fuel reserve OPEL FRONTERA 1998 Workshop Manual

6A–48
ENGINE MECHANICAL
Engine Assembly
Removal
035RW027
1. Disconnect battery ground and positive cable.
2. Remove battery.
3. Make alignment mark on the engine hood and hinges
before removal in order to return the hood to original
position exactly.
4. Remove engine hood.
5. Drain radiator coolant.
6. Disconnect accelerator cable and automatic cruise
control cable from throttle valve on common
chamber.
7. Disconnect air duct with air cleaner cover.
8. Remove air cleaner assembly.
9. Disconnect canister vacuum hose.
10. Disconnect vacuum booster hose.
11. Disconnect three engine harness connectors.
12. Disconnect harness connector to transmission (left
front side of engine compartment), disconnect shift
on the fly harness connector from front side of front
axle and remove transmission harness bracket from
engine left side.
13. Disconnect ground cable between engine and frame.
14. Disconnect bonding cable connector on the back of
right dash panel.
15. Disconnect bonding cable terminal on the left bank.
16. Disconnect starter harness connector from starter.
17. Disconnect generator harness connector from
generator.
18. Disconnect coolant reserve tank hose from radiator.
19. Remove radiator upper and lower hoses.
20. Remove upper fan shroud.
21. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
22. Move drive belt tensioner to loose side using wrench
then remove drive belt.23. Remove power steering pump fixing bolts, then
power steering pump. Place the power steering pump
along with piping on the body side.
24. Remove air conditioning compressor fixing bolts from
bracket and place the compressor along with piping
on the body side.
25. Remove O
2 sensor harness connectors from exhaust
front pipe.
26. Remove three exhaust pipe fixing nuts from each
bank.
27. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side of
vehicle.
28. Remove flywheel dust covers.
29. Disconnect two heater hoses from engine.
30. Disconnect fuel hoses from right side of transmission.
CAUTION: Plug fuel pipes on engine side and fuel
hoses from fuel tank.
31. Remove transmission assembly. Refer to
Transmission section in this manual.
32. Support the engine by engine hoist.
33. Remove two left side engine mount fixing bolts from
engine mount on chassis side.
34. Remove two right side engine mount fixing bolts from
engine mount on chassis side.
35. Remove engine assembly.
Installation
CAUTION: W h e n a s s e m b l i n g t h e e n g i n e a n d
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the automatic
transmission.

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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6A–48
ENGINE MECHANICAL
Engine Assembly
Removal
035RW027
1. Disconnect battery ground and positive cable.
2. Remove battery.
3. Make alignment mark on the engine hood and hinges
before removal in order to return the hood to original
position exactly.
4. Remove engine hood.
5. Drain radiator coolant.
6. Disconnect accelerator cable and automatic cruise
control cable from throttle valve on common
chamber.
7. Disconnect air duct with air cleaner cover.
8. Remove air cleaner assembly.
9. Disconnect canister vacuum hose.
10. Disconnect vacuum booster hose.
11. Disconnect three engine harness connectors.
12. Disconnect harness connector to transmission (left
front side of engine compartment), disconnect shift
on the fly harness connector from front side of front
axle and remove transmission harness bracket from
engine left side.
13. Disconnect ground cable between engine and frame.
14. Disconnect bonding cable connector on the back of
right dash panel.
15. Disconnect bonding cable terminal on the left bank.
16. Disconnect starter harness connector from starter.
17. Disconnect generator harness connector from
generator.
18. Disconnect coolant reserve tank hose from radiator.
19. Remove radiator upper and lower hoses.
20. Remove upper fan shroud.
21. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
22. Move drive belt tensioner to loose side using wrench
then remove drive belt.23. Remove power steering pump fixing bolts, then
power steering pump. Place the power steering pump
along with piping on the body side.
24. Remove air conditioning compressor fixing bolts from
bracket and place the compressor along with piping
on the body side.
25. Remove O
2 sensor harness connectors from exhaust
front pipe.
26. Remove three exhaust pipe fixing nuts from each
bank.
27. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side of
vehicle.
28. Remove flywheel dust covers.
29. Disconnect two heater hoses from engine.
30. Disconnect fuel hoses from right side of transmission.
CAUTION: Plug fuel pipes on engine side and fuel
hoses from fuel tank.
31. Remove transmission assembly. Refer to
Transmission section in this manual.
32. Support the engine by engine hoist.
33. Remove two left side engine mount fixing bolts from
engine mount on chassis side.
34. Remove two right side engine mount fixing bolts from
engine mount on chassis side.
35. Remove engine assembly.
Installation
CAUTION: W h e n a s s e m b l i n g t h e e n g i n e a n d
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the automatic
transmission.

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.
012RW112
012RW078
1
012RW111
012RW080