torque OPEL FRONTERA 1998 Workshop Manual

6C–12
ENGINE FUEL
Fuel Filler Cap
General Description
Fuel filler cap includes vacuum valve and pressure valve.
In case any high vacuum and any high pressure happen in
tank, each valve works to adjust the pressure to prevent
the tank from being damaged.
140RW021
Legend
(1) Vacuum Valve
(2) Pressure Valve
Inspection
Check the seal ring in the filler cap for presence of any
abnormality and for seal condition.
Replace the filler cap, if abnormal.
CAUTION: The fuel filler cap valves have
characteristics.
A defective valve, no valve at all or a valve with the
wrong characteristics will do a lot of harm to engine
operating characteristics; be sure to use the same
fuel filler cap as installed in this vehicle.
Main Data and Specifications
Torque Specification
Nꞏm (Kgꞏm/lb ft)
035RW141

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.

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.

6D2–3
IGNITION SYSTEM
Ignition Coil
Removal
1. Disconnect battery ground cable.
2. Ignition coil connector and ignition coil.
Disconnect three connector from ignition coil.
Remove harness bracket bolt on cylinder head
cover.
Remove fixing bolts on ignition coil.
060RW121
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly
Inspection and Repair
Check the ignition coil assembly for insulation. Check
terminals for corrosion or damage, and replace as
necessary.
Measuring resistance of ignition coil assembly.
Terminal No.
Limit
1 to 2Without 0 ohm or infinity
maximum ohm.
1 to 3Same as above
2 to 3Same as above
Measure resistance of ignition coil assembly, and replace
the ignition coil assembly if its value exceeds the
standard.
060RW006
Installation
1. Install the ignition coil assembly (3).
Connect ignition coil connector (1) and ignition coil
(3), then tighten bolt (2) to the specified torque.
Torque: 4 Nꞏm (0.4 Kgꞏm/35 lb in)
060RW121
2. Connect battery ground cable.

6D2–4
IGNITION SYSTEM
Spark Plug
Removal
1. Remove spark plugs.
Inspection and Repair
The spark plug affects entire engine performance and
therefore its inspection is very important.
Check electrode and insulator for presence of cracks,
and replace if any.
Check electrode for wear, and replace if necessary.
Check gasket for damage, and replace if necessary.
Measure insulation resistance with an ohmmeter, and
replace if faulty.
Adjust spark plug gap to 1.0 mm (0.04 in) 1.1 mm
(0.043 in).
Check fuel and electrical systems if spark plug is
extremely dirty.
Use spark plugs having low heat value (hot type plug)
if fuel and electrical systems are normal.
Use spark plugs having high heat value (cold type
plug) if insulator and electrode are extremely burned.
Sooty Spark Plugs
Much deposit of carbon or oil on the electrode and
insulator of spark plug reduces the engine performance.
Possible causes:
Too rich mixture
Presence of oil in combustion chamber
Incorrectly adjusted spark plug gap
Burning Electrodes
This fault is characterized by scorched or heavily oxidized
electrode or blistered insulator nose.
Possible causes:
Too lean mixture
Improper heat value
Measuring Insulation Resistance
Measure insulation resistance using a 500 volt
megaohm meter.
Replace spark plugs if measured value is out of
standard.
Insulation resistance: 50 M
or more
011RS010
Cleaning Spark Plugs
Clean spark plugs with a spark plug cleaner.
Raise the ground electrode to an angle of 45 to 60
degrees. If electrode is wet, dry it before cleaning.
After spark plug is thoroughly cleaned, check
insulator for presence of cracks.
Clean threads and metal body with a wire brush.
File the electrode tip if electrode is extremely worn.
Bend the ground electrode to adjust the spark plug
gap.
011RS011
Installation
1. Spark plugs
Tighten spark plugs to the specified torque.
Torque: 18 Nꞏm (1.8 Kgꞏm/13 lb ft)

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.

6D2–6
IGNITION SYSTEM
Main Data and Specifications
General Specifications
Ignition System
Ignition FormElectronic Ignition System (El system) with Crankshaft angle Sensor
Spark Plug
Ty p eK16PR–P11
RC10PYP4
PK16PR11
Plug gap1.0 mm (0.04 in) – 1.1 mm (0.043 in)
To r q u e18 Nꞏm (1.8 Kgꞏm/13 lb ft)
Torque Specifications
Nꞏm (Kgꞏm/lb ft)
E06RW038

6D3–1 STARTING AND CHARGING SYSTEM
ENGINE
STARTING AND CHARGING SYSTEM
CONTENTS
Service Precaution 6D3–1. . . . . . . . . . . . . . . . . . . . . .
Starting System 6D3–2. . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6D3–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6D3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter 6D3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 6D3–6. . . . . . . . . . . . . . . . . . . .
Disassembly 6D3–7. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D3–9. . . . . . . . . . . . . . . . . .
Reassembly 6D3–13. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D3–15. . . . . . . . . . .
Charging System 6D3–18. . . . . . . . . . . . . . . . . . . . . . . . General Description 6D3–18. . . . . . . . . . . . . . . . . . . . .
General On–Vehicle Inspection 6D3–18. . . . . . . . . . .
Generator 6D3–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D3–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6D3–19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D3–19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 6D3–20. . . . . . . . . . . . . . . . . . . .
Disassembly 6D3–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D3–23. . . . . . . . . . . . . . . . . .
Reassembly 6D3–24. . . . . . . . . . . . . . . . . . . . . . . . . .
Bench Test 6D3–25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D3–26. . . . . . . . . . .
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.

6D3–5 STARTING AND CHARGING SYSTEM
Starter
Removal
1. Battery ground cable.
2. Remove exhaust front left pipe(1).
150RW062
3. Remove heat protector(3).
4. Disconnect starter wiring connector from terminals
“B” and “S”(4).
5. Remove starter assembly mounting bolts on inside
and outside(5).
6. Remove starter assembly toward the bottom of
engine(6).
065RW027
Installation
1. Install starter assembly(6).2. Install mounting bolts and tighten bolts to specified
torque(5).
Torque: 40 Nꞏm (4.1 Kgꞏm/30 lb ft)
3. Reconnect the connectors to terminals “B” and “S”
and tighten Terminals “B” to specified torque.
Torque: 9 Nꞏm (0.9 Kgꞏm/80 lb in)
4. Install heat protector(3).
065RW027
5. Install exhaust front left pipe and tighten bolts and
nuts to specified torque(2).
Stud Nuts
Torque: 67 Nꞏm (6.8 Kgꞏm/49 lb ft)
Nuts
Torque: 43 Nꞏm (4.4 Kgꞏm/32 lb ft)
150RW062
6. Reconnect the battery ground cable.

6D3–13 STARTING AND CHARGING SYSTEM
Measure inner diameter of bushing in the rear cover, and
replace if it exceeds the limit.
Standard: 12.50 mm to 12.527 mm (0.492 in to
0.4932 in)
Limit: 12.60 mm (0.4961 in)
065RS028Measure inner diameter of bushing in the center bracket
(P), and replace if it exceeds the limit.
Standard: 18.01 mm to 18.127 mm (0.7091 in to
0.7137 in)
Limit: 18.15 mm (0.7146 in)
065RS029
Reassembly
To install, follow the removal steps in the reverse order,
noting the following points:
Grease application places
Bushing in rear cover and center bracket
Gears in reduction gear
Shift lever operating portion
Sliding portion of pinion
Plunger sliding portion of magnetic switch
Reassembling Yoke Assembly
Before reassembly, make sure that no metallic parts
attach to the yoke assembly. Because of strong magnetic
force, hold the yoke assembly and insert it slowly into the
armature.
To r q u e
Torque for each part (See Torque Specifications in
this section)
Pinion Jump–out Dimension
Connect the “+” cable of battery to terminal S and the “–”
cable to terminal M. Turn the switch on, and measure
pinion travel dimension in thrust direction from the
jump–out position.
In measuring the dimension, pull the pinion out a little in
the arrow direction.
Dimension(L): 0.05 mm to 1.5 mm (0.002 in to
0.06 in)
065RS030