1998 OPEL FRONTERA lock

6E–337 ENGINE DRIVEABILITY AND EMISSIONS
0018
Knock Sensor
Insufficient gasoline octane levels may cause detonation
in some engines. Detonation is an uncontrolled explosion
(burn) in the combustion chamber. This uncontrolled
explosion results from a flame front opposite that of the
normal flame front produced by the spark plug. The
rattling sound normally associated with detonation is the
result of two or more opposing pressures (flame fronts)
colliding within the combustion chamber. Light
detonation is sometimes considered normal, but heavy
detonation could result in engine damage.
A knock sensor system is used to control detonation. This
system is designed to retard spark timing up to 20
degrees to reduce detonation in the engine. This allows
the engine to use maximum spark advance to improve
driveability and fuel economy.
The knock sensor system has two major components:
The knock sensor (KS) module.
The knock sensor.
The knock sensor, mounted in the engine block near the
cylinders, detects abnormal vibration in the engine. The
sensor produces an AC output signal of about 10
millivolts. The signal amplitude and frequency are
dependent on the amount of knock being experienced.
The signal voltage increases with the severity of the
knock. This signal voltage is input to the PCM. The PCM
then retards the ignition control (IC) spark timing based
on the KS signal being received.
The PCM determines whether knock is occurring by
comparing the signal level on the KS circuit with the
voltage level on the noise channel. The noise channel
allows the PCM to reject any false knock signal by
indicating the amount of normal engine mechanical noise
present. Normal engine noise varies depending on the
engine speed and load. If the voltage level on the KS
noise channel circuit is below the range considered
normal, DTC P0327 will set, indicating a fault in the KScircuit or the knock sensor. If the PCM determines that an
abnormal minimum or maximum noise level is being
experienced, DTC P0325 will set.
The PCM contains a knock sensor (KS) module. The KS
module contains the circuitry which allows the PCM to
utilize the KS signal and diagnose the KS sensor and the
KS circuitry. If the KS module is missing or faulty, a
continuous knock condition will be indicated, and the
PCM will set DTC P0325.
Although it is a plug-in device, the KS module is not
replaceable. If the KS module is faulty, the entire PCM
must be replaced.
0009
Linear Exhaust Gas Recirculation (EGR)
Control
The PCM monitors the exhaust gas recirculation (EGR)
actual position and adjusts the pintle position accordingly.
The PCM 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.
Mass Air Flow (MAF) Sensor
The mass air flow (MAF) sensor measures the difference
between the volume and the quantity of air that enters the
engine. “Volume” means the size of the space to be filled.
“Quantity” means the number of air molecules that will fit
into the space. This information is important to the PCM
because heavier, denser air will hold more fuel than
lighter, thinner air. The PCM adjusts the air/fuel ratio as
needed depending on the MAF value. Tech 2 reads the
MAF value and displays it in terms of grams per second
(gm/s). At idle, Tech 2 should read between 4-7 gm/s on a
fully warmed up engine. Values should change quickly on
acceleration. Values should remain stable at any given

6E–354
ENGINE DRIVEABILITY AND EMISSIONS
ILLUSTRATIONTOOL NO.
TOOL NAME
5-8840-2607-0
(J 41413)
EVAP Pressure/Purge
Diagnostic Station
5-8840-2608-0
(J 41416)
Ultrasonic Leak Detector
1. 5-8840-2607-0 (J-41413)EVAP Pressure/Purge
Diagnostic Station is a multipurpose tool which is
used to perform several diagnostic procedures for
enhanced emission testing. The station will
accommodate a nitrogen gas filled cylinder which is
used to pressurize the vehicle EVAP system for a
leakdown test and leak location test when a vehicle is
repaired for leakage in the enhanced evaporative
emission control system. It also has two additional
gauges (inches of mercury and inches of water) which
are used to measure both source vacuum and EVAP
canister purge vacuum to verify correct operation and
vapor flow within the canister purge circuit.
2. 5-8840-2608-0 (J-41416) Ultrasonic Leak Detector is
a microprocessor-based device used to detect leaks
in the enhanced evaporative emission control
system. The evaporative system is pressurized to 30
inches of water using the 5-8840-2607-0 (J-41413)
EVAP Pressure/Purge Diagnostic System. Small
leaks in the EVAP system will emit sound at a high
frequency undetectable by a human ear but
detectable with the 5-8840-2608-0 (J-41416). The
technician traces along the evaporative system and
can pinpoint leaks due to corroded lines, cracked
hoses, or a damaged EVAP component. The
detector includes a high quality set of headphones to
block out surrounding shop noise and the LED
sensitivity meter allows a visual reference for locating
leaks in conjunction with the audio output heard
through the headphones. Powered by (1) nine volt
battery.

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.

6F–3 ENGINE EXHAUST
For Isuzu General Motors (IGM)
150RW058
When inspecting or replacing exhaust system
components, make sure there is adequate clearance
from all points on the underbody to prevent overheating
the floor pan and possible damage to the passenger
compartment insulation and trim materials.
Check complete exhaust system and nearby body areas
and rear compartment lid for broken, damaged, missing
or mispositioned parts, open seams, holes, loose
connections or other deterioration which could permit
exhaust fumes to seep into the rear compartment or
passenger compartment. Dust or water in the rear
compartment may be an indication of a problem in one of
these areas. Any faulty areas should be corrected
immediately.
Hangers
Various types of hangers are used to support exhaust
system(s). These include conventional rubber straps,
rubber rings, and rubber blocks.
The installation of exhaust system supports is very
important, as improperly installed supports can cause
annoying vibrations which can be difficult to diagnose.
Three Way Catalytic Converter
The three way catalytic converter is an emission control
device added to the exhaust system to reduce pollutants
from the exhaust gas stream.
CAUTION: The catalytic converter requires the use
of unleaded fuel only.
Periodic maintenance of the exhaust system is not
required. If the vehicle is raised for other service, it is
advisable to check the condition of the complete exhaust
system.
A dual bed monolith catalytic converter is used in
combination with three way catalytic converter.
Catalytic Types:
Three way (Reduction/Oxidation) catalyst
The catalyst coating on the three way (reduction)
converter contains platinum and rhodium which lowers
the levels of nitrous oxide (NOx) as well as hydrocarbons
(HC) and carbon monoxide (Co).
Gasket
The gasket must be replaced whenever a new exhaust
pipe, muffler or catalytic converter is installed.

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.

6G–10
ENGINE LUBRICATION
Oil Pump
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankcase assembly.
Refer to removal procedure for Oil Pan and
Crankcase in this manual.
4. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft Pulley in
this manual.
5. Remove timing belt.
Refer to removal procedure for Timing Belt in this
manual.
6. Remove timing pulley from crankshaft.
7. Remove four fixing bolts from oil filter assembly.
8. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
9. Remove three bolts from oil pipe and O-ring.
10. Remove eight oil pump fixing bolts, then oil pump
assembly.
11. Remove sealant from mounting surface of oil pump
assembly, cylinder block and take care not to damage
mounting surfaces of oil pump and cylinder block.
Installation
1. Install oil pump assembly
Apply sealant (TB-1207B or equivalent) to the oil
pump mounting surfaces as shown in the
illustration.
The oil pump assembly must be installed within 5
minutes after sealant application before the sealant
hardens.
NOTE: Do not apply sealant to the oil ports.
051RW002
Use 5–8840–2287–0 installer when installing new
oil seal.
Apply engine oil to oil seal lip.
Install oil pump assembly to the cylinder block.
NOTE: Do not damage oil seal during installation of oil
pump assembly.
015RS001
Tighten fixing bolts to the specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)
051RW001
2. Install oil pipe with O-ring, tighten fixing bolt to the
specified torque.
Torque : 10 Nꞏm (1.0 Kgꞏm/89 lb in)
3. Install oil strainer with O-ring, tighten fixing bolt to the
specified torque.
Torque : 25 Nꞏm (2.5 Kgꞏm/18 lb ft)

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.

6H–2
ENGINE SPEED CONTROL SYSTEM
Accelerator Pedal Control Cable
Removal
1. Loosen the adjusting nut(5) on the cable bracket
mounted on the common chamber.
2. Remove cable clip(3).
3. Disconnect accelerator pedal (AP) control cable(6).
(on throttle valve side)
4. Disconnect AP control cable(1). (on AP pedal(7) side)
5. Remove molding cap(2).
6. Remove AP control cable(4).
101RW001
Inspection
Check the following items, and replace the control cable if
any abnormality is found:
The control cable should move smoothly.
The control cable should not be bent or kinked.
The control cable should be free of damage and
corrosion.
Installation
1. Install AP control cable(4).
2. Install molding cap(2).
3. Connect AP control cable(1). (on AP side)
4. Connect AP control cable(6). (on throttle valve side)
5. Install cable clip(3).
6. Install adjusting nut(5).
101RW001
Adjustment
1. Loosen adjusting nut and lock nut.
2. Pull outer cable while closing fully the throttle valve.
3. Tighten adjusting nut and lock nut temporarily.
4. Loosen adjusting nut by three turns and tighten lock
nut.
Then, manually operating the throttle valve, make
sure that the valve lever returns up to the stopper
screw.
If it does not reach the stopper screw, repeat from
step 1.
035RW004
Legend
(1) Clearance
(2) Lock Nut
(3) Adjusting Nut