service OPEL FRONTERA 1998 Owner's Manual

5A–1 BRAKE CONTROL SYSTEM
BRAKES
CONTENTS
Brake Control System 5A. . . . . . . . . . . . . . . . . . . .
Anti–lock Brake System 5B. . . . . . . . . . . . . . . . . . Power–Assisted Brake System 5C. . . . . . . . . . . .
Parking Brakes 5D. . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE CONTROL SYSTEM
CONTENTS
Service Precaution 5A–2. . . . . . . . . . . . . . . . . . . . . .
General Description 5A–3. . . . . . . . . . . . . . . . . . . . .
System Components 5A–3. . . . . . . . . . . . . . . . . . .
Electronic Hydraulic Control Unit (EHCU) 5A–3.
ABS Warning Light 5A–4. . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor 5A–4. . . . . . . . . . . . . . . . . .
G-Sensor 5A–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal and Anti-lock Braking 5A–4. . . . . . . . . . .
Brake Pedal Travel 5A–4. . . . . . . . . . . . . . . . . . . .
Acronyms and Abbreviations 5A–4. . . . . . . . . . . .
General Diagnosis 5A–5. . . . . . . . . . . . . . . . . . . . . . .
General Information 5A–5. . . . . . . . . . . . . . . . . . . .
ABS Service Precautions 5A–5. . . . . . . . . . . . . . .
Computer System Service Precautions 5A–5. . .
General Service Precautions 5A–5. . . . . . . . . . . .
Note on Intermittents 5A–5. . . . . . . . . . . . . . . . . . .
Test Driving ABS Complaint Vehicles 5A–6. . . . .
“ABS” Warning Light 5A–6. . . . . . . . . . . . . . . . . . .
Normal Operation 5A–6. . . . . . . . . . . . . . . . . . . . .
Basic Diagnostic Flow Chart 5A–6. . . . . . . . . . . .
Basic Inspection Procedure 5A–7. . . . . . . . . . . . .
Tech 2 Scan Tool 5A–8. . . . . . . . . . . . . . . . . . . . . .
Getting Started 5A–9. . . . . . . . . . . . . . . . . . . . . . . .
Operating Procedure 5A–10. . . . . . . . . . . . . . . . . . .
Data List 5A–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EHCU Connector Pin-out Checks 5A–12. . . . . . . .
Circuit Diagram (LHD model / 6VD1 and
4JG2) 5A–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram (LHD model / 4JG2) 5A–14. . . . .
Circuit Diagram (LHD model / 4JG2) 5A–15. . . . .
Circuit Diagram (LHD model / 6VD1) 5A–16. . . . .
Circuit Diagram (LHD model / 6VD1) 5A–17. . . . .
Connector List (LHD model) 5A–18. . . . . . . . . . . .
Part Location (LHD model) 5A–20. . . . . . . . . . . . . .
Circuit Diagram (RHD model / 6VD1 and
4JG2) 5A–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram (RHD model / 4JG2) 5A–22. . . . .
Circuit Diagram (RHD model / 4JG2) 5A–23. . . . .
Circuit Diagram (RHD model / 6VD1) 5A–24. . . . .
Circuit Diagram (RHD model / 6VD1) 5A–25. . . . .
Circuit Diagram (RHD model / 6VE1 and
4JX1) 5A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Diagram (RHD model / 4JX1) 5A–27. . . . .
Circuit Diagram (RHD model / 4JX1) 5A–28. . . . .
Circuit Diagram (RHD model / 6VE1) 5A–29. . . . .
Circuit Diagram (RHD model / 6VE1) 5A–30. . . . .
Connector List (RHD model) 5A–31. . . . . . . . . . . .
Part Location (RHD model) 5A–34. . . . . . . . . . . . .
Symptom Diagnosis 5A–35. . . . . . . . . . . . . . . . . . . . .
Chart A–1 ABS Works Frequently But
Vehicle Does Not Decelerate 5A–35. . . . . . . . . . .
Chart TA-1 ABS Works Frequently But
Vehicle Does Not Decelerate (Use
TECH 2) 5A–36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart A-2 Uneven Braking Occurs While
ABS Works 5A–36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart A-3, TA-3 The Wheels Are Locked 5A–36.
Chart A-4 Brake Pedal Feed Is Abnormal 5A–37.
Chart A-5, TA-5 Braking Sound (From
EHCU) Is Heard While Not Braking 5A–38. . . . . .
Diagnostic Trouble Codes 5A–39. . . . . . . . . . . . . . . .
Diagnosis By “ABS” Warning Light
Illumination Pattern 5A–40. . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes (DTCs) 5A–40. . . . . . .
Chart B-1 With the key in the ON position
(Before starting the engine). Warning light
(W/L) is not activated. 5A–43. . . . . . . . . . . . . . . . .
Chart B-2 EHCU Abnormality (DTC 14) 5A–43. . .
Chart B-3 Power Voltage Drop (DTC 15) 5A–44. .
Chart B-4 CLASS-2 Communication Line
Abnormality (DTC 16) 5A–44. . . . . . . . . . . . . . . . .
Chart B-5 G-Sensor Circuit (DTC 21) 5A–45. . . . .
Chart B-6 Abnormal Transmission Input
(DTC 23) 5A–46. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-7 Transfer Monitor (DTC 24) 5A–47. . . . .
Chart B-8 EHCU Pump Motor And Motor
Relay Circuit (DTC 32) 5A–47. . . . . . . . . . . . . . . . .
Chart B-9 EHCU Pump Valve And Valve
Relay Circuit (DTC 35) 5A–47. . . . . . . . . . . . . . . . .
Chart B-10 FL Isolation Solenoid Valve
Abnormality (DTC 41) 5A–48. . . . . . . . . . . . . . . . .
Chart B-11 FL Dump Solenoid Valve
Abnormality (DTC 42) 5A–48. . . . . . . . . . . . . . . . .
Chart B-12 FR Isolation Solenoid Valve
Abnormality (DTC 43) 5A–48. . . . . . . . . . . . . . . . .
Chart B-13 FR Dump Solenoid Valve
Abnormality (DTC 44) 5A–49. . . . . . . . . . . . . . . . .
Chart B-14 Rear Isolation Solenoid Valve
Abnormality (DTC 45) 5A–49. . . . . . . . . . . . . . . . .
Chart B-15 Rear Dump Solenoid Valve
Abnormality (DTC 46) 5A–49. . . . . . . . . . . . . . . . .

5A–2
BRAKE CONTROL SYSTEM
Chart B-16 FL Speed Sensor Disconnection
(DTC 51) 5A–50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-17 FR Speed Sensor Disconnection
(DTC 52) 5A–50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-18 RL Speed Sensor Disconnection
(DTC 53) 5A–51. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-19 RR Speed Sensor Disconnection
(DTC 54) 5A–51. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-20 FL Speed Sensor Short Circuit
(DTC 61) 5A–52. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-21 FR Speed Sensor Short Circuit
(DTC 62) 5A–53. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-22 RL Speed Sensor Short Circuit
(DTC 63) 5A–54. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-23 RR Speed Sensor Short Circuit
(DTC 64) 5A–55. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart B-24 Sensor Signal Input Abnormality
(DTC 65) 5A–56. . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor Signal Abnormality Criteria using
TECH 2 5A–56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Inspection Procedure 5A–57. . . . . . . . . . . . . . . .
Chart C-1-1 FL Sensor Output Inspection
Procedure 5A–57. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart C-1-2 FR Sensor Output Inspection
Procedure 5A–58. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart C-1-3 RL Sensor Output Inspection
Procedure 5A–58. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart C-1-4 RR Sensor Output Inspection
Procedure 5A–59. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart TC-1 Sensor Output Inspection
Procedure (Use TECH 2) 5A–59. . . . . . . . . . . . . .
Chart C-2 Transmission Input Inspection
Procedure 5A–60. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart TC-2 Transmission Input Inspection
Procedure (Use TECH 2) 5A–61. . . . . . . . . . . . . .
Special Tools 5A–62. . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

5A–5 BRAKE CONTROL SYSTEM
FR
Front Right
GEN
Generator
MV
Millivolts
RL
Rear Left
RR
Rear RightRPS
Revolution per Second
VDC
Vo l t s D C
VA C
Vo l t s A C
W/L
Warning Light
WSS
Wheel Speed Sensor
General Diagnosis
General Information
ABS malfunction can be classified into two types, those
which can be detected by the ABS warning light and those
which can be detected as a vehicle abnormality by the
driver.
In either case, locate the fault in accordance with the
“BASIC DIAGNOSTIC FLOWCHART” and repair.
Please refer to Section 5C for the diagnosis of
mechanical troubles such as brake noise, brake judder
(brake pedal or vehicle vibration felt when braking),
uneven braking, and parking brake trouble.
ABS Service Precautions
Required Tools and Items:
Box Wrench
Brake Fluid
Special Tool
Some diagnosis procedures in this section require the
installation of a special tool.
J-39200 High Impedance Multimeter
When circuit measurements are requested, use a circuit
tester with high impedance.
Computer System Service Precautions
The Anti-lock Brake System interfaces directly with the
Electronic Hydraulic Control Unit (EHCU) which is a
control computer that is similar in some regards to the
Powertrain Control Module. These modules are designed
to withstand normal current draws associated with
vehicle operation. However, care must be taken to avoid
overloading any of the EHCU circuits. In testing for opens
or shorts, do not ground or apply voltage to any of the
circuits unless instructed to do so by the appropriate
diagnostic procedure. These circuits should only be
tested with a high impedance multimeter (J-39200) or
special tools as described in this section. Power should
never be removed or applied to any control module with
the ignition in the “ON” position.
Before removing or connecting battery cables, fuses or
connectors, always turn the ignition switch to the “OFF”
position.
General Service Precautions
The following are general precautions which should be
observed when servicing and diagnosing the Anti-lock
Brake System and/or other vehicle systems. Failure toobserve these precautions may result in Anti-lock Brake
System damage.
If welding work is to be performed on the vehicle using
an electric arc welder, the EHCU and valve block
connectors should be disconnected before the
welding operation begins.
The EHCU and valve block connectors should never
be connected or disconnected with the ignition “ON” .
EHCU of the Anti-lock Brake System are not
separately serviceable and must be replaced as
assemblies. Do not disassemble any component
which is designated as non-serviceable in this
Section.
If only rear wheels are rotated using jacks or drum
tester, the system will diagnose a speed sensor
malfunction and the “ABS” warning light will
illuminate. But actually no trouble exists. After
inspection stop the engine once and re-start it, then
make sure that the “ABS” warning light does not
illuminate.
If the battery has been discharged
The engine may stall if the battery has been completely
discharged and the engine is started via jumper cables.
This is because the Anti-lock Brake System (ABS)
requires a large quantity of electricity. In this case, wait
until the battery is recharged, or set the ABS to a
non-operative state by removing the fuse for the ABS
(40A). After the battery has been recharged, stop the
engine and install the ABS fuse. Start the engine again,
and confirm that the ABS warning light does not light.
Note on Intermittents
As with virtually any electronic system, it is difficult to
identify an intermittent failure. In such a case duplicating
the system malfunction during a test drive or a good
description of vehicle behavior from the customer may be
helpful in locating a “most likely” failed component or
circuit. The symptom diagnosis chart may also be useful
in isolating the failure. Most intermittent problems are
caused by faulty electrical connections or wiring. When
an intermittent failure is encountered, check suspect
circuits for:
Suspected harness damage.
Poor mating of connector halves or terminals not fully
seated in the connector body (backed out).
Improperly formed or damaged terminals.

5A–8
BRAKE CONTROL SYSTEM
Tech 2 Scan Tool
From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2 scan
tool user guide.
901RW257
Legend
(1) PCMCIA Card
(2) SAE 16/19 Adaptor(3) DLC Cable
(4) Tech–2

5B–1 ANTI–LOCK BRAKE SYSTEM
BRAKES
ANTI-LOCK BRAKE SYSTEM
CONTENTS
Service Precaution 5B–1. . . . . . . . . . . . . . . . . . . . . .
Electronic Hydraulic Control Unit 5B–2. . . . . . . . . .
Electronic Hydraulic Control Unit and
Associated Parts 5B–2. . . . . . . . . . . . . . . . . . . . . .
Removal 5B–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5B–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
G-Sensor 5B–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5B–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5B–3. . . . . . . . . . . . . . . . . .
Installation 5B–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Speed Sensor 5B–4. . . . . . . . . . . . . . . Front Wheel Speed Sensor and
Associated Parts 5B–4. . . . . . . . . . . . . . . . . . . . . .
Removal 5B–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5B–5. . . . . . . . . . . . . . . . . .
Installation 5B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Speed Sensor 5B–6. . . . . . . . . . . . . . .
Rear Wheel Speed Sensor and
Associated Parts 5B–6. . . . . . . . . . . . . . . . . . . . . .
Removal 5B–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5B–6. . . . . . . . . . . . . . . . . .
Installation 5B–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.CAUTION: Replace all components included in
repair kits used to service this system. Lubricate
rubber parts with clean, fresh brake fluid to ease
assembly. Do not use shop air with in–line
lubricators on brake parts, as damage to rubber
components may result. If any hydraulic component
is removed or brake line disconnected, it may be
necessary to bleed part or all of the brake system.
NOTE: The use of rubber hoses or parts other than those
furnished specifically for the Anti–lock Brake System may
lead to functional problems requiring major overhaul.

6A–1
ENGINE MECHANICAL
ENGINE
CONTENTS
Engine Mechanical 6A. . . . . . . . . . . . . . . . . . . . . .
Engine Cooling 6B. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Fuel 6C. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical 6D1. . . . . . . . . . . . . . . . . . . . . . . .
Ignition System 6D2. . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Charging System 6D3. . . . . . . . . . . . Driveability and Emissions 6E. . . . . . . . . . . . . . . .
Engine Exhaust 6F. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication 6G. . . . . . . . . . . . . . . . . . . . . .
Engine Speed Control System 6H. . . . . . . . . . . .
Inducton 6J. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MECHANICAL
CONTENTS
Service Precaution 6A–2. . . . . . . . . . . . . . . . . . . . . .
General Description 6A–3. . . . . . . . . . . . . . . . . . . . .
Engine Diagnosis 6A–4. . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover LH 6A–18. . . . . . . . . . . . . . . . .
Removal 6A–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover RH 6A–21. . . . . . . . . . . . . . . . .
Removal 6A–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Chamber 6A–24. . . . . . . . . . . . . . . . . . . . . .
Removal 6A–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold LH 6A–26. . . . . . . . . . . . . . . . . . . . .
Removal 6A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold RH 6A–27. . . . . . . . . . . . . . . . . . . .
Removal 6A–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Pulley 6A–28. . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 6A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 6A–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 6A–37. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–37. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Oil Controller , Valve Spring and
Valve Guide 6A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Ring and Connecting Rod 6A–40. . . Removal 6A–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Main Bearings 6A–42. . . . . . . . . . . .
Removal 6A–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal 6A–47. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–47. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly 6A–48. . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 6A–52. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Associated Parts 6A–52. . . . .
Disassembly 6A–52. . . . . . . . . . . . . . . . . . . . . . . . . .
Clean 6A–53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–53
. . . . . . . . . . . . . . . . . .
Reassembly 6A–53. . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve,
Valve Guide 6A–56. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve,
Valve Guide and Associated Parts 6A–56. . . . . . .
Disassembly 6A–56. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–57. . . . . . . . . . . . . . . . . .
Reassembly 6A–60. . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Clearance Adjustments 6A–61. . . . . . . . . . . . .
Camshaft 6A–63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Associated Parts 6A–63. . . . . . . . .
Disassembly 6A–63. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–64. . . . . . . . . . . . . . . . . .
Reassembly 6A–66. . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 6A–69. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Associated Parts 6A–69. . . . . . . .
Disassembly 6A–69. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–70. . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–71. . . . . . . . . . . . . . . . . .
Reassembly 6A–73. . . . . . . . . . . . . . . . . . . . . . . . . .

6A–2
ENGINE MECHANICAL
Piston and Connecting Rod 6A–77. . . . . . . . . . . . . . .
Piston, Connecting Rod and Associate
Parts 6A–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 6A–77. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–78. . . . . . . . . . . . . . . . . .
Reassembly 6A–82. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block 6A–85. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block and Associated Parts 6A–85. . . . .
Disassembly 6A–85. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–86. . . . . . . . . . . . . . . . . .
Reassembly 6A–87. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specification 6A–90. . . . . . . . . . . . . .
Special Tool 6A–96. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

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–78
ENGINE MECHANICAL
015RS031
Remove any ridge or carbon build up from the top
end of the cylinder.
9. Remove the piston rings (8) with a piston ring
expander. Arrange the removed piston rings in the
cylinder number order.
015RS022
10. Remove the piston pin (9) using 5–8840–0551–0
piston pin service set and piston support with a press.
NOTE: Keep the parts removed from each cylinder
separate. All parts must be reinstalled in their original
positions. Heating the connecting rod will permit easy
removal of the piston pin.
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
11. Piston (10)
12. Connecting rod (11)
Inspection and Repair
Pistons (10)
Carefully clean away all the carbon adhering to the piston
head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston for
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must be
replaced.
Piston Diameter
1. Measure the piston outside diameter with micrometer
at the piston grading position and a right angle to the
piston pin.
Piston grading position (from piston head)
Piston grading position : 43.0 mm (1.6929 in)

6A–83
ENGINE MECHANICAL
Attach the piston to the connecting rod with the
piston front mark and the connecting rod front mark
on the same side.
015RS036
With 5–8840–0551–0 Piston pin service set and a
press, press fit the piston pin.
NOTE: Heat the connecting rod small end to a suitable
temperature to ensure smooth installation.
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
4. Install piston ring with the piston ring expander.
The compression ring must be set with the T mark (1)
facing up.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring
015RS027
Install piston rings in the following sequence.
1. Oil ring
1. Expander ring
2. Upper side rail
3. Lower side rail
2. 2nd compression ring
3. 1st compression ring
The compression rings must be set with the T or T2
mark facing up.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring
After installation, apply engine oil to the entire
circumference of the piston rings. Check to see that
all the rings rotate smoothly.
015RS038
5. Install piston and connecting rod assembly.
Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces and
nuts.