oil level OPEL FRONTERA 1998 Manual PDF

6E–349 ENGINE DRIVEABILITY AND EMISSIONS
Damage during re-gapping can happen if the gapping
tool is pushed against the center electrode or the
insulator around it, causing the insulator to crack.
When re-gapping a spark plug, make the adjustment
by bending only the ground side terminal, keeping the
tool clear of other parts.
”Heat shock” breakage in the lower insulator tip
generally occurs during several engine operating
conditions (high speeds or heavy loading) and may be
caused by over-advanced timing or low grade fuels.
Heat shock refers to a rapid increase in the tip
temperature that causes the insulator material to
crack.
Spark plugs with less than the recommended amount of
service can sometimes be cleaned and re-gapped , then
returned to service. However, if there is any doubt about
the serviceability of a spark plug, replace it. Spark plugs
with cracked or broken insulators should always be
replaced.
A/C Clutch Diagnosis
A/C Clutch Circuit Operation
A 12-volt signal is supplied to the A/C request input of the
PCM when the A/C is selected through the A/C control
switch.
The A/C compressor clutch relay is controlled through the
PCM. This allows the PCM to modify the idle air control
position prior to the A/C clutch engagement for better idle
quality. If the engine operating conditions are within their
specified calibrated acceptable ranges, the PCM will
enable the A/C compressor relay. This is done by
providing a ground path for the A/C relay coil within the
PCM. When the A/C compressor relay is enabled,
battery voltage is supplied to the compressor clutch coil.
The PCM will enable the A/C compressor clutch
whenever the engine is running and the A/C has been
requested. The PCM will not enable the A/C compressor
clutch if any of the following conditions are met:
The throttle is greater than 90%.
The engine speed is greater than 6315 RPM.
The ECT is greater than 119C (246F).
The IAT is less than 5C (41F).
The throttle is more than 80% open.
A/C Clutch Circuit Purpose
The A/C compressor operation is controlled by the
powertrain control module (PCM) for the following
reasons:
It improvises idle quality during compressor clutch
engagement.
It improvises wide open throttle (WOT) performance.
It provides A/C compressor protection from operation
with incorrect refrigerant pressures.
The A/C electrical system consists of the following
components:
The A/C control head.
The A/C refrigerant pressure switches.
The A/C compressor clutch.
The A/C compressor clutch relay.
The PCM.
A/C Request Signal
This signal tells the PCM when the A/C mode is selected
at the A/C control head. The PCM uses this to adjust the
idle speed before turning on the A/C clutch. The A/C
compressor will be inoperative if this signal is not
available to the PCM.
Refer to
A/C Clutch Circuit Diagnosis for A/C wiring
diagrams and diagnosis for A/C electrical system.
General Description (Exhaust Gas
Recirculation (EGR) System)
EGR Purpose
The exhaust gas recirculation (EGR) system is use to
reduce emission levels of oxides of nitrogen (NOx). NOx
emission levels are caused by a high combustion
temperature. The EGR system lowers the NOx emission
levels by decreasing the combustion temperature.
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Linear EGR Valve
The main element of the system is the linear EGR valve.
The EGR valve feeds small amounts of exhaust gas back
into the combustion chamber. The fuel/air mixture will be
diluted and combustion temperatures reduced.
Linear EGR Control
The PCM monitors the EGR actual positron and adjusts
the pintle position accordingly. The uses information from
the following sensors to control the pintle position:
Engine coolant temperature (ECT) sensor.
Throttle position (TP) sensor.
Mass air flow (MAF) sensor.
Linear EGR Valve Operation and Results
of Incorrect Operation
The linear EGR valve is designed to accurately supply
EGR to the engine independent of intake manifold
vacuum. The valve controls EGR flow from the exhaust

6G–7 ENGINE LUBRICATION
Oil Pan and Crankcase
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Lift vehicle by supporting the frame.
4. Remove front wheels.
5. Remove oil level dipstick from level gauge tube.
6. Remove stone guard.
7. Remove radiator under fan shroud.
8. Remove suspension cross member fixing bolts, 2 pcs
each per side and remove suspension cross member.
9. Remove pitman arm and relay lever assembly, using
the 5–8840–2005–0 remover, remove pitman arm
from the steering unit and remove four fixing bolts for
relay lever assembly.
10. Remove axle housing assembly four fixing bolts from
housing isolator side and mounting bolts from wheel
side. At this time support the axle with a garage jack
and remove axle housing assembly.
11. Remove oil pan fixing bolts.
12. Remove oil pan, using 5–8840–2153–0 sealer cutter,
remove oil pan.
013RS003
13. Remove crankcase fixing bolts.
14. Remove crankcase, using 5–8840–2153–0 sealer
cutter, remove crankcase.
NOTE: Do not deform or damage the flange of oil pan and
crankcase.
Replace the oil pan and/or crankcase if deformed or dam-
aged.
013RS003
Installation
1. Install crankcase.
1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB-1207C or equivalent) to mounting
surface of crankcase.
Sealant beat must be continuous.
The crankcase must be installed within 5
minutes after sealant application before the
sealant hardens.
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6G–9 ENGINE LUBRICATION
6. Install suspension cross member and tighten fixing
bolts to the specified torque.
Torque : 78 Nꞏm (8.0 Kgꞏm/58 lb ft)
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7. Install radiator under fan shroud.
8. Install stone guard.
9. Install engine oil level dipstick.
10. Fill engine oil until full level on engine oil gauge
dipstick.

6G–11 ENGINE LUBRICATION
4. Install oil filter assembly and tighten bolts to the
specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
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Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
5. Install timing pulley on crankshaft.
Install timing belt.
Refer to installation procedure for Timing Belt in this
manual.
6. Install crankshaft pulley.
Refer to install procedure for Crankshaft Pulley in
this manual.
7. Install crankcase assembly.
Refer to installation procedure for Oil Pan and
Crankcase in this manual.
8. Refill engine oil until full level on engine oil dipstick.

6G–12
ENGINE LUBRICATION
Oil Pump Oil Seal
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
4. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
5. Remove timing pulley from crankshaft.
6. Remove oil pump oil seal using a sealer puller.
NOTE: Take care not to damage sealing surfaces of oil
pump and crankshaft when removing oil seal.
Installation
1. Install oil pump oil seal, apply engine oil to oil seal lip,
then install oil seal using 5–8840–2287–0 installer.
015RS001
2. Install timing pulley to crankshaft.
3. Install timing belt.
Refer to installation procedure for Timing Belt in this
manual.
4. Install crankshaft pulley.
Refer to installation procedure for Crankshaft
Pulley in this manual.
5. Refill engine oil until full level.

6G–13 ENGINE LUBRICATION
Oil Filter
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove oil filter using 5-8840-0203-0 filter wrench.
Installation
1. Clean filter fitting surface and apply small amount of
engine oil to sealing surface.
2. Install oil filter cartridge by hand until it comes in
contact with sealing surface then rotate additional 2/3
turn to tighten using 5-8840-0203-0 filter wrench.
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Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Filter
(5) To Filter
3. Fill engine oil until full level on dipstick.
4. Reconnect battery ground cable.

6A – 10 ENGINE MECHANICAL
8. Check the engine oil level and replenish to the
specified level if required.
9. Start the engine and check for oil leakage from the
main oil filter.
FUEL SYSTEM
Fuel filter
Replacement Procedure
1. Loosen the used fuel filter by turning it
counterclockwise with the filter wrench.
Filter Wrench : 5-8840-0203-0
2. Clean the filter cover fitting faces.
This will allow the new fuel filter to seat properly.
3. Apply a light coat of engine oil to the O-ring.
4. Turn the fuel filter until the sealing face comes in
contact with the O-ring.
5. Turn the fuel filter with a filter wrench 2/3 of a turn
until sealed.
Filter Wrench: 5-8840-0203-0Legend
(1) Priming pump
6. Operate the priming pump until the air is discharged
completely from fuel system.
NOTE: The use of an Isuzu genuine fuel filter is
strongly recommended.
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator
reserve tank as necessary.
If the coolant level falls below the “‘MIN” line, carefully
check the cooling system for leakage. Then add
enough coolant to bring the level up to the “MAX” line.
NOTE: Do not overfill the reserve tank.
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ENGINE MECHANICAL 6A – 33
INTAKE MANIFOLD
REMOVAL
1. Drain engine coolant and disconnect water hose
from thermostat hosing.
2. Remove intercooler assembly
Refer to “Intercooler” in this manual.
3. Remove bracket bolt of oil level gauge guide tube.
4. Remove PCV Hose.
5. Remove hoses from EGR, EGR vacuum sensor
and inlet/outlet of heater.
6. Disconnect harness connector form MAP sensor,
EGR vacuum sensor, ETC sensor, water
temperature unit, IAT sensor and EVRV.
7. Remove high pressure oil pipe.
8. Remove the two way valve.
9. Remove fuel pipe from between intake manifold
and high pressure oil pump.
10. Remove fixing bolts and nuts on the intake
manifold, then remove the intake manifold
assembly.
INSTALLATION
1. Install the intake manifold, tighten bolts and nuts to
the specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) for bolt and nut
2. Install the fuel pipe and tighten to the specified
torque.To r q u e :
M16 bolt (apply engine oil) 4 Nꞏm (0.4 kgꞏm/2.9
lb ft)
Cap nut (M10) 13Nꞏm (1.3 kgꞏm/9.4 lb ft)
Fuel pipe (M10 apply engine oil) 14 Nꞏm (1.4
kgꞏm/10 lb ft)
3. Install two way 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 starting the engine will be
longer.
5. Install the high pressure oil pipe immediately and
tighten the sleeve nut to the specified torque.
Torque : 80 Nꞏm (8 kgꞏm/57.9 lb ft)
6. Reconnect harness connector to MAP sensor, EGR
vacuum sensor, ETC sensor, Water temperature
unit, IAT sensor and EVRV.
7. Connect the hoses to EGR valve, EGR vacuum
sensor, and water inlet/outlet pipe for heater.
8. Connect PCV hose.
9. Install the oil level gauge guide tube and tighten
bracket bolt.
10. Install the intercooler assembly.
Refer to “Intercooler” in this manual.
11. Connect the hose to the thermostat housing and fill
with engine coolant.
2
3
4
1
025RX001
Legend
(1) Intake Manifold
(2) Throttle Valve Assembly
(3) EGR Valve
(4) Gasket

6A – 40 ENGINE MECHANICAL
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove air cleaner and air duct.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Remove PCV hose.
7. Remove EGR vacuum hose.
8. Disconnect harness connector around the cylinder
head.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out fan belt.
12. Remove heat protector and remove valve
assembly.
13. Remove water hose and oil pipe from turbocharger.
14. Remove turbocharger assembly.
15. Remove water hose between thermostat and
radiator.
16. Remove cylinder head noise insulator cover.
NOTE: Do not make damage to the harness.
17. Remove high pressure pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner and remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove water pipe between cylinder head and
water pump.
24. Remove fuel pipe between fuel pump and intake
manifold.
25. Remove fuel return pipe.
26. Remove intake manifold assembly.
27. Disconnect glow plug wiring and remove glow plug.
28. Remove cylinder head cover.
29. Drain oil from oil rail.
30. Disconnect injector harness connector.
31. Disconnect harness connector from oil pressure
sensor and oil temperature sensor on the oil rail.
32. Disconnect injector harness assembly.
33. Remove injector clamp.
34. Remove injector spacer.
35. Remove injector assembly.
36. Remove oil rail assembly.
37. Remove camshaft carrier.
38. Remove cylinder head assembly.
39. Remove cylinder gasket.
INSTALLATION
1. Install cylinder head gasket with top mark up.
NOTE: Determine cylinder head gasket grade by
measuring projection of piston head.2. Selection cylinder head gasket.
1) Measure the piston head projection by injector
gauge.
2) Measure the projection of piston head at the
nearest possible point to the cylinder bore.
3) Obtain the largest measurement from among all
cylinders.
4) Determine cylinder head gasket grade by
maximum value of measuring projection of
piston head.
Legend
(1) Top Mark
(2) Grade Mark
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6A – 42 ENGINE MECHANICAL
Legend
(1) Cylinder Head Noise Insulator Cover
(2) Insulator
(3) Bolt
(4) Oil Seal
(5) Gasket
(6) Cylinder Head Cover
(7) Bolt
21. Install water hose between thermostat and radiator.
22. Install turbocharger assembly to exhaust manifold.
Torque: 27 Nꞏm (2.8 kgꞏm/20.2 lb ft)
23. Install water hose and oil pipe for turbocharger.
24. Install exhaust valve assembly and heat protector.
Torque: 27 Nꞏm (2.8 kgꞏm/20.2 lb ft) for valve
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft) for heat protector25. Install generator assembly.
Torque: 40 Nꞏm (4.0 kgꞏm/29 lb ft) for ACG bracket
Torque: 40 Nꞏm (4.0 kgꞏm/29 lb ft) between ACG and
bracket
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) between ACG
and adjuster plate
26.Fix the A/C compressor bracket and install A/C
compressor.
Torque: 47 Nꞏm (4.7 kgꞏm/34 lb ft) for A/C bracket
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) for belt tensioner
27. Reconnect harness connector around cylinder
head.
28. Connect EGR vacuum hose.
29. Install oil level gauge guide assembly.
Tighten nuts lower portion and tighten bolt.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
30. Install intercooler assembly.
Refer to “Intercooler” in this manual.
31. Install air duct between air cleaner and
turbocharger.
32. Fill engine coolant.
33. Reconnect battery.
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2
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4
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