1998 OPEL FRONTERA Workshop Manual

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Page 1073 of 6000

OPEL FRONTERA 1998 Workshop Manual 6C–6
ENGINE FUEL
Fuel Pump
Fuel Pump and Associated Parts
035RW047
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connect

Page 1074 of 6000

OPEL FRONTERA 1998 Workshop Manual 6C–7
ENGINE FUEL
Fuel Pump Relay
General Description
In order to control the FP operation, the FP relay is
provided. When the starter switch is turned to “ON”
position, the FP

Page 1075 of 6000

OPEL FRONTERA 1998 Workshop Manual 6C–8
ENGINE FUEL
7. Disconnect two fuel tank wiring connectors(4) on
front right side of tank.
8. Disconnect evapo fuel hose(5).
9. Disconnect fuel feed tube and fuel return tube(6).
NOTE: Han

6C–8
ENGINE FUEL
7. Disconnect two fuel tank wiring connectors(4) on
front right side of tank.
8. Disconnect evapo fuel hose(5).
9. Disconnect fuel feed tube and fuel return tube(6).
NOTE: Handling of the fuel tube, be sure to refer “Fuel
Tube/Quick–Connect Fittings” in this section.
10. Remove fuel tank fixing bolts on both sides and
remove fuel tank(7).
Installation
1. Install fuel tank(7).
Place a flange on right side of tank on the bracket.
Install a flange on left side on the bracket from the
bottom, and tighten bolts to the specified torque.
Torque: 36 Nꞏm (3.7 Kgꞏm/27 lb ft)
2. Connect fuel feed tube and fuel return tube(6).
3. Connect evapo fuel hose(5).
4. Connect fuel tank wiring connector(4).
5. Install undercover(3).
6. Connect fuel filler hose, air breather hose and evapo
hose(2).
7. Install fender liner(1).
Mount fender liner to the wheel well.
Fill the tank with fuel and tighten fuel filler cap.
Connect battery ground cable.
Fuel Tube / Quick – Connect Fittings
Precautions
Lighting of Fires Prohibited.
Keep flames away from your work area to prevent the
inflammable from catching fire.
Disconnect the battery negative cable to prevent
shorting during work.
When welding or conducting other heat-generating
work on other parts, be sure to provide pretreatment
to protect the piping system from thermal damage or
spattering.
Cautions During Work
Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spilt
battery electorolyte.
The piping wet with battery electrolyte cannot be used.
Be careful not to give a bending or twisting force to the
piping during the work. If deformed, replace with a new
piping.
Removal
1. Open the fuel cap to relieve the fuel pressure in the
tank.
If the fuel quick-connect fittings are dusty, clean with
an air blower, etc. and then remove it.
141RW016As some pressure may remain in the piping, cover the
connector with a cloth, etc. to prevent the splashing
of fuel in the first disconnection of the piping.

Page 1076 of 6000

OPEL FRONTERA 1998 Workshop Manual 6C–9
ENGINE FUEL
2. For removal of the delivery pipe (feeding fuel to the
engine), hold the connector in one hand, and hold the
retainer tab with the other hand and pull out the
connector,

Page 1077 of 6000

OPEL FRONTERA 1998 Workshop Manual 6C–10
ENGINE FUEL
Reuse of Quick–Connector
(Delivery Pipe)
Replace the pipe and connector if scratch, dent or
crack is found.
Remove mud and dust from the pipe and make sure
that the end i

6C–10
ENGINE FUEL
Reuse of Quick–Connector
(Delivery Pipe)
Replace the pipe and connector if scratch, dent or
crack is found.
Remove mud and dust from the pipe and make sure
that the end including spool is free of defects, such as
scratch, rust, and dent, which may cause poor
sealability. If defective, replace with a new pipe.
If the retainer removed according to the removal step
above is attached to the pipe, clean and insert it
straight into the quick-connector till it clicks. After it
clicks, try pulling it out to make sure that it is not drawn
and is securely locked.
NOTE: The retainer, once removed from the pipe, cannot
be reused. Just replace with a new retainer. Insert the
new retainer into the connector side until it clicks, and
connect the pipe as inserting it into the retainer until it
clicks.
141RW018
(Return Pipe)
Replace the pipe and connector if scratch, dent or
crack is found.
Remove mud or dust from the pipe and make sure
that the end including spool is free from defects, such
as scratch, rust, and dent, which may cause poor
sealability. If defective, replace with a new pipe.
After cleaning the pipe, insert it straight into the
connector until it clicks. After it clicks, try pulling it out
to make sure that it is not drawn and is securely
locked.
141RW017
Assembling Advice
Application of engine oil or light oil to the pipe facilitates
connecting work. The work should be started immediately
after lubrication, since dust may stick to the pipe surface
to cause poor sealability if a long time passes after
lubrication.
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Turn the ignition key to the “ON” position and check
pump startup sound. As the pump is actuated to raise
fuel pressure, check and see fuel leak from the piping
system.
3. Make sure of no fuel leakage by conducting the above
fuel leak check a few times.
4. Start the engine and make sure of stable idling speed
and normal vehicle run.The entry of dust during the
work may sometimes affect the fuel injection system.

Page 1078 of 6000

OPEL FRONTERA 1998 Workshop Manual 6C–11
ENGINE FUEL
Fuel Gauge Unit
Fuel Gauge Unit and Associated Parts
140RS004
Legend
(1) Wiring Connector
(2) Fuel Gauge Unit
Removal
CAUTION: When repair to the fuel system has been
completed, s

Page 1079 of 6000

OPEL FRONTERA 1998 Workshop Manual 6C–12
ENGINE FUEL
Fuel Filler Cap
General Description
Fuel filler cap includes vacuum valve and pressure valve.
In case any high vacuum and any high pressure happen in
tank, each valve works to adju

Page 1080 of 6000

OPEL FRONTERA 1998 Workshop Manual ENGINE ELECTRICAL6D1–1
ENGINE
ENGINE ELECTRICAL
CONTENTS
Service Precaution 6D1–1. . . . . . . . . . . . . . . . . . . . . .
Battery 6D1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE ELECTRICAL6D1–1
ENGINE
ENGINE ELECTRICAL
CONTENTS
Service Precaution 6D1–1. . . . . . . . . . . . . . . . . . . . . .
Battery 6D1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6D1–2. . . . . . . . . . . . . . . . . . . .
Diagnosis 6D1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging 6D1–3. . . . . . . . . . . . . . . . . . . . . . Jump Starting 6D1–3. . . . . . . . . . . . . . . . . . . . . . . . .
Battery Removal 6D1–4. . . . . . . . . . . . . . . . . . . . . .
Battery Installation 6D1–4. . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D1–5. . . . . . . . . . .
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.

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