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick–up unit.
The 12–volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.
Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum die–cast casting
for 75
V–type six cylinders. It has a rear plate integrated
structure and employs a deep skint. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width of No.3 bearing
on the body side is different in order to support the thrust
bearing. The bearing cap is made of nodular cast iron and
each bearing cap uses four bolts and two side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent–roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V–type design. The ports are cross–flow
type.
Va l v e Tr a i n
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast–iron. Pins and
journals are graded for correct size selection for their
bearing.
Engine Lubrication
The oil discharged by a trochoid–type oil pump driven by
the crankshaft is fed through full–flow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.

6C–1
ENGINE FUEL
ENGINE
ENGINE FUEL
CONTENTS
Service Precaution 6C–1. . . . . . . . . . . . . . . . . . . . . .
General Description 6C–2. . . . . . . . . . . . . . . . . . . . .
Fuel Metering 6C–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 6C–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter and Associated Parts 6C–4. . . . . . . . .
Removal 6C–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6C–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6C–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
In–Tank Fuel Filter 6C–5. . . . . . . . . . . . . . . . . . . . .
Fuel Pump Flow Test 6C–5. . . . . . . . . . . . . . . . . . .
Fuel Pump 6C–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump and Associated Parts 6C–6. . . . . . . .
Removal 6C–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay 6C–7. . . . . . . . . . . . . . . . . . . . . . . .
General Description 6C–7. . . . . . . . . . . . . . . . . . . . .
Fuel Tank 6C–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank and Associated Parts 6C–7. . . . . . . . .
Removal 6C–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tube / Quick – Connect Fittings 6C–8. . . . . . .
Precautions 6C–8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions During Work 6C–8. . . . . . . . . . . . . . . . . .
Removal 6C–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reuse of Quick–Connector 6C–10. . . . . . . . . . . . . . .
Assembling Advice 6C–10. . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Unit 6C–11. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Unit and Associated Parts 6C–11. . .
Removal 6C–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filler Cap 6C–12. . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6C–12. . . . . . . . . . . . . . . . . . . . .
Inspection 6C–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6C–12. . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

6E–29 ENGINE DRIVEABILITY AND EMISSIONS
Engine Component Locator Table
Number
NameLocation
1Linear Exhaust Gas Recirculation (EGR) ValveRear right side of the engine
2Throttle Position (TP) SensorOn the rear of the throttle body
3Intake Air Temperature (IAT) SensorOn the intake air duct near the throttle body
4Check Engine (MIL) LightOn the instrument panel beneath the
tachometer
5Positive Crankcase Ventilation (PCV) ValveOn the left of the cylinder head cover
6Air CleanerLeft front of the engine bay
7Mass Air Flow (MAF) SensorAttached to the air filter box
8Camshaft Position (CMP) SensorOn the rear right side at the left of the cylinder
head cover
9Fuel Pressure RegulatorRear right side of the engine
10Idle Air Control (IAC) ValveOn the left of the throttle body
11Upper Intake ManifoldTop of the engine
12Fuse/Relay BoxAlong the inside of the right fender
13Manifold Absolute Pressure (MAP) SensorBolted to the top of the upper intake manifold
14Throttle BodyBetween the intake air duct and the upper
intake manifold
15Engine Coolant Temperature SensorOn the coolant crossover pipe at the front of
the engine, near the throttle body

6E–31 ENGINE DRIVEABILITY AND EMISSIONS
Engine Component Locator Table
Number
NameLocation
1Linear Exhaust Gas Recirculation (EGR) ValveRear right side of the engine
2Throttle Position (TP) SensorOn the rear of the throttle body
3Intake Air Temperature (IAT) SensorOn the intake air duct near the throttle body
4Check Engine (MIL) LightOn the instrument panel beneath the
tachometer
5Positive Crankcase Ventilation (PCV) ValveOn the left of the cylinder head cover
6Air CleanerLeft front of the engine bay
7Mass Air Flow (MAF) SensorAttached to the air filter box
8Camshaft Position (CMP) SensorOn the rear right side at the left of the cylinder
head cover
9Fuel Pressure RegulatorRear right side of the engine
10Idle Air Control (IAC) ValveOn the left of the throttle body
11Upper Intake ManifoldTop of the engine
12Fuse/Relay BoxAlong the inside of the right fender
13Manifold Absolute Pressure (MAP) SensorBolted to the top of the upper intake manifold
14Throttle BodyBetween the intake air duct and the upper
intake manifold
15Engine Coolant Temperature SensorOn the coolant crossover pipe at the front of
the engine, near the throttle body

6E–32
ENGINE DRIVEABILITY AND EMISSIONS
Undercarriage Component Locator
F00RW040
Undercarriage Component Locator Table (Automatic Transmission)
Number
NameLocation
1Fuel Pump AssemblyInstalled in the top of the fuel tank
2Fuel Gauge UnitInstalled in the front edge of the fuel tank, on
the right side
3Fuel FilterLocated along the inside of the right frame rail,
ahead of the rear axle
4Vehicle Speed Sensor (VSS)2WD: Protrudes from the transmission
housing, just ahead of the propeller shaft.
4WD: Protrudes from the rear output shaft
housing of the transfer case.
5Heated Oxygen Sensor (Bank 1, HO2S 1)Threaded into the exhaust pipe ahead of the
right-hand catalytic converter
6Heated Oxygen Sensor (Bank 2, HO2S 1)Threaded into the exhaust pipe ahead the
left-hand catalytic converter

6E–33 ENGINE DRIVEABILITY AND EMISSIONS
Undercarriage Component Locator Table (Manual Transmission)
Number
NameLocation
1Fuel Pump AssemblyInstalled in the top of the fuel tank
2Fuel Gauge UnitInstalled in the front edge of the right frame
rail, ahead of the rear axle
3Fuel FilterLocated along the inside of the right frame rail,
ahead of the rear axle
4Vehicle Speed Sensor (VSS)2WD: Protrudes from the transmission
housing, just ahead of the propeller shaft.
4WD: Protrudes from the rear output shaft
housing of the transfer case.
5Heated Oxygen Sensor (Bank 1, HO2S 1)Threaded into the exhaust pipe ahead of the
right-hand catalytic converter
6Heated Oxygen Sensor (Bank 2, HO2S 1)Threaded into the exhaust pipe ahead of the
left-hand catalytic converter
Fuse and Relay Panel (Underhood Electrical Center)
TS23336

6E–107 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency
T321122
Circuit Description
The mass air flow (MAF) sensor measures the amount of
air which passes through it into the engine during a given
time. The powertrain control module (PCM) uses the
mass air flow information to monitor engine operating
conditions for fuel delivery calculations. A large quantity
of air entering the engine indicates an acceleration or high
load situation, while a small quantity of air indicates
deceleration or idle.
The MAF sensor produces a frequency signal which can
be monitored using a Tech 2. The frequency will vary
within a range of around 2500 Hz at idle to around
1900 Hz at maximum engine load. DTC P0102 will be set
if the signal from the MAF sensor is below the possible
range of a normally operating MAF sensor.
Conditions for Setting the DTC
The engine is running above 500 RPM for greater than
10 seconds.
System voltage is above 11.5 volts.
MAF signal frequency is below 1000 Hz for a total of
50-percent of the last 1000 samples monitored. A
sample is taken every cylinder event.
Action Taken When the DTC Sets
The PCM will illuminate the malfunction indicator lamp
(MIL) the first time the fault is detected.
The PCM calculates an air flow value based on idle air
control valve position, throttle position, RPM and
barometric pressure.
The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
Failure Records data.
Conditions for Clearing the MIL/DTC
DTC P0102 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
feed.
Diagnostic Aids
Check for the following conditions:
Poor connection at PCM – Inspect harness connectors
for backed-out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
poor terminal-to-wire connection.
Misrouted harness – Inspect the MAF sensor harness
to ensure that it is not routed too close to high voltage
wires.
Damaged harness – Inspect the wiring harness for
damage. If the harness appears to be OK, observe the
Tech 2 while moving connectors and wiring harnesses
related to the MAF sensor. A change in the display will
indicate the location of the fault.
Plugged intake air duct or filter element – A wide-open
throttle acceleration from a stop should cause the
mass air flow displayed on a Tech 2 to increase from
about 3-6 g/second at idle to 100 g/second or greater
at the time of the 1-2 shift. If not, check for a restriction.
If DTC P0102 cannot be duplicated, the information
included in the Failure Records data can be useful in
determining vehicle mileage since the DTC was last set.

6E–19 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Component Locator
Engine Component Locator Table
F06RW051
NumberNameLocation
1AP (Accelerator Pedal Position) SensorAP Bracket
2CKP (Crankshaft Position) SensorInside the right front flywheel Housing
3Oil RailMounted on the camshaft carrier
4Oil (Rail) Pressure SensorMounted on the Oil Rail
5OT (Oil Temperature) SensorMounted on the Oil Rail
6Fuel InjectorIn the Cylinder Head Cover
7Fuel Return OrificeInside the Cylinder Head
8FT (Fuel Temperature) SensorFuel Return Adaptor
9IntercoolerOn the Cylinder Head Cover
10Intake Throttle MotorBehind the Intake Manifold
11Intake ThrottleBehind the Intake Manifold
122 Way Check ValveBelow the Intake Manifold
13VSV (Vacuum Switching Valve)At the left Cylinder Body
14EGR Pressure SensorBelow the Intake Manifold
15Fuel FilterAt the left Engine Room
16CMP (Camshaft Position) SensorOn the forward of Timing Gear Case
17IAT (Intake Air Temperature) SensorBelow the Intake Manifold
18ECT (Engine Coolant Temperature)Thermostat Housing
19High Pressure Oil PumpOn the back Timing Gear Case

6E–181 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Lack of Power, Sluggish or Spongy Symptom
StepActionVa l u e ( s )Ye sNo
1DEFINITION:
Engine delivers less than expected power. Little or no
increase in speed when accelerator pedal is pushed
down part-way.
Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2
Go to OBD
System
Check
21. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?
—Verify repairGo to Step 3
3Was a visual/physical check performed?
—Go to Step 4
Go to Visual/
Physical
Check
41. Remove and check the air filter element for dirt or
restrictions. Refer to
Air Intake System in
On-Vehicle Service.
2. Replace the air filter element if necessary.
Was a repair required?
—Verify repairGo to Step 5
51. Check AP sensor system. Refer to AP sensor
diagnostic
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 6
61. Check for water-or alcohol-contaminated fuel.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 7
71. Using a Tech 2, Injector test.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 8
81. Check the ECM grounds for the cleanliness,
tightness and proper locations. Refer to the ECM
wiring diagrams in
Electrical Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 9
91. Check the exhaust system for possible restriction:
Inspect the exhaust system for damaged or
collapsed pipes.
Inspect the muffler for heat distress or possible
internal failure.
Check for a possible plugged catalytic
converter by checking the exhaust system
back pressure. Refer to
Restricted Exhaust
System Check
.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 10
101. Check the torque converter clutch (TCC) for proper
operation. Refer to
Transmission Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found?
—Verify repairGo to Step 11

6A–3
ENGINE MECHANICAL
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.
Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance:
When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick–up unit.
The 12–volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.
Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum die–cast casting
for 75
V–type six cylinders. It has a rear plate integrated
structure and employs a deep skint. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width of No.3 bearing
on the body side is different in order to support the thrust
bearing. The bearing cap is made of nodular cast iron and
each bearing cap uses four bolts and two side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent–roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V–type design. The ports are cross–flow
type.
Va l v e Tr a i n
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast–iron. Pins and
journals are graded for correct size selection for their
bearing.
Engine Lubrication
The oil discharged by a trochoid–type oil pump driven by
the crankshaft is fed through full–flow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.