fuel pump OPEL FRONTERA 1998 Owners Manual

6A–8
ENGINE MECHANICAL
Hesitation
ConditionPossible causeCorrection
Hesitation on accelerationThrottle Position Sensor adjustment
incorrectReplace throttle valve assembly
Throttle Position Sensor circuit open
or shortedCorrect or replace
Excessive play in accelerator linkageAdjust or replace
Mass Airflow Sensor circuit open or
poor connectionsCorrect or replace
Mass Airflow Sensor defectiveReplace
Manifold Absolute Pressure (MAP)
Sensor circuit open or shortedCorrect or replace
MAP Sensor defectiveReplace
Intake Air Temperature (IAT) Sensor
circuit open or shortedCorrect or replace
Knock Sensor (KS) Circuit open or
poor connectionsCorrect or replace
KS defectiveReplace
KS Module circuits open or shortedCorrect or replace
KS Module defectiveReplace
IAT Sensor defectiveReplace
Hesitation at high speedsFuel tank strainer cloggedClean or replace
(Fuel pressure too low)Fuel pipe cloggedClean or replace
Fuel filter cloggedReplace
Defective fuel pump systemCheck and replace
Fuel Pressure Control Valve leakingReplace
Hesitation at high speeds
(Fuel injector not working normally)Power supply or ground circuit for
Multiport Fuel Injection System
shorted or openCheck and correct or replace
Fuel Injector defectiveReplace
Cable of Multiport Fuel Injection
System circuit open or poor
connectionsCorrect or replace

6A–10
ENGINE MECHANICAL
Engine Lacks Power
ConditionPossible causeCorrection
Trouble in fuel systemFuel Pressure Control Valve not
working normallyReplace
Fuel injector cloggedClean or replace
Fuel pipe cloggedClean
Fuel filter clogged or fouledReplace
Fuel pump drive circuit not working
normallyCorrect or replace
Fuel tank not sufficiently breathing
due to clogged Evaporative
Emission Control System circuitClean or replace
Water in fuel systemClean
Inferior quality fuel in fuel systemUse fuel of specified octane rating
Powertrain Control Module supplied
poor voltageCorrect circuit
Throttle Position Sensor cable
broken or poor connectionsCorrect or replace
Throttle Position Sensor defectiveReplace
Mass Airflow Sensor not working
normallyReplace
Manifold Absolute Pressure Sensor
not working normallyReplace
Intake Air Temperature Sensor not
working normallyReplace
Engine Coolant Temperature Sensor
circuit open or shortedCorrect or replace
Engine Coolant Temperature Sensor
defectiveReplace
Powertrain Control Module defectiveReplace
Trouble in intake or exhaust systemAir Cleaner Filter cloggedReplace filter element
Air duct kinked or flattenedCorrect or replace
Ignition failure————Refer to Hard Start Troubleshooting
Guide
Heat range of spark plug inadequateInstall spark plugs of adequate heat
range
Ignition coil defectiveReplace

6A–13
ENGINE MECHANICAL
Condition CorrectionPossible cause
Engine knockingPreignition due to use of spark plugs
of inadequate heat rangeInstall Spark Plugs of adequate heat
range
Carbon deposits in combustion
chambersClean
Fuel too low in octane ratingReplace fuel
Wide Open Throttle enrichment
system failureRefer to Section 6E
Selection of transmission gear
incorrectCaution operator of incorrect gear
selection
Engine overheatingRefer to “Engine Lacks Power”
OthersWater pump defectiveReplace
Drive belt slippingReplace auto tentioner or drive belt
Abnormal Combustion
ConditionPossible causeCorrection
Trouble in fuel systemFuel pressure control valve defectiveReplace
Fuel filter cloggedReplace
Fuel pump cloggedClean or replace
Fuel tank or fuel pipe cloggedClean or replace
Fuel injector cloggedClean or replace
Fuel pump relay defectiveReplace
Power supply cable for fuel pump
broken or poor connectionsReconnect, correct or replace
Mass Airflow (MAF) sensor circuit
open or defectiveCorrect or replace
MAF Sensor defectiveReplace
Manifold Absolute Pressure Sensor
circuit open or shortedCorrect or replace
Manifold Absolute Pressure Sensor
defectiveReplace
Engine Coolant Temperature (ECT)
Sensor circuit open or shortedCorrect or replace
ECT Sensor defectiveReplace
Throttle Position Sensor adjustment
incorrectReadjust
Throttle Position Sensor defectiveReplace
Throttle Position Sensor connector
poor connectionsReconnect
Vehicle Speed Sensor cable poor
connections or defectiveCorrect or replace
Vehicle Speed Sensor loosely fixedFix tightly
Vehicle Speed Sensor in wrong
contact or defectiveReplace
Powertrain Control Module cable
poor connections or defectiveCorrect or replace

6A–21
ENGINE MECHANICAL
Cylinder Head Cover RH
Removal
1. Disconnect battery ground cable.
2. Remove battery from the vehicle.
3. Drain engine coolant from faucet bottom of radiator.
4. Remove engine cover from the dowels on the
common chamber.
F06RW018
5. Remove air cleaner duct assembly (3) and air cleaner
element (4).
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.
6. Disconnect following wiring connectors and bonding
cable:
Exhaust Gas Recirculation (EGR) valve
Fuel injectors for right bank
Ignition coils for right bank
Bonding cable
Othres as necessitated
7. Disconnect radiator upper and lower hoses.
8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
F06RW019
Legend
(1) Crankshaft Pulley
(2) Generator
(3) Auto Tensioner
(4) Idle Pulley
(5) Cooling Fan Pulley
(6) Power Steering Oil Pump
(7) Drive Belt
(8) Air Conditioner Compressor
12. Remove fan pulley and bracket assembly.
13. Remove idle pulley assembly.
14. Remove auto tensioner assembly.
15. Remove crankshaft pulley using 5–8840–0133–0
crankshaft holder.

6A–48
ENGINE MECHANICAL
Engine Assembly
Removal
035RW027
1. Disconnect battery ground and positive cable.
2. Remove battery.
3. Make alignment mark on the engine hood and hinges
before removal in order to return the hood to original
position exactly.
4. Remove engine hood.
5. Drain radiator coolant.
6. Disconnect accelerator cable and automatic cruise
control cable from throttle valve on common
chamber.
7. Disconnect air duct with air cleaner cover.
8. Remove air cleaner assembly.
9. Disconnect canister vacuum hose.
10. Disconnect vacuum booster hose.
11. Disconnect three engine harness connectors.
12. Disconnect harness connector to transmission (left
front side of engine compartment), disconnect shift
on the fly harness connector from front side of front
axle and remove transmission harness bracket from
engine left side.
13. Disconnect ground cable between engine and frame.
14. Disconnect bonding cable connector on the back of
right dash panel.
15. Disconnect bonding cable terminal on the left bank.
16. Disconnect starter harness connector from starter.
17. Disconnect generator harness connector from
generator.
18. Disconnect coolant reserve tank hose from radiator.
19. Remove radiator upper and lower hoses.
20. Remove upper fan shroud.
21. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
22. Move drive belt tensioner to loose side using wrench
then remove drive belt.23. Remove power steering pump fixing bolts, then
power steering pump. Place the power steering pump
along with piping on the body side.
24. Remove air conditioning compressor fixing bolts from
bracket and place the compressor along with piping
on the body side.
25. Remove O
2 sensor harness connectors from exhaust
front pipe.
26. Remove three exhaust pipe fixing nuts from each
bank.
27. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side of
vehicle.
28. Remove flywheel dust covers.
29. Disconnect two heater hoses from engine.
30. Disconnect fuel hoses from right side of transmission.
CAUTION: Plug fuel pipes on engine side and fuel
hoses from fuel tank.
31. Remove transmission assembly. Refer to
Transmission section in this manual.
32. Support the engine by engine hoist.
33. Remove two left side engine mount fixing bolts from
engine mount on chassis side.
34. Remove two right side engine mount fixing bolts from
engine mount on chassis side.
35. Remove engine assembly.
Installation
CAUTION: W h e n a s s e m b l i n g t h e e n g i n e a n d
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the automatic
transmission.

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.

6C–2
ENGINE FUEL
General Description
140RW030
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(4) Fuel Pump
(5) Fuel Filter
(6) Fuel Rail Right
(7) Right Bank(8) Fuel Rail Left
(9) Left Bank
(10) Fuel Pressure Control Valve
(11) Common Chamber
(12) Duty Solenoid Valve
(13) Throttle Valve
(14) Canister
When working on the fuel system, there are several
things to keep in mind:
Any time the fuel system is being worked on,
disconnect the negative battery cable except for
those tests where battery voltage is required.
Always keep a dry chemical (Class B) fire
extinguisher near the work area.
Replace all pipes with the same pipe and fittings that
were removed.
Clean and inspect “O” rings. Replace if required.
Always relieve the line pressure before servicing any
fuel system components.
Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.

6C–5
ENGINE FUEL
Installation
1. Install the fuel filter in the proper direction.
2. Install fuel filter holder fixing bolt.
3. Connect fuel hoses on engine side(1) and fuel tank
side(2).
041RW001
4. Install fuel filler cap
5. Connect the battery ground cable.
Inspection
After installation, start engine and check for fuel leakage.
In–Tank Fuel Filter
The filter is located on the lower end of fuel pickup tube in
the fuel tank. It prevents dirt from entering the fuel pipe
and also stops water unless the filter is completely
submerged in the water. It is a self cleaning type, not
requiring scheduled maintenance. Excess water and
sediment in the tank restricts fuel supply to the engine,
resulting in engine stoppage. In such a case, the tank
must be cleaned thoroughly.
Fuel Pump Flow Test
If reduction of fuel supply is suspected, perform the
following checks:
1. Make sure that there is fuel in the tank.
2. With the engine running, check the fuel feed pipe and
hose from fuel tank to injector for evidence of
leakage. Retighten, if pipe or hose connection is
loose. Also, check pipes and hoses for squashing or
clogging.
3. Insert the hose from fuel feed pipe into a clean
container, and check for fuel pump flow rate.4. Connect the pump relay terminals with a jumper
wire(1) as shown and start the fuel pump to measure
delivery.
140RW002
CAUTION: Never generate sparks when connecting
a jumper wire.
Delivery
Delivery
15 seconds0.38 liters minimum
If the measure value is out of standard, conduct the
pressure test.
Pressure test
For the pressure test to the fuel system, see Section 6E
“Fuel Control System”.

6C–6
ENGINE FUEL
Fuel Pump
Fuel Pump and Associated Parts
035RW047
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission”.
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.
3. Drain fuel.
Tighten drain plug to the specified torque after
draining fuel.
Torque: 20 Nꞏm (2.0 Kgꞏm/14 lb ft) — M8
4. Remove fuel tank assembly(1). Refer to “Fuel Tank
Removal” in this section.
5. Remove fuel pump (FP) assembly(2) fixing screws
and remove the FP assembly.
NOTE: After removing FP, cover fuel tank to prevent any
dust entering.
Installation
1. Install FP assembly(2).
2. Install fuel tank assembly(1). Refer to “Fuel Tank
Installation”.
3. Fill the tank with fuel and tighten fuel filler cap.
4. Connect battery ground cable.

6C–7
ENGINE FUEL
Fuel Pump Relay
General Description
In order to control the FP operation, the FP relay is
provided. When the starter switch is turned to “ON”
position, the FP relay operates the FP for 2 seconds.When it is turned to “START” position, the Power Train
Control Module (PCM) receives the reference pulse from
the Ignition Control Module and it operates the relay,
again causing the FP to feed fuel.
Fuel Tank
Fuel Tank and Associated Parts
035RW048
Legend
(1) Fender Liner
(2) Fuel Filler Hose and Air Breather Hose and
Evapo Hose
(3) Undercover(4) Fuel Tank Wiring Connector
(5) Evapo Fuel Hose
(6) Fuel Feed Tube and Fuel Return
Tube/Quick–Connect Fittings
(7) Fuel Tank
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission”.
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.3. Drain fuel.
Tighten drain plug to the specified torque after
draining fuel.
Torque: 20 Nꞏm (2.0 Kgꞏm/14 lb ft) — M8
4. Remove fender liner (1) of wheel well on rear right
side.
5. Fuel filler hose, air breather hose and evapo hose (2).
6. Remove undercover fixing bolts on both sides and
remove under cover(3).