lock OPEL FRONTERA 1998 Workshop Manual
[x] Cancel search | Manufacturer: OPEL, Model Year: 1998, Model line: FRONTERA, Model: OPEL FRONTERA 1998Pages: 6000, PDF Size: 97 MB
Page 1045 of 6000

6A–89
ENGINE MECHANICAL
012RS007
7. Install cylinder block side bolts (1) and tighten
crankcase bolts in sequence shown in the illustration.
Torque : 39 Nꞏm (4.0 Kgꞏm/29 lb ft)
012RW005
8. Install oil pump assembly. Refer to “Oil Pump” in this
manual.
9. Install oil strainer and O-ring.
10. Install oil pipe and O-ring.
11. Install crankcase with oil pan.
1. Completely remove all residual sealant, lubricant
and moisture from the sealing surfaces. The
surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB– 1207C
or its equivalent) to the contact surfaces of the
crankcase. There must be no gaps in the bead.
3. The oil pan must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
4. Tighten the bolts and nuts to the specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
013RW010
Legend
(1) Portion Between Both Holes
(2) Bolt Hole Portions
12. Install cylinder head gasket.
13. Install cylinder head assembly. Refer to “Cylinder
Head” in this manual.
Page 1054 of 6000

ENGINE COOLING6B–1
ENGINE
ENGINE COOLING
CONTENTS
Service Precaution 6B–1. . . . . . . . . . . . . . . . . . . . . .
General Description 6B–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Refilling Cooling System 6B–6. . . . .
Water Pump 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump and Associated Parts 6B–7. . . . . . .
Removal 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat 6B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat and Associated Parts 6B–8. . . . . . . .
Removal 6B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 6B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator 6B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator and Associated Parts 6B–9. . . . . . . . . .
Removal 6B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6B–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Belt and Cooling Fan 6B–12. . . . . . . . . . . . . . .
Drive Belt and Associated Parts 6B–12. . . . . . . . .
Inspection 6B–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6B–13. . . . . . . . . . . . .
Special Tool 6B–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
Page 1055 of 6000

6B–2
ENGINE COOLING
General Description
030RW001
Legend
(1) Water Pump
(2) Thermostat
(3) Radiator
(4) Reserve Tank
(5) Cooling Fan
(6) Cylinder Block(7) Cylinder Head
(8) Right Bank
(9) Throttle Body
(10) Cylinder Block
(11) Cylinder Head
(12) Left Bank
(13) Heater
The cooling system is a pressurized Engine Coolant (EC)
forced circulation type which consists of a water pump,
thermostat cooling fan, radiator and other components.
The automatic transmission fluid is cooled by the EC in
radiator.
Water Pump
The EC pump is a centrifugal impeller type and is driven
by a timing belt.
030RS001
Page 1059 of 6000

6B–6
ENGINE COOLING
Draining and Refilling Cooling
System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order. The
engine coolant (EC) level should be between the “MIN”
and “MAX” lines of reserve tank when the engine is cold.
If low, check for leakage and add EC up to the “MAX” line.
There should not be any excessive deposit of rust or
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the
drain plug (2) at the bottom of the radiator.
110RW002
2. Remove the radiator cap.
WARNING: TO AVOID THE DANGER OF BEING
BURNED, DO NOT REMOVE THE CAP WHILE THE
ENGINE AND RADIATOR ARE STILL HOT.
SCALDING FLUID AND STEAM CAN BE BLOWN OUT
UNDER PRESSURE.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution
that is at least 50 percent antifreeze but no more than
70 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to “MAX” line when the engine
is cold.
6. Block the drive wheels and firmly apply the parking
brake. Shift an automatic transmission to “P” (Park)
or a manual transmission to neutral.
7. Remove the radiator cap. Start the engine and warm
it up at 2,500
3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck
and the EC level has gone down, replenish with the
EC. Repeat this procedure until the EC level does not
go down. Then stop the engine and install the radiator
cap. Let the engine cool down.9. After the engine has cooled, replenish with EC up to
the “MAX” line of the reserve tank.
10. Start the engine. With the engine running at 3,000
rpm, make sure there is no running water sound from
the heater core (behind the center console).
11. If the running water sound is heard, repeat steps 8 to
10.
Page 1062 of 6000

ENGINE COOLING6B–9
Radiator
Radiator and Associated Parts
110RW003
Legend
(1) Oil Cooler Hose For Automatic Transmission
(2) Radiator Hose
(3) Fan Guide, Lower(4) Reserve Tank Hose
(5) Bracket
(6) Radiator Assembly
(7) Reserve Tank
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug(2) to drain EC.
3. Disconnect oil cooler hose(1) on automatic
transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from
the engine.
110RW002
5. Remove fan guide(1), clips(3) on both sides and the
bottom lock, then remove lower fan guide(3) with fan
shroud(4).
110RW001
Page 1068 of 6000

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.
Page 1077 of 6000

6C–10
ENGINE FUEL
Reuse of Quick–Connector
(Delivery Pipe)
Replace the pipe and connector if scratch, dent or
crack is found.
Remove mud and dust from the pipe and make sure
that the end including spool is free of defects, such as
scratch, rust, and dent, which may cause poor
sealability. If defective, replace with a new pipe.
If the retainer removed according to the removal step
above is attached to the pipe, clean and insert it
straight into the quick-connector till it clicks. After it
clicks, try pulling it out to make sure that it is not drawn
and is securely locked.
NOTE: The retainer, once removed from the pipe, cannot
be reused. Just replace with a new retainer. Insert the
new retainer into the connector side until it clicks, and
connect the pipe as inserting it into the retainer until it
clicks.
141RW018
(Return Pipe)
Replace the pipe and connector if scratch, dent or
crack is found.
Remove mud or dust from the pipe and make sure
that the end including spool is free from defects, such
as scratch, rust, and dent, which may cause poor
sealability. If defective, replace with a new pipe.
After cleaning the pipe, insert it straight into the
connector until it clicks. After it clicks, try pulling it out
to make sure that it is not drawn and is securely
locked.
141RW017
Assembling Advice
Application of engine oil or light oil to the pipe facilitates
connecting work. The work should be started immediately
after lubrication, since dust may stick to the pipe surface
to cause poor sealability if a long time passes after
lubrication.
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Turn the ignition key to the “ON” position and check
pump startup sound. As the pump is actuated to raise
fuel pressure, check and see fuel leak from the piping
system.
3. Make sure of no fuel leakage by conducting the above
fuel leak check a few times.
4. Start the engine and make sure of stable idling speed
and normal vehicle run.The entry of dust during the
work may sometimes affect the fuel injection system.
Page 1080 of 6000

ENGINE ELECTRICAL6D1–1
ENGINE
ENGINE ELECTRICAL
CONTENTS
Service Precaution 6D1–1. . . . . . . . . . . . . . . . . . . . . .
Battery 6D1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6D1–2. . . . . . . . . . . . . . . . . . . .
Diagnosis 6D1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging 6D1–3. . . . . . . . . . . . . . . . . . . . . . Jump Starting 6D1–3. . . . . . . . . . . . . . . . . . . . . . . . .
Battery Removal 6D1–4. . . . . . . . . . . . . . . . . . . . . .
Battery Installation 6D1–4. . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D1–5. . . . . . . . . . .
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.
Page 1086 of 6000

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.
Page 1090 of 6000

6D2–5
IGNITION SYSTEM
Crankshaft Angle Sensor
Removal
1. Disconnect battery ground cable
2. Wiring connector from crankshaft angle sensor.
3. Remove crankshaft angle sensor from cylinder block.
012RS008
Installation
1. Install crankshaft angle sensor into the cylinder block.
Before installation,apply small amount of engine oil to
the O–ring.
Torque: 10 Nꞏm (1.0 Kgꞏm/89 lb in)
2. Reconnect wiring connector to crankshaft angle
sensor.