warning OPEL FRONTERA 1998 Service Manual

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.

6D3–18STARTING AND CHARGING SYSTEM
Charging System
General Description
The IC integral regulator charging system and its main
components are connected as shown in the illustration.
The regulator is a solid state type and it is mounted along
with the brush holder assembly inside the generator
installed on the rear end cover.
The generator does not require particular maintenance
such as voltage adjustment.
The rectifier connected to the stator coil has eight diodes
to transform AC voltage into DC voltage.
This DC voltage is connected to the output terminal of
generator.
General On–Vehicle Inspection
The operating condition of charging system is indicated
by the charge warning lamp. The warning lamp comes on
when the starter switch is turned to “ON” position. The
charging system operates normally if the lamp goes off
when the engine starts.
If the warning lamp shows abnormality or if undercharged
or overcharged battery condition is suspected, perform
diagnosis by checking the charging system as follows:
1. Check visually the belt and wiring connector.
2. With the engine stopped, turn the stator switch to
“ON” position and observe the warning lamp.
If lamp does not come on:
Disconnect wiring connector from generator, and
ground the terminal “L” on connector side.
If lamp comes on:
Repair or replace the generator.
F06RW009

6D3–25 STARTING AND CHARGING SYSTEM
1. Using a press with a socket wrench attached,
reassemble rotor and rear end cover assembly in the
front cover.
066RS022
2. Install pulley on the rotor.
Secure the pulley directly in the vise between two
copper plates, and tighten nut to the specified torque.
Torque: 111 Nꞏm (11.3 Kgꞏm/82 lb ft)
066RS010
Bench Test
Conduct a bench test of the generator.
066RS023
Preparation
Remove generator from the vehicle (see “Generator
removal”).
1. Secure generator to the bench test equipment and
connect wires.
Terminal “IG” for energization
Terminal “L” for neutral (warning lamp)
Terminal “B” for output
2. Conduct the generator characteristic test.
Characteristics of generator are shown in illustration.
Repair or replace the generator if its outputs are
abnormal.
B06RW001

6E–298
ENGINE DRIVEABILITY AND EMISSIONS
4. Remove the MAP sensor from the mounting bracket.
055RW002
Installation Procedure
1. Install the MAP sensor in the mounting bracket.
055RW002
2. Install the mounting bracket retaining bolt on the
common chamber.
3. Connect the MAP electrical connector.
055RW005
4. Connect the negative battery cable.
Malfunction Indicator Lamp
(MIL)
Removal and Installation Procedure
Refer to Warning light bulb, indicator light valve,
illumination light bulb, A/T indicator light bulb in Meter and
Gauge.
Powertrain Control Module
(PCM)
Service Precaution
NOTE: To prevent possible electrostatic discharge
damage to the PCM, do not touch the connector pins or
soldered components on the circuit board.
Electrostatic Discharge (ESD)
Damage
Electronic components used in the control systems are
often designed to carry very low voltage. Electronic
components are susceptible to damage caused by
electrostatic discharge. Less than 100 volts of static
electricity can cause damage to some electronic
components. By comparison, it takes as much as 4,000
volts for a person to even feel the zap of a static
discharge.
There are several ways for a person to become statically
charged. The most common methods of charging are by
friction and by induction. An example of charging by
friction is a person sliding across a car seat.
Charging by induction occurs when a person with well
insulated shoes stands near a highly charged object and
momentarily touches ground. Charges of the same
polarity are drained off leaving the person highly charged
with the opposite polarity. Static charges can cause

6F–1 ENGINE EXHAUST
ENGINE
ENGINE EXHAUST
CONTENTS
Service Precaution 6F–1. . . . . . . . . . . . . . . . . . . . . .
General Description 6F–2. . . . . . . . . . . . . . . . . . . . .
Front Exhaust Pipe 6F–4. . . . . . . . . . . . . . . . . . . . . .
Front Exhaust Pipe and Associated Parts 6F–4.
Removal 6F–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6F–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three Way Catalytic Converter 6F–5. . . . . . . . . . . .
Removal 6F–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6F–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Silencer 6F–6. . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Silencer and Associated Parts 6F–6. . .
Removal 6F–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6F–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Exhaust pipe 6F–7. . . . . . . . . . . . . . . . . . . . . . .
Rear Exhaust pipe and Associated Parts 6F–7.
Removal 6F–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6F–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6F–8. . . . . . . . . . . . .
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.

6G–1 ENGINE LUBRICATION
ENGINE
ENGINE LUBRICATION
CONTENTS
Service Precaution 6G–1. . . . . . . . . . . . . . . . . . . . . .
General Description 6G–2. . . . . . . . . . . . . . . . . . . . .
Oil Pump 6G–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump and Associated Parts 6G–3. . . . . . . . . .
Oil Pump and Associated Parts 6G–3. . . . . . . . . .
Inspection and Repair 6G–4. . . . . . . . . . . . . . . . . .
Reassembly 6G–5. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan and Crankcase 6G–7. . . . . . . . . . . . . . . . . .
Removal 6G–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6G–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 6G–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 6G–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6G–10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Oil Seal 6G–12. . . . . . . . . . . . . . . . . . . . . . .
Removal 6G–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6G–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter 6G–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6G–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6G–13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specification 6G–14. . . . . . . . . . . . . .
Special Tool 6G–15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

6H–1 ENGINE SPEED CONTROL SYSTEM
ENGINE
ENGINE SPEED CONTROL SYSTEM
CONTENTS
Service Precaution 6H–1. . . . . . . . . . . . . . . . . . . . . .
Accelerator Pedal Control Cable 6H–2. . . . . . . . . .
Removal 6H–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6H–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6H–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 6H–2. . . . . . . . . . . . . . . . . . . . . . . . . . . Accelerator Pedal 6H–3. . . . . . . . . . . . . . . . . . . . . . .
Accelerator Pedal and Associated Parts 6H–3. .
Removal 6H–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6H–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment 6H–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

INDUCTION6J–1
ENGINE
INDUCTION
CONTENTS
Service Precaution 6J–1. . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Element 6J–2. . . . . . . . . . . . . . . . . . . . .
Removal 6J–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6J–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6J–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

ENGINE COOLING 6B – 5
ENGINE COOLANT CHANGE
PROCEDURE
1. To change engine coolant, make sure that the
engine is cool.
WARNING:
When the coolant is heated to a high temperature,
be sure not to loosen or remove the radiator cap.
Otherwise you might get scalded by hot vapor or
boiling water. To open the radiator cap, put a piece
of thick cloth on the cap and loosen the cap slowly
to reduce the pressure once the coolant has
become cooler.
2. Open radiator cap and drain the cooling system by
loosening the drain valve on the radiator and on the
cylinder body.
NOTE: For best results it is suggested that the engine
cooling system be flushed at least once a year. It is
advisable to flush the interior of the cooling system
including the radiator before using anti-freeze
(ethylene-glycol based).
Replace damaged rubber hoses as the engine anti-
freeze coolant is liable to leak out even minor cracks.
Isuzu recommends using Isuzu genuine anti-freeze
(ethylene-glycol based) or equivalent, for the cooling
system and not add any inhibitors or additives.
CAUTION:
A failure to correctly fill the engine cooling system
in changing or topping off coolant may sometimes
cause the coolant to overflow from the filler neck
even before the engine and radiator are completely
full.
If the engine runs under this condition, shortage of
coolant may possibly result in engine overheating.
To avoid such trouble, the following precautions
should be taken in filling the system.
3. To refill engine coolant, pour coolant up to filler neck
using a filling hose which is smaller in outside
diameter than the filler neck. Otherwise air between
the filler neck and the filling hose will block entry,
preventing the system from completely filling up.
4. Keep a filling rate of 9 liter/min. or less. Filling over
this maximum rate may force air inside the engine
and radiator.
And also, the coolant overflow will increase, making
it difficult to determine whether or not the system is
completely full.
5. After filling the system full, pull out the filling hose
and check to see if air trapped in the system is
dislodged and the coolant level goes down. Should
the coolant level go down, repeat topping-off until
there is no more drop in the coolant level.
6. Directly after filling the radiator, fill the reservoir to
the maximum level.
7. Install and tighten radiator cap and start the engine.
After idling for 2 to 3 minutes, stop the engine and
reopen radiator cap. If the water level is lower,
replenish.WARNING:
When the coolant is heated to a high temperature,
be sure not to loosen or remove the radiator cap.
Otherwise you might get scalded by hot vapor or
boiling water. To open the radiator cap, put a piece
of thick cloth on the cap and loosen the cap slowly
to reduce the pressure once the coolant has
become cooler.
8. After tightening radiator cap, warm up the engine at
about 2,000 rpm.
Set heater adjustment to the highest temperature
position, and let the coolant circulate also into
heater water system.
9. Check to see the thermostat has opened by the
needle position of a water thermometer, conduct a
5-minute idle again and stop the engine.
10. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant be found, check the
coolant system and reservoir tank hose for leakage.
11. Fill the coolant into the reservoir tank up to “MAX”
line.

ENGINE ELECTRICAL 6D – 3
ON-VEHICLE SERVICE
BATTERY CHARGING
Observe the following safety precautions when
charging the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during the
charging procedure.
Battery charging should be discontinued or the rate
of charge reduced if the battery feels hot to the
touch.
Battery charging should be discontinued or the rate
of charge reduced if the battery begins to gas or
spew electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue
dot or ring, it may be necessary to jiggle or tilt the
battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be
either quick-charged or slow-charged in the same
manner as other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
JUMP STARTING
JUMP STARTING WITH AN AUXILIARY
(BOOSTER) BATTERY
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: Failure to carefully follow the jump
starting procedure could result in the following:
1. Serious personal injury, particularly to your
eyes.
2. Property damage from a battery explosion,
battery acid, or an electrical fire.
3. Damage to the electronic components of one or
both vehicles.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode. Remove any rings, watches, or other jewelry
before working around the battery. Protect your eyes by
wearing an approved set of goggles.
Never allow battery fluid to come in contact with your
eyes or skin.
Never allow battery fluid to come in contact with fabrics
or painted surfaces.
Battery fluid is a highly corrosive acid.Should battery fluid come in contact with your eyes,
skin, fabric, or a painted surface, immediately and
thoroughly rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of the reach of young
children.
JUMP STARTING PROCEDURE
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector lever in the “PARK”
position.
If the vehicle is equipped with a manual
transmission place the shift lever in the “NEUTRAL”
position.
Turn “OFF” the ignition.
Turn “OFF” all lights and any other accessory
requiring electrical power.
2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the
positive terminal of the discharged battery.
Do not allow the vehicles to touch each other.
This will cause a ground connection, effectively
neutralizing the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the
negative terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the A/C compressor
bracket or the generator mounting bracket) of the
vehicle with the discharged battery.
This ground connection must be at least 450 mm
(18 in) from the battery of the vehicle whose battery
is being charged.
WARNING: Never attach the end of the jumper
cable directly to the negative terminal of the dead
battery.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical
accessories have been turned “OFF”.
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above
directions in the reverse order.
Be sure to first disconnect the negative cable from
the vehicle with the discharged battery.