fuel pressure OPEL FRONTERA 1998 Workshop Manual

METER AND GAUGE8E–1
METER AND GAUGE
CONTENTS
Service Precaution 8E–1. . . . . . . . . . . . . . . . . . . . . .
General Description 8E–1. . . . . . . . . . . . . . . . . . . . .
Meter Assembly 8E–2. . . . . . . . . . . . . . . . . . . . . . . . .
General Description 8E–2. . . . . . . . . . . . . . . . . . . . .
Layout for Meters/Gauges, Warning Lights,
Indicator Lights and Illumination Lights 8E–2. . .
Table for Meter/Gauge Connector Terminal
Connections 8E–8. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8E–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8E–14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Light Bulb, Indicator Light Bulb,
Illumination Light Bulb, A/T Indicator
Light Bulb 8E–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8E–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8E–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Speed Sensor 8E–15. . . . . . . . . . . . . . . . . . .
Removal 8E–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8E–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Unit 8E–15. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8E–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8E–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multi Meter 8E–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8E–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8E–16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Sensor 8E–16. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8E–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8E–16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 8E–17. . . . . . . . . . . . .
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.
General Description
The circuit consists of the starter switch, meter assembly,
vehicle speed sensor, transmission switch, lighting
switch, turn signal switch, thermo unit, oil pressure unit,
Powertrain Control Module (PCM), fuel tank unit, 4WD
switch, oil pressure switch, parking brake switch, brake
fluid switch, seat belt switch, illumination controller, multi
meter and ambient sensor.

8E–2METER AND GAUGE
Meter Assembly
General Description
The meter assembly has the speedometer, tachometer,
engine coolant temperature gauge, fuel gauge and
warning/indicator lights. In addition, the meter assembly
containing TOD (Torque on Demand) has the TOD
indicator light, or the meter assembly not containing TOD
has the voltmeter and oil pressure gauge instead of the
TOD indicator.
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination
Lights
Meter Assembly–Gasoline W/O TOD (Front View)
825RW207
Legend
(1) Voltmeter & Engine Coolant Temperature
Gauge
(2) Tachometer
(3) Warning Light Lens
(4) Speedometer(5) Oil Pressure Gauge & Fuel Gauge
(6) Warning Light Lens
(7) Reset Knob
(8) A/T Shift Indicator
(9) Warning Light Lens

METER AND GAUGE8E–9
Meter Assembly–Gasoline W/O TOD–2
Connector No. I–9
Te r m i n a lFunction
1A/T oil temp warning light
2Seat belt warning light
3Check trans warning light
4Brake warning light
5Check engine warning light
6Charge warning light
7Cigarette lighter illumination light
8Illumination controller
9Tachometer
10D position (A/T)
11—
12A/T shift indicator control unit
13—
142 position (A/T)
15Starter switch
16Cruise set indicator light
17Cruise main indicator light
184WD indicator light
19Ground (Gauge)
20—
21Winter drive indicator light
22Oil pressure warning light
23—
24Air bag warning light
25Power drive indicator light
26—
27—
28Turn signal indicator light (Left)
29—
30Ground
Connector No. I–10
Te r m i n a lFunction
1Turn signal indicator light (Right)
2L position (A/T)
3R position (A/T)
4Engine coolant temperature gauge
5Speedometer
6—
7—
8Battery (+)
9—
10Rear fog light
11P position (A/T)
12N position (A/T)
133 position (A/T)
14High-beam indicator light (–)
15High-beam indicator light (+)
16ABS indicator light
17—
18Fuel warning light
19Oil pressure gauge
20Fuel gauge
21—
22—

METER AND GAUGE8E–11
Meter Assembly–Gasoline W/TOD–2
Connector No. I–9
Te r m i n a lFunction
1—
2Air bag warning light
3A/T oil temp warning light
4Charge warning light
5Check engine warning light
6Check trans warning light
7Brake warning light
8—
9Tachometer
10—
11Turn signal indicator light (Left)
12A/T shift indicator control unit
132 position (A/T)
14D position (A/T)
15Rear (TOD)
16Auto (TOD)
17Check (TOD)
18Cruise set indicator light
19Cruise main indicator light
20Oil pressure warning light
21Front “1” (TOD)
22Front “2” (TOD)
23Front “3” (TOD)
24Cigarette lighter illumination light
25Illumination controller
26Starter switch
27—
28Winter drive indicator light
29Power drive indicator light
30—
Connector No. I–10
Te r m i n a lFunction
1Turn signal indicator light (Right)
2L position (A/T)
3R position (A/T)
4Check engine warning light
5Speedometer
6—
7—
8Battery (+)
9Engine coolant temperature gauge
10Ground
11P position (A/T)
12N position (A/T)
133 position (A/T)
14High beam indicator light (–)
15High beam indicator light (+)
16ABS indicator light
17—
18Fuel warning light
19—
20Fuel gauge
21Ground (Gauge)
22—

METER AND GAUGE8E–13
Meter Assembly–Diesel–2
Connector No. I–9
Te r m i n a lFunction
1—
2Seat belt warning light
3—
4Brake warning light
5—
6Charge warning light
7Cigarette lighter illumination light
8Illumination controller
9Tachometer
10—
11—
12—
13—
14—
15Starter switch
16—
17—
184WD indicator light
19Ground (Gauge)
20—
21—
22Oil pressure warning light
23Water sedimenter
24Air bag warning light
25—
26Glow indicator light
27—
28Turn signal indicator light (Left)
29—
30Ground
Connector No. I–10
Te r m i n a lFunction
1Turn signal indicator light (Right)
2—
3—
4Engine coolant temperature gauge
5Speedometer
6—
7—
8Battery (+)
9—
10—
11—
12—
13—
14High-beam indicator light (–)
15High-beam indicator light (+)
16ABS indicator light
17—
18Fuel warning light
19Oil pressure gauge
20Fuel gauge
21—
22—

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.

6A–5
ENGINE MECHANICAL
4. Engine Lacks Compression
Condition
Possible causeCorrection
Engine lacks compressionSpark plug loosely fitted or spark
plug gasket defectiveTighten to specified torque or replace
gasket
Valve timing incorrectAdjust
Cylinder head gasket defectiveReplace gasket
Valve incorrectly seatedLap valve
Valve stem seizedReplace valve and valve guide
Valve spring weakened or brokenReplace
Cylinder or piston rings wornOverhaul engine
Piston ring seizedOverhaul engine.
Engine Compression Test Procedure
1. Start and run the engine until the engine reaches
normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and fuse
box.
6. Engage the starter and check that the cranking speed
is approximately 300 rpm.7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the starter
engaged until the compression gage needle reaches
the maximum level. Note the reading.
9. Repeat the test with each cylinder.
If the compression pressure obtained falls below the
limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)

6A–6
ENGINE MECHANICAL
Rough Engine Idling or Engine Stalling
ConditionPossible causeCorrection
Trouble in fuel injection systemIdle air control valve defectiveReplace
Throttle shutting off incompleteCorrect or replace
Throttle position sensor circuit open
or shortedCorrect or replace
Fuel injector circuits open or shortedCorrect or replace
Fuel injectors damagedReplace
Fuel pump relay defectiveReplace
Mass Airflow Sensor circuit open or
poor connectionsCorrect or replace
Mass Airflow Sensor defectiveReplace
Manifold Absolute Pressure Sensor
circuit open or poor connectionsCorrect or replace
Manifold Absolute Pressure Sensor
defectiveReplace
Engine Coolant Temperature Sensor
circuit open or poor connectionsCorrect or replace
Engine Coolant Temperature Sensor
defectiveReplace
Intake Air Temperature sensor circuit
open or poor connectionsCorrect or replace
Intake Air Temperature sensor
defectiveReplace
Knock Sensor (KS) cable broken or
poor connectionsCorrect or replace
KS defectiveReplace
KS Module circuits open or groundCorrect or replace
KS Module defectiveReplace
Vehicle Speed Sensor circuit open or
shortedCorrect or replace
Vehicle Speed Sensor defectiveReplace
Trouble in emission control systemPowertrain Control Module defectiveReplace
Exhaust Gas Recirculation Valve
circuit open or poor connectionsCorrect or replace
Exhaust Gas Recirculation Valve
faultyReplace
Canister purge valve circuit open or
poor connectionsCorrect or replace
Canister purge valve defectiveReplace
Evaporative Emission Canister
Purge control valve defectiveReplace
Trouble in ignition systemRefer to “Hard Start”

6A–7
ENGINE MECHANICAL
Condition CorrectionPossible cause
OthersEngine lacks compressionRefer to “Hard Start”
Valve incorrectly seatedLap valve
Air Cleaner Filter cloggedReplace filter element
Valve timing incorrectReadjust
Idle air control valve brokenReplace
Fast idle solenoid defectiveReplace
Positive Crankcase Ventilation valve
defective or cloggedReplace
Rough Engine Running
ConditionPossible causeCorrection
Engine misfires periodicallyIgnition coil layer shortedReplace
Spark plugs foulingClean or install hotter type plug
Spark plug(s) insulator nose leakingReplace
Fuel injector(s) defectiveReplace
Powertrain control module faultyReplace
Engine knocks periodicallySpark plugs running too hotInstall colder type spark plugs
Powertrain control module faultyReplace
Engine lacks powerSpark plugs fouledClean
Fuel injectors defectiveReplace
Mass Airflow Sensor or Intake
Airflow Sensor circuit defectiveCorrect or replace
Manifold Absolute Pressure (MAP)
Sensor or Manifold Absolute
Pressure Sensor circuit defectiveCorrect or replace
Engine Coolant Temperature Sensor
or Engine Coolant Temperature
Sensor circuit defectiveCorrect or replace
Powertrain Control Module faultyReplace
Intake Air Temperature Sensor or
Intake Air Temperature Sensor
circuit defectiveCorrect or replace
Throttle Position Sensor or Throttle
Position Sensor circuit defectiveCorrect or replace
Knock Sensor or Knock Sensor
circuits defectiveCorrect or replace
Knock Sensor Module or Knock
Sensor Module circuits defectiveCorrect or replace

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