sensor OPEL FRONTERA 1998 Workshop Manual

6A–27
ENGINE MECHANICAL
Exhaust Manifold RH
Removal
1. Disconnect battery ground cable.
2. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
3. Remove exhaust front pipe three stud nuts and two
nuts then disconnect exhaust front pipe.
150RW061
Legend
(1) Exhaust Front Pipe RH
(2) O
2 Sensor (for IGM)
4. Remove heat protector two fixing bolts then the heat
protector.
5. Remove exhaust gas recirculation (EGR) pipe fixing
bolt and nut from exhaust manifold, remove a nut
from EGR valve and a bolt from rear side of cylinder
head for bracket of EGR pipe then remove the EGR
pipe.
056RW001
Legend
(1) Exhaust Gas Recirculation (EGR) Valve
(2) EGR Pipe
6. Remove exhaust manifold eight fixing nuts then the
exhaust manifold.
Installation
1. Install exhaust manifold and tighten bolts to the
specified torque.
Torque : 57 Nꞏm (5.8 Kgꞏm/42 lb ft)
2. Install the EGR pipe, tighten bolt and nut on exhaust
manifold to specified torque.
Torque : 28 Nꞏm (2.9 Kgꞏm/21 lb ft)
Tighten nut to EGR valve to the specified torque.
Torque : 44 Nꞏm (4.5 Kgꞏm/33 lb ft)
Tighten the bolt for EGR pipe bracket to specified
torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
3. Install heat protector
4. Install exhaust front pipe and tighten three stud nuts
and two nuts to the specified torque.
To r q u e :
Stud nuts: 67 Nꞏm (6.8 Kgꞏm/49 lb ft)
Nuts: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
5. Install the torsion bar and readjust the vehicle height.
Refer to installation and vehicle height adjustment
procedure for Front Suspension.

6A–28
ENGINE MECHANICAL
Crankshaft Pulley
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
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
3. Remove radiator upper fan shroud from radiator.
4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Serpentine Belt
5. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
6. Remove crankshaft pulley assembly using J-8614-01
crankshaft holder, hold crankshaft pulley then
remove center bolt and pulley.
Installation
1. Install crankshaft pulley using J-8614-01 crankshaft
holder, hold the crankshaft pulley and tighten center
bolt to the specified torque.
Torque : 167 Nꞏm (17.0 Kgꞏm/123 lb ft)
2. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in) for fan and
clutch assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.

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.

6A–49
ENGINE MECHANICAL
If the engine is assembled in the condition that the
dowels have not been mounted in the specified posi-
tions, the transmission may be damaged the trans-
mission.
012RS009
1. Install engine assembly. Tighten engine mount fixing
bolts to frame to the specified torque.
Torque: 41 Nꞏm (4.2 Kgꞏm/30 lb ft)
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to Transmission
section in this manual.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two (each
bank) rear exhaust flange nuts then tighten three stud
nuts (each bank) between exhaust manifold and
exhaust pipe, finally tighten rear side nuts to the
specified torque.
Torque:
Nuts: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
Stud nuts: 67 Nꞏm (6.8 Kgꞏm/49 lb ft)
150RW061
Legend
(1) Exhaust Front Pipe RH
(2) O
2 Sensor (for IGM)
150RW062
Legend
(1) Exhaust Front Pipe LH
7. Reconnect O2 sensor connector.
8. Install cooling fan assembly and tighten bolts/nuts to
the specified torque.
Torque : 22 Nꞏm (2.2 Kgꞏm/16 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nꞏm (1.0 Kgꞏm/88.5 lb in) for fan and
clutch assembly.

6A–50
ENGINE MECHANICAL
9. Install air conditioner compressor to engine and
tighten to the specified torque.
Torque :
M8 bolts : 22 Nꞏm (2.2 Kgꞏm/16 lb ft)
M10 bolts : 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
10. Install power steering pump, tighten fixing bolt to the
specified torque.
Torque :
M8 bolts : 22Nꞏm (2.2 Kgꞏm/16 lb ft)
M10 bolts : 46 Nꞏm (4.7 Kgꞏm/34 lb ft)
11. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt
12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of right
dash panel.19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.
24. Install air cleaner assembly.
25. Reconnect air duct.
26. Reconnect accelerator cable and automatic cruise
control cable to throttle valve on common chamber.
035RW007
Legend
(1) Throttle Valve Assembly
(2) Throttle Lever
(3) Idle Air Control Valve
(4) Throttle Position Sensor
27. Install engine hood to the original position.
Refer to installation procedure for Body section in
this manual.
Accelerator pedal cable adjustment
1. Loosen adjusting nut and lock nut.
2. Pull outer cable while fully closing the throttle
valve.
3. Tighten adjusting nut and lock nut temporarily.
4. Loosen adjusting nut by three turns and tighten
lock nut.
Then, manually operating the throttle valve, make
s u r e t h a t t h e v a l v e l e v e r r e t u r n s u p t o t h e s t o p p e r
screw.

6A–91
ENGINE MECHANICAL
Torque Specifications
Ignition coil, Spark plug, Crankshaft angle sensor and Under cover
Nꞏm (Kgꞏm/Ib ft)
E06RW038

ENGINE COOLING6B–5
Diagnosis
Engine Cooling Trouble
ConditionPossible causeCorrection
Engine overheatingLow Engine Coolant levelReplenish
Incorrect fan installedReplace
Thermo meter unit faultyReplace
Faulty thermostatReplace
Faulty Engine Coolant temperature
sensorRepair or replace
Clogged radiatorClean or replace
Faulty radiator capReplace
Low engine oil level or use of
improper engine oilReplenish or change oil
Clogged exhaust systemClean exhaust system or replace
faulty parts
Faulty Throttle Position sensorReplace throttle valve assembly
Open or shorted Throttle Position
sensor circuitRepair or replace
Damaged cylinder head gasketReplace
Engine overcoolingFaulty thermostatReplace
Engine slow to warm–upFaulty thermostatReplace
Thermo unit faultyReplace

6C–3
ENGINE FUEL
Adhere to all Notices and Cautions.
All gasoline engines are designed to use only unleaded
gasoline. Unleaded gasoline must be used for proper
emission control system operation.
Its use will also minimize spark plug fouling and extend
engine oil life. Using leaded gasoline can damage the
emission control system and could result in loss of
emission warranty coverage.
All cars are equipped with an Evaporative Emission
Control System. The purpose of the system is to minimize
the escape of fuel vapors to the atmosphere.
Fuel Metering
The Engine Control Module (ECM) is in complete control
of this fuel delivery system during normal driving
conditions.
The intake manifold function, like that of a diesel, is used
only to let air into the engine. The fuel is injected by
separate injectors that are mounted over the intake
manifold.
The Manifold Absolute Pressure (MAP) sensor measures
the changes in the intake manifold pressure which result
from engine load and speed changes, which the MAP
sensor converts to a voltage output.
This sensor generates the voltage to change
corresponding to the flow of the air drawn into the engine.
The changing voltage is transformed into an electric
signal and provided to the ECM.
With receipt of the signals sent from the MAP sensor,
Intake Air Temperature sensor and others, the ECM
determines an appropriate fuel injection pulse width
feeding such information to the fuel injector valves to
effect an appropriate air/fuel ratio.
The Multiport Fuel Injection system utilizes an injection
system where the injectors turn on at every crankshaft
re vol u tion . Th e EC M con tro ls t he in je cto r on tim e so t ha t
the correct amount of fuel is metered depending on
driving conditions.
Two interchangeable “O” rings are used on the injector
that must be replaced when the injectors are removed.
The fuel rail is attached to the top of the intake manifold
and supplies fuel to all the injectors.
Fuel is recirculated through the rail continually while the
engine is running. This removes air and vapors from the
fuel as well as keeping the fuel cool during hot weather
operation.
The fuel pressure control valve that is mounted on the fuel
rail maintains a pressure differential across the injectors
under all operating conditions. It is accomplished by
controlling the amount of fuel that is recirculated back to
the fuel tank based on engine demand.
See Section “Driveability and Emission” for more
information and diagnosis.

6D2–1
IGNITION SYSTEM
ENGINE
IGNITION SYSTEM
CONTENTS
Service Precaution 6D2–1. . . . . . . . . . . . . . . . . . . . . .
General Description 6D2–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6D2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil 6D2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D2–3. . . . . . . . . . . . . . . . . .
Installation 6D2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug 6D2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 6D2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D2–4. . . . . . . . . . . . . . . . . .
Installation 6D2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Angle Sensor 6D2–5. . . . . . . . . . . . . . . . .
Removal 6D2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D2–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D2–6. . . . . . . . . . . . .
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.

6D2–2
IGNITION SYSTEM
General Description
Ignition is done by the electronic ignition (El) that directly
fires the spark plugs from ignition coils through spark plug
wires without using a distributor. A pair of ignition coils for
the cylinders having different phases by 360
(No.1 and
No.4,No.2 and No.5,No.3 and No.6) are fired
simultaneously.
Since the cylinder on exhaust stroke requires less energy
to fire its ignition plug, energy from the ignition coils can be
utilized to fire the mating cylinder on compression stroke.
After additional 360
rotation, respective cylinder strokes
are reversed.
The EI consists of six ignition coils,ignition control
module, crank angle sensor, powertrain control module
(PCM) and other components.The ignition coils are connected with the PCM by means
of a 32 pin connector.
The ignition control module turns on/off the primary circuit
of ignition coils, and also it controls the ignition timing at
the engine speed below 538 rpm.
A notch in the timing disc on the crankshaft activates the
crank angle sensor which then sends information such as
firing order and starting timing of each ignition coil to the
PCM.
Further, the El employs ignition control (IC) to control
similar to a distributor system.
By receiving signals such as crank position,engine
speed, water temperature and Manifold Absolute
Pressure (MAP), the PCM controls the ignition timing.
D06RW084
Diagnosis
Refer to Section Drivability and Emissions for the
diagnosis to electronic ignition system (El system).