1998 OPEL FRONTERA fuel pump

6A–5
ENGINE MECHANICAL
4. Engine Lacks Compression
Condition
Possible causeCorrection
Engine lacks compressionSpark plug loosely fitted or spark
plug gasket defectiveTighten to specified torque or replace
gasket
Valve timing incorrectAdjust
Cylinder head gasket defectiveReplace gasket
Valve incorrectly seatedLap valve
Valve stem seizedReplace valve and valve guide
Valve spring weakened or brokenReplace
Cylinder or piston rings wornOverhaul engine
Piston ring seizedOverhaul engine.
Engine Compression Test Procedure
1. Start and run the engine until the engine reaches
normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and fuse
box.
6. Engage the starter and check that the cranking speed
is approximately 300 rpm.7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the starter
engaged until the compression gage needle reaches
the maximum level. Note the reading.
9. Repeat the test with each cylinder.
If the compression pressure obtained falls below the
limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)

6A–6
ENGINE MECHANICAL
Rough Engine Idling or Engine Stalling
ConditionPossible causeCorrection
Trouble in fuel injection systemIdle air control valve defectiveReplace
Throttle shutting off incompleteCorrect or replace
Throttle position sensor circuit open
or shortedCorrect or replace
Fuel injector circuits open or shortedCorrect or replace
Fuel injectors damagedReplace
Fuel pump relay defectiveReplace
Mass Airflow Sensor circuit open or
poor connectionsCorrect or replace
Mass Airflow Sensor defectiveReplace
Manifold Absolute Pressure Sensor
circuit open or poor connectionsCorrect or replace
Manifold Absolute Pressure Sensor
defectiveReplace
Engine Coolant Temperature Sensor
circuit open or poor connectionsCorrect or replace
Engine Coolant Temperature Sensor
defectiveReplace
Intake Air Temperature sensor circuit
open or poor connectionsCorrect or replace
Intake Air Temperature sensor
defectiveReplace
Knock Sensor (KS) cable broken or
poor connectionsCorrect or replace
KS defectiveReplace
KS Module circuits open or groundCorrect or replace
KS Module defectiveReplace
Vehicle Speed Sensor circuit open or
shortedCorrect or replace
Vehicle Speed Sensor defectiveReplace
Trouble in emission control systemPowertrain Control Module defectiveReplace
Exhaust Gas Recirculation Valve
circuit open or poor connectionsCorrect or replace
Exhaust Gas Recirculation Valve
faultyReplace
Canister purge valve circuit open or
poor connectionsCorrect or replace
Canister purge valve defectiveReplace
Evaporative Emission Canister
Purge control valve defectiveReplace
Trouble in ignition systemRefer to “Hard Start”

6A–8
ENGINE MECHANICAL
Hesitation
ConditionPossible causeCorrection
Hesitation on accelerationThrottle Position Sensor adjustment
incorrectReplace throttle valve assembly
Throttle Position Sensor circuit open
or shortedCorrect or replace
Excessive play in accelerator linkageAdjust or replace
Mass Airflow Sensor circuit open or
poor connectionsCorrect or replace
Mass Airflow Sensor defectiveReplace
Manifold Absolute Pressure (MAP)
Sensor circuit open or shortedCorrect or replace
MAP Sensor defectiveReplace
Intake Air Temperature (IAT) Sensor
circuit open or shortedCorrect or replace
Knock Sensor (KS) Circuit open or
poor connectionsCorrect or replace
KS defectiveReplace
KS Module circuits open or shortedCorrect or replace
KS Module defectiveReplace
IAT Sensor defectiveReplace
Hesitation at high speedsFuel tank strainer cloggedClean or replace
(Fuel pressure too low)Fuel pipe cloggedClean or replace
Fuel filter cloggedReplace
Defective fuel pump systemCheck and replace
Fuel Pressure Control Valve leakingReplace
Hesitation at high speeds
(Fuel injector not working normally)Power supply or ground circuit for
Multiport Fuel Injection System
shorted or openCheck and correct or replace
Fuel Injector defectiveReplace
Cable of Multiport Fuel Injection
System circuit open or poor
connectionsCorrect or replace

6A–10
ENGINE MECHANICAL
Engine Lacks Power
ConditionPossible causeCorrection
Trouble in fuel systemFuel Pressure Control Valve not
working normallyReplace
Fuel injector cloggedClean or replace
Fuel pipe cloggedClean
Fuel filter clogged or fouledReplace
Fuel pump drive circuit not working
normallyCorrect or replace
Fuel tank not sufficiently breathing
due to clogged Evaporative
Emission Control System circuitClean or replace
Water in fuel systemClean
Inferior quality fuel in fuel systemUse fuel of specified octane rating
Powertrain Control Module supplied
poor voltageCorrect circuit
Throttle Position Sensor cable
broken or poor connectionsCorrect or replace
Throttle Position Sensor defectiveReplace
Mass Airflow Sensor not working
normallyReplace
Manifold Absolute Pressure Sensor
not working normallyReplace
Intake Air Temperature Sensor not
working normallyReplace
Engine Coolant Temperature Sensor
circuit open or shortedCorrect or replace
Engine Coolant Temperature Sensor
defectiveReplace
Powertrain Control Module defectiveReplace
Trouble in intake or exhaust systemAir Cleaner Filter cloggedReplace filter element
Air duct kinked or flattenedCorrect or replace
Ignition failure————Refer to Hard Start Troubleshooting
Guide
Heat range of spark plug inadequateInstall spark plugs of adequate heat
range
Ignition coil defectiveReplace

6A–13
ENGINE MECHANICAL
Condition CorrectionPossible cause
Engine knockingPreignition due to use of spark plugs
of inadequate heat rangeInstall Spark Plugs of adequate heat
range
Carbon deposits in combustion
chambersClean
Fuel too low in octane ratingReplace fuel
Wide Open Throttle enrichment
system failureRefer to Section 6E
Selection of transmission gear
incorrectCaution operator of incorrect gear
selection
Engine overheatingRefer to “Engine Lacks Power”
OthersWater pump defectiveReplace
Drive belt slippingReplace auto tentioner or drive belt
Abnormal Combustion
ConditionPossible causeCorrection
Trouble in fuel systemFuel pressure control valve defectiveReplace
Fuel filter cloggedReplace
Fuel pump cloggedClean or replace
Fuel tank or fuel pipe cloggedClean or replace
Fuel injector cloggedClean or replace
Fuel pump relay defectiveReplace
Power supply cable for fuel pump
broken or poor connectionsReconnect, correct or replace
Mass Airflow (MAF) sensor circuit
open or defectiveCorrect or replace
MAF Sensor defectiveReplace
Manifold Absolute Pressure Sensor
circuit open or shortedCorrect or replace
Manifold Absolute Pressure Sensor
defectiveReplace
Engine Coolant Temperature (ECT)
Sensor circuit open or shortedCorrect or replace
ECT Sensor defectiveReplace
Throttle Position Sensor adjustment
incorrectReadjust
Throttle Position Sensor defectiveReplace
Throttle Position Sensor connector
poor connectionsReconnect
Vehicle Speed Sensor cable poor
connections or defectiveCorrect or replace
Vehicle Speed Sensor loosely fixedFix tightly
Vehicle Speed Sensor in wrong
contact or defectiveReplace
Powertrain Control Module cable
poor connections or defectiveCorrect or replace

6A–21
ENGINE MECHANICAL
Cylinder Head Cover RH
Removal
1. Disconnect battery ground cable.
2. Remove battery from the vehicle.
3. Drain engine coolant from faucet bottom of radiator.
4. Remove engine cover from the dowels on the
common chamber.
F06RW018
5. Remove air cleaner duct assembly (3) and air cleaner
element (4).
130RW001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Cleaner Element
(5) Mass Air Flow Sensor
NOTE: Disconnect the mass air flow (MAF) sensor
connector, intake air temperature (IAT) sensor connector,
and positive crankcase ventilation (PCV) hose before
hand the air cleaner duct assembly is removed.
6. Disconnect following wiring connectors and bonding
cable:
Exhaust Gas Recirculation (EGR) valve
Fuel injectors for right bank
Ignition coils for right bank
Bonding cable
Othres as necessitated
7. Disconnect radiator upper and lower hoses.
8. Remove engine harness from the cylinder head
cover.
9. Remove the upper fan guide.
10. Remove cooling fan and clutch assembly.
11. Remove drive belt by pushing down the auto
tensioner using spanner as illustrated.
F06RW019
Legend
(1) Crankshaft Pulley
(2) Generator
(3) Auto Tensioner
(4) Idle Pulley
(5) Cooling Fan Pulley
(6) Power Steering Oil Pump
(7) Drive Belt
(8) Air Conditioner Compressor
12. Remove fan pulley and bracket assembly.
13. Remove idle pulley assembly.
14. Remove auto tensioner assembly.
15. Remove crankshaft pulley using 5–8840–0133–0
crankshaft holder.

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.

6C–1
ENGINE FUEL
ENGINE
ENGINE FUEL
CONTENTS
Service Precaution 6C–1. . . . . . . . . . . . . . . . . . . . . .
General Description 6C–2. . . . . . . . . . . . . . . . . . . . .
Fuel Metering 6C–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 6C–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter and Associated Parts 6C–4. . . . . . . . .
Removal 6C–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6C–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6C–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
In–Tank Fuel Filter 6C–5. . . . . . . . . . . . . . . . . . . . .
Fuel Pump Flow Test 6C–5. . . . . . . . . . . . . . . . . . .
Fuel Pump 6C–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump and Associated Parts 6C–6. . . . . . . .
Removal 6C–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay 6C–7. . . . . . . . . . . . . . . . . . . . . . . .
General Description 6C–7. . . . . . . . . . . . . . . . . . . . .
Fuel Tank 6C–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank and Associated Parts 6C–7. . . . . . . . .
Removal 6C–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tube / Quick – Connect Fittings 6C–8. . . . . . .
Precautions 6C–8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions During Work 6C–8. . . . . . . . . . . . . . . . . .
Removal 6C–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reuse of Quick–Connector 6C–10. . . . . . . . . . . . . . .
Assembling Advice 6C–10. . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Unit 6C–11. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Unit and Associated Parts 6C–11. . .
Removal 6C–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filler Cap 6C–12. . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6C–12. . . . . . . . . . . . . . . . . . . . .
Inspection 6C–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6C–12. . . . . . . . . . . . .
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.