motor OPEL FRONTERA 1998 Workshop Manual

6J–2
INDUCTION
Air Cleaner Element
Removal
1. Remove positive ventilation hose from connector(1).
2. Remove intake air temperature sensor(2).
3. Remove air flow sensor(3).
4. Remove air cleaner duct cover(4).
5. Remove air cleaner element(5).
130RW003
Inspection
Check the air cleaner element for damage or dust
clogging. Replace if it is damaged, or clean if it is clogged.
Cleaning Method
Tap the air cleaner element gently so as not to damage
the paper element, or clean the element by blowing with
compressed air of about 490 kPa (71 psi) from the clean
side if it is extremely dirty.
130RW002
Installation
1. Install air cleaner element(5).
2. Attach the air cleaner duct cover (4) to the body
completely, then clamp it with the clip.
3. Install mass air flow sensor(3).
4. Install air temperature sensor(2).
5. Connect positive crankcase ventilation hose to
connector(1).
For General Export Model
130RW003
For Isuzu General Motors (IGM) Model
130RW006

ENGINE MECHANICAL 6A – 13
VALVE CLEARANCE ADJUSTMENT
1. Install 2.80 mm valve adjuster (shim) first when
reassembling the engine.
Thickness mark faces down.
2. Measure the valve clearance after installing cam
carrier assy with camshafts.
3. Change the adjuster using a special tool when the
clearance is out of tolerance.
Valve Clearance Adjusting Tool: 5-8840-2590-0
VALVE CLEARANCE (When cold condition)
Inlet 0.15 ± 0.05 mm
Exh 0.25 ± 0.05 mm
COMPRESSION PRESSURE
MEASUREMENT
1. Start the engine and allow it to idle until the coolant
temperature reaches 70 – 80°C (158 – 176°F).
2. Remove the following parts.
Glow plugs
Fuel cut solenoid connector
QOS (Quick-On Start System) fuse in the fuse
box.
3. Set the adapter and compression gauge to the No.
1 cylinder glow plug hole.
Compression Gauge
(with Adapter): 5-8840-2008-0
4. Turn the engine over with the starter motor and take
the compression gauge reading.
Compression Pressure at 200 rpm
Standard: 3038 kPa (31 kg/cm
2/441 psi)
Limit: 2157 kPa (22 kg/cm
2/313 psi)
5. Repeat the procedure (Steps 3 and 4) for the
remaining cylinders.
QUICK-ON START 4 SYSTEM
Quick-On Start System Inspection Procedure
1. Disconnect the ECT-sensor connection around the
thermostat outlet pipe.
2. Turn the starter switch to the “ON” position.
If the Quick-On Start 4 System is operating
properly, the glow relay will make a clicking sound
within seven seconds after the starter switch is
turned on.
3. Measure the glow plug terminal voltage with a
circuit tester immediately after turning the starter
switch to the “ON” position.
Glow Plug Terminal Voltage: 8 – 9V
NOTE: Electrical power to the quick-on start system will
be cut after the starter has remained in the “ON”
position for twenty seconds.
Turn the starter switch to the “OFF” position and back
to the “ON” position.
This will reset the Quick-On Start 4 System.
014RW150

ENGINE MECHANICAL 6A – 37
CYLINDER HEAD
3
4
1
2
012RW096
Legend
(1) Glow Plug
(2) Plate
(3) Cylinder Head Bolt
(4) Cylinder Head
NOTE:
During disassembly, be sure that the valve train
components are kept together and identified so that
they can be re-installed in their original locations.
Before removing the cylinder head from the engine
and before disassembling the valve mechanism, do
a compression test and note the results.
DISASSEMBLY
1. Injector Assy
2. Glow Plug and Glow Plug Connector
3. Cylinder Head Assembly
Refer to “Cylinder Head Gasket”
CLEAN
Cylinder head bolts
Cylinder head
Carefully remove all varnish, soot and carbon on
the bare metal. Do not use a motorized wire brush
on any gasket sealing surface.
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Cylinder head gasket and mating surfaces for
leaks, corrosion and blow-by. If the gasket has
failed, determine the cause;
– Improper installation
– Loosen or warped cylinder head
– Insufficient torque on head bolts
– Warped cylinder block surface

6A – 56 ENGINE MECHANICAL
VALVE STEM SEAL, VALVE SPRING AND ADJUSTER
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove the air duct from between air cleaner and
turbocharger.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Disconnect PCV hose.
7. Disconnect EGR vacuum hose.
8. Disconnect harness connectors around the cylinder
head such as the injector, CMP sensor, MAP
sensor, EGR sensor, EVRV, IAT sensor, A/C
compressor, TP stepping motor, TP sensor and fuel
temperature sensor etc.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out drivebelt.
12. Remove heat protector, remove exhaust valve
assembly.
13. Remove water cooling hose and lubrication pipe for
turbocharger.
14. Remove turbocharger assembly.
15. Remove hose between thermostat and radiator.
16. Remove noise insulator cover of cylinder head.
NOTE: Do not damage injector harness.
17. Remove high pressure oil pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner then remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove engine coolant pipe between cylinder
head and water pump.
1
2
3
4
5
6
9
10
7
8
011RW031
Legend
(1) Adjuster
(2) Tappet
(3) Split Collar
(4) Spring Seat Upper
(5) Valve Spring(6) Spring Seat Lower
(7) Valve Stem Seal
(8) Valve Guide
(9) Valve Seat
(10) Valve

ENGINE ELECTRICAL 6D – 5
STARTING SYTEM
GENERAL DESCRIPTION
STARTING CIRCUIT
The cranking system consists of a battery, starter, starter switch, starter relay, etc. and these main
components are connected as shown in the illustration.
“S”
“B”
“M”
5
4
32 IG1ST
B2
B1
1
76
P
NN
Legend
(1) Inhibitor Switch
(2) Starter Switch
(3) Battery(4) Magnetic Switch
(5) Pinion Clutch
(6) Starter Motor
(7) Starter Relay
065RW039
STARTER
The starting system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion
shaft. When the starter switch is turned on, the contacts
of the magnetic switch are closed, and the armature
rotates. At the same time, the plunger is activated, and
the pinion is pushed forward by the shift lever to mesh
with ring gear.Then, the ring gear runs to start the engine. When the
engine starts and the starter switch is turned off, the
plunger returns, the pinion is disengaged from the ring
gear, and the armature stops rotation. When the engine
speed is higher than the pinion, the pinion idles, so that
the armature is not driven.

ENGINE ELECTRICAL 6D – 7
ON-VEHICLE SERVICE
STARTER
REMOVAL
1 Battery ground cable
2 Remove the slave cylinder and bind with wire it to
the frame.
3 Disconnect the connector from terminals “B” and
“S”.
4. Remove mounting bolts
5. Remove starter assembly
INSTALLATION
1. Install starter assembly, tighten the fixing bolt and
nut to the specified torque.
Torque: 94 Nꞏm (9.6 kgꞏm/69 lb ft)
2. Reconnect the starter terminals.
CAUTION: When installing the starter motor wiring,
do not allow the S-circuit wiring to obstruct the B-
circuit terminal.
Install the wiring exactly as shown on the attached
illustration.
If S-circuit wiring obstructs the B-circuit terminal,
harness cover breakage and short circuiting may
occur.2-1. Install the wire harness from the battery to the
terminal “B” with tightening torque 8.6 Nꞏm
(0.88 kgꞏm/6.4 lbꞏft).
2-2. Cover the terminal “B” together with wire
harness.
2-3. Connect the wire harness from starter relay to
the terminal “S”.
3. Install the clutch slave cylinder, tighten the fixing
bolt and nut to the specified torque.
Torque: 78 Nꞏm (8.0 kgꞏm/58 lbꞏft)
1
32
4
Legend
(1) Clutch Slave Cylinder
(2) Magnetic Switch(3) Bolt
(4) Starter Assembly
065RW00003
Do not recommend
wiring route.
Recommend wiring route
from S terminal.From
battery
From
starter relay Terminal B
Terminal MTerminal SIn this area,
Scratch to break the wire
cover and make shortage.
065RW00002

6D – 8 ENGINE ELECTRICAL
UNIT REPAIR
8
241 3
23
25
2
14
15 21222019181716
109
11
13
127
6
5
4
Legend
(1) Terminal
(2) Bolt
(3) Magnetic Switch
(4) Torsion Spring
(5) Plunger
(6) Shim
(7) Magnetic Switch
(8) Through Bolt
(9) Rear Cover
(10) Motor Assembly
(11) Brush Holder
(12) Armature(13) Yoke Assembly
(14) Bearing Retainer
(15) Pinion Assembly
(16) Bearing Holder
(17) Bearing
(18) Clip
(19) Stopper
(20) Spring
(21) Pinion Shaft
(22) Clutch
(23) Dust Cover
(24) Shift Lever
(25) Gear Case
065RW040

ENGINE ELECTRICAL 6D – 9
DISASSEMBLY
1. Terminal Nut
1) Loosen the nut on terminal “M” of magnetic
switch and disconnect the connector cable.
2. Bolt (2 pcs)
3. Magnetic Switch Assembly
4. Torsion Spring
1) Remove torsion spring from magnetic switch
assembly.
5. Plunger
6. Shim
7. Magnetic Switch
8. Through Bolt
9. Rear Cover
1) Remove the through bolts, then remove the rear
cover.10. Motor Assembly
11. Brush Holder
1) Raise a brush spring to detach the negative side
of the brushes (2 pcs) from the commutator face
and remove the positive side of brushes (2 pcs)
from the positive side of brushes (2 pcs) from
the brush holder.
12. Armature
13. Yoke Assembly
14. Bearing Retainer
15. Pinion Assembly
16. Bearing Holder
17. Bearing
18. Pinion Stopper Clip
1) Remove the stopper clip using a screw driver of
equivalent size.
19. Pinion Stopper
20. Return Spring
21. Pinion Shaft
22. Clutch
23. Dust Cover
24. Shift Lever
25. Gear Case
065RW044
065RW043
065RW042

6E–4
4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Aids 6E–122. . . . . . . . . . . . . . . . . . . . . . . .
Test Description 6E–122. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0380
(Flash DTC 66) Glow Relay Circuit
Open/Short 6E–126. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–126. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–126. . . . . . .
Conditions for Clearing the MIL/DTC 6E–126. . . . .
Diagnostic Aids 6E–126. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0381
(Flash DTC 67) Glow Lamp Circuit
Open/Short 6E–128. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–128. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–128. . . . . . .
Conditions for Clearing the MIL/DTC 6E–128. . . . .
Diagnostic Aids 6E–128. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1403
(Flash DTC 32) EGR EVRV Fault 6E–130. . . . . . . . .
Circuit Description 6E–130. . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids 6E–130. . . . . . . . . . . . . . . . . . . . . . . .
Test Description 6E–130. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1404
(Flash DTC 31) EGR VSV Circuit 6E–132. . . . . . . . .
Circuit Description 6E–132. . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids 6E–132. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0405
(Flash DTC 26) EGR Pressure Sensor
Low Voltage 6E–134. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–134. . . . . . .
Conditions for Clearing the MIL/DTC 6E–134. . . . .
Diagnostic Aids 6E–134. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1405
(Flash DTC 37) EGR EVRV Circuit
Open/Short 6E–136. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–136. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–136. . . . . . .
Conditions for Clearing the MIL/DTC 6E–136. . . . .
Diagnostic Aids 6E–136. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0406
(Flash DTC 26) EGR Pressure Sensor
High Voltage 6E–138. . . . . . . . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–138. . . . . . .
Conditions for Clearing the MIL/DTC 6E–138. . . . .
Diagnostic Aids 6E–138. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0475
(Flash DTC 71) EXH #1 VSV Circuit 6E–140. . . . . . .
Circuit Description 6E–140. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–140. . . . . . .
Conditions for Clearing the MIL/DTC 6E–140. . . . .
Diagnostic Aids 6E–140. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1475
(Flash DTC 71) EXH #2 VSV Circuit
Open/Short 6E–142. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–142. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–142. . . . . . . Conditions for Clearing the MIL/DTC 6E–142. . . . .
Diagnostic Aids 6E–142. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1485
(Flash DTC 74) ITP (Intake Thorottle Position)
Sensor Low Voltage 6E–144. . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–144. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–144. . . . . . .
Conditions for Clearing the MIL/DTC 6E–144. . . . .
Diagnostic Aids 6E–144. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1486
(Flash DTC 74) ITP (Intake Throttle Position)
Sensor High Voltage 6E–146. . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–146. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–146. . . . . . .
Conditions for Clearing the MIL/DTC 6E–146. . . . .
Diagnostic Aids 6E–146. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1487
(Flash DTC 73) Intake Throttle System
Circuit Open/Start 6E–148. . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–148. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–148. . . . . . .
Conditions for Clearing the MIL/DTC 6E–148. . . . .
Diagnostic Aids 6E–148. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1488
(Flash DTC 72) Intake Throttle Motor Control
Circuit Signal Gap 6E–150. . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–150. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–150. . . . . . .
Conditions for Clearing the MIL/DTC 6E–150. . . . .
Diagnostic Aids 6E–150. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0502
(Flash DTC 24) VSS (Vehicle Speed Sensor)
No Signal 6E–152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–152. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–152. . . . . . .
Conditions for Clearing the MIL/DTC 6E–152. . . . .
Test Description 6E–153. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0510
(Flash DTC 75) Idle SW Malfunction, Open
Circuit 6E–155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–155. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–155. . . . . . .
Conditions for Clearing the MIL/DTC 6E–155. . . . .
Diagnostic Aids 6E–155. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1510
(Flash DTC 75) Idle SW Malfunction
Short Circuit 6E–157. . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–157. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–157. . . . . . .
Conditions for Clearing the MIL/DTC 6E–157. . . . .
Diagnostic Aids 6E–157. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0562
(Flash DTC 35) System Voltage Too Low 6E–159. .
Circuit Description 6E–159. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–159. . . . . . .

6E–19 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Component Locator
Engine Component Locator Table
F06RW051
NumberNameLocation
1AP (Accelerator Pedal Position) SensorAP Bracket
2CKP (Crankshaft Position) SensorInside the right front flywheel Housing
3Oil RailMounted on the camshaft carrier
4Oil (Rail) Pressure SensorMounted on the Oil Rail
5OT (Oil Temperature) SensorMounted on the Oil Rail
6Fuel InjectorIn the Cylinder Head Cover
7Fuel Return OrificeInside the Cylinder Head
8FT (Fuel Temperature) SensorFuel Return Adaptor
9IntercoolerOn the Cylinder Head Cover
10Intake Throttle MotorBehind the Intake Manifold
11Intake ThrottleBehind the Intake Manifold
122 Way Check ValveBelow the Intake Manifold
13VSV (Vacuum Switching Valve)At the left Cylinder Body
14EGR Pressure SensorBelow the Intake Manifold
15Fuel FilterAt the left Engine Room
16CMP (Camshaft Position) SensorOn the forward of Timing Gear Case
17IAT (Intake Air Temperature) SensorBelow the Intake Manifold
18ECT (Engine Coolant Temperature)Thermostat Housing
19High Pressure Oil PumpOn the back Timing Gear Case