heater OPEL FRONTERA 1998 Service Manual

6G – 6 ENGINE LUBRICATION
OIL COOLER ASSEMBLY
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove front exhaust pipe.
4. Remove heat protector.
5. Remove exhaust valve assembly.
6. Oil cooler assembly.
1) Remove water hose from water inlet and outlet
side.
2) Cloth should be put under the oil cooler to
prevent oil from flowing out.
3) Loosen fixing bolt then remove oil cooler
assembly.
Legend
(1) Oil cooler assembly
(2) Oil filter assembly
INSPECTION AND REPAIR
1. Inspect for corrosion, wear, and breaks on the oil
cooler core.
2. If a problem is found on the oil cooler core, the oil
cooler assembly must be replaced.
INSTALLATION
1. Oil cooler assembly
1) Tighten oil cooler fixing bolt to the specified
torque and install water hoses.
Torque: 29 Nꞏm (3.0 kgꞏm / 21.7 lb ft)
2. Install exhaust valve assembly to turbocharger
assembly and tighten to the specified torque.
Torque: 27 Nꞏm (2.7 kgꞏm / 19.5 lb ft)3. Install front exhaust pipe to the exhaust valve.
Torque:
67 Nꞏm (6.8 kgꞏ.m / 49.2 lb ft)
(At exhaust valve side)
43 Nꞏm (4.4 kgꞏm / 32 lb ft)
(At center exhaust pipe side)
4. Install heater protector.
5. Fill engine coolant.
6. Connect battery ground cable.
7. Start engine and carefully check for leakage of oil
and coolant.
OIL COOLER SPECIFICATIONS
OIL FILTER
REMOVAL
1. Put container under the oil filter to prevent oil from
the oil filter from flowing out.
2. Use filter wrench to remove oil filter.
Filter wrench: 5-8840-0203-0
INSTALLATION
1. Apply engine oil thinly to oil filter O-ring.
2. Tighten oil filter by hand until O-ring comes in
contact with the sealing surface.
3. Use filter wrench to tighten oil filter one turn and 1/8
turn.
4. Start engine and carefully check for oil leakage from
oil filter.
SUB OIL FILTER
The sub oil filter requires no servicing until the
replacement interval is reached.
The element is designed to provide special filtering
efficiency until it becomes due for replacement.
It is recommended to check and replace the sub oil filter
when the engine is being overhauled or if it is broken
inside the engine.
For Europe1
2
050R200001

INDUCTION 6J – 11
INTAKE MANIFOLD
REMOVAL
1. Drain engine coolant and remove water hose from
thermostat housing
2. Remove intercooler assembly.
3. Remove bracket fixing bolt of oil level gauge guide
tube.
4. Remove PCV hose.
5. Remove hoses from EGR valve, EGR vacuum
sensor and outlet of heater unit.
6. Disconnect harness connector from MAP sensor,
EGR vacuum sensor, ETC sensor, Water
temperature unit, IAT sensor and EVRV.
7. Remove high pressure oil pipe.
8. Remove two way check valve.
9. Remove fuel pipe.
10. Remove fixing bolts and nuts of intake manifold,
remove intake manifold assembly.
Legend
(1) Intake manifold
(2) Fixing portion of throttle valve
(3) EGR passage
(4) EGR valve
For Europe
2
1
3
3 1 42
Legend
(1) Intake Manifold
(2) Throttle Valve Assembly
(3) EGR Valve
(4) Gasket
025R200005
3124
025RW031

6J – 12 INDUCTION
INSPECTION AND RAPAIR
1. Visually check for cracks/clogs inside intake
manifold.
2. If foreign material is observed, it should be taken
out, and if there are some cracks on the intake
manifold, it must be replaced.
INSTALLATION
1. Install the intake manifold assembly, tighten bolts
and to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft) for bolt
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft) for nut
2. Install fuel pipe.
Torque: 4 Nꞏm (0.4 kgꞏm / 2.9 lb ft) for M16 nut
(Apply engine oil)
Torque: 13 Nꞏm (1.3 kgꞏm / 9.4 lb ft) for M10 cap nut
Torque: 14 Nꞏm (1.4 kgꞏm / 10 lb ft) for M10
(Apply engine oil)
3. Install two way check valve.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
4. Fill with about 300 cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil filler.
If assembled without filling the oil rail with oil, the
time for engine starting will be longer.
5. Install high pressure oil pipe, then tighten sleeve nut
to the specified torque.
Torque: 29 Nꞏm (3.0 kgꞏm / 21.7 lb ft)
6. Reconnect harness connector to MAP sensor, EGR
vacuum sensor, ETC sensor, Water thermo unit,
IAT sensor and EVRV sensor.
7. Install hoses to EGR valve, EGR vacuum sensor
and Water outlet of heater.
8. Connect PCV hose.
9. Install oil level gauge guide and fix it.
10. Install intercooler assembly.
Refer to “Intercooler” in this manual.
11. Install water hose to thermostat housing and fill with
engine coolant.
Model of Turbocharger IHI RHF5
Turbine Maximum Speed 180,000 rpm
Maximum Inlet Gas Temperature 800 °C (1472 °F)
Vibration Peak (G) criteria Maximum 4 (G) at Turbine Rotor Speed 140,000 rpm
Tolerance Limit of Compressor Blade Height Less then 0.5 mm (0.0197 in)
MAIN DATA AND SPECIFICATIONS

8A–2LIGHTING SYSTEM
Vanity Mirror Illumination Bulb 8A–16. . . . . . . . . . . . .
Removal 8A–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Switch 8A–17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighting Switch (Combination Switch) 8A–18. . . . . .
Removal 8A–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog Light Switch 8A–19. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stoplight Switch (W/O Cruise Control) 8A–20. . . . . .
Removal 8A–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Switch (W/Cruise Control) 8A–21. . . . . . . . . .
Removal 8A–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal Switch (Combination Switch) 8A–21. . .
Removal and Installation 8A–21. . . . . . . . . . . . . . .
Hazard Warning Switch 8A–22. . . . . . . . . . . . . . . . . .
Removal 8A–22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 8A–22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate Switch 8A–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Switch 8A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 8A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Defogger Switch 8A–24. . . . . . . . . . . . . . . . . . .
Removal 8A–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Heater Switch 8A–25. . . . . . . . . . . . . . . . . . . . . .
Removal 8A–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key Remind Switch (Starter Switch) 8A–25. . . . . . .
Removal and Installation 8A–25. . . . . . . . . . . . . . .
Illumination Controller 8A–26. . . . . . . . . . . . . . . . . . . .
Removal 8A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–26. . . . . . . . . . . . . . . . . . . . . . . . . . .
Power/Winter Switch 8A–27. . . . . . . . . . . . . . . . . . . . .
Removal 8A–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8A–27. . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 8A–28. . . . . . . . . . . . .
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.

LIGHTING SYSTEM8A–25
Seat Heater Switch
Removal
1. Disconnect the battery ground cable.
2. Remove four fixing screws and disconnect the switch
connectors to remove the front console assembly(4).
3. Push the lock from the back side of the front console
assembly to remove the seat heater switch(5).
825RW025
Installation
To install, follow the removal steps in the reverse order,
noting the following point.
1. Push the switch with your fingers until it locks
securely.
Key Remind Switch (Starter Switch)
Removal and Installation
Refer to the removal and installation on steps of the
Starter Switch in this section.

8A–30LIGHTING SYSTEM
Power drive1.4w1Meter
Winter drive1.4w1Meter
Air bag2w1Meter
Engine warming SW0.84w1
FRT fog light SW0.84w1
RR fog light SW0.84w1
Glove box1.2w1
Ashtray1.4w1
Illumination controller0.7w1
Heater bezel150mA2
Hazard warning light SW0.84w1
Meter3.4w4Meter ASM
IlluminationCigar lighter1.4w1Light
Rear wiper & washer SW0.84w1
Rear defogger SW0.84w1
Mirror control SW45mA1
Mirror defogger SW0.7w1
Mirror folding SW0.7w1
A/T select lever1.2w1
Power & Winter SW50mA2
Cruise control main SW0.84w1
Headlight wiper SW0.84w1
Torque Specifications
ApplicationNꞏmkgꞏmLb FtLb In
Steering Shaft Nut343.525—

3.0
B/Y3.0
B/Y
3.0
B/Y3.0
B/Y3.0
W/G3.0
B/R
3.0
B/R 3.0
B/Y
0.5
R/B
HAZARD
WARNING
SW
(8)PCM
MAIN
RELAY
(1)IGNITION
COILMETER STARTER
RELAY
(6)SEAT
HEATERWINDSHIELD
WIPER
MOTORRR
WIPER
MOTORHEADLIGHT
WIPER
MOTOR
AC GENERATOR
(IG) ALARM & RELAY
CONTROL UNIT C-3 10A
TURN
BACK
0.5
L/WC-4 10A
ELEC.
IGN.
0.5
L/YC-10 10A
METER
GAUGE
0.5
W/RC-1 10A
STARTER
RELAY
0.85
W/LC-5 15A
FRT WIPER
& WASHERC-6 10A
RR WIPER
& WASHERC-7 10A
H/LAMP
WIPER
FUSE BOX
1.25
B/OC-9 15A
IG COIL C-8 15A
ENGINE
0.5
L/B
0.85
B/Y
0.85
B/Y
0.5
R
0.75
B/R
SDM
(12)C-21 10A
SRS
1.25
G/RC-2 15A
SEAT
HEATER
H-631
3
H-63

D08RWB15

3.0
W
3.0
L/R 3.0
L/B
0.5
O/G
AUDIO
CIGARETTE
LIGHTERBLOWER
MOTORMAGNETIC
CLUTCHPOWER
WINDOW
RELAY
(2)STOPLIGHT AUDIO
(14)
DOME LIGHTRR DEFOGGER
FRT DOOR LOCK &
POWER WINDOW SW C-11 10A
AUDIO
(ACC)
MIRROR
0.5
BRC-20 10A
AIR CON
0.85
G/WC-14 15A
STOP
A/T CONT
1.25
R/WC-15 20A
AUDIO (B)
3.0
L/OC-17 25A
RR
DEFOG
FUSE BOX
1.25
O/BC-12 20A
CIGAR
3.0
LC-19 25A
BLOWER
3.0
B/L 3.0
W5.0
W 5.0
W
5.0
W
C/B-2 30A
P/W,P/S,
S/R
0.5
R/WC-16 10A
CLOCK (B)
ROOM
1.25
LG/WC-18 20A
DOOR
LOCK
HEATER &
A/C RELAY
B-36
2
B-364
D08RWB16

E
HI
3.0
W
3.0
W/R 3.0
W/L
3.0
R/B
FG
CERAMIC
HEATERGLOW
PLUG
HEADLIGHT
LIGHTING
RELAY RELAY & FUSE BOX
3.0
W
1
X-1
4
3X-1
X-1
FL-3 40A
CERAMIC
HEATER
FL-5 50A
GLOW
3.0
W/G
EHCU
FL-6 40A
ABS
D08RWB45

3.0
B/Y3.0
B/Y
3.0
B/Y3.0
B/Y3.0
W/G3.0
B/R
3.0
B/R 3.0
B/Y
0.5
R/B
HAZARD
WARNING
SW
(8)C-3 10A
TURN
BACK
0.5
L/WC-4 10A
ELEC.
IGN.
0.5
L/Y
METER ECM
(J2-9) ALARM & RELAY
C O NTR O L UNITC-10 10A
METER
GAUGE
0.5
W/R
STARTER
RELAY
(6)C-1 10A
STARTER
RELAY
0.85
W/L
WINDSHIELD
WIPER
MOTORC-5 15A
FRT WIPER
& WASHERC-6 10A
RR WIPER
& WASHERC-7 10A
H/LAMP
WIPER
FUSE BOX
C-8 15A
ENGINE
0.5
L/B
RR
WIPER
MOTORHEADLIGHT
WIPER
MOTOR
0.85
B/Y
0.5
R
0.75
B/R
SDM
(12)C-21 10A
SRS
1.25
G/R
SEAT
HEATERC-2 15A
SEAT
HEATER
H-631
3
H-63

D08RWB20