1998 OPEL FRONTERA engine

5A–11 BRAKE CONTROL SYSTEM
Data List
DisplayContentOK/NG Criteria for Data
Battery VoltageVo l t a g eBetween 10-16.9V
Brake Light SwitchOpen/CloseOpen(0V) when pedal is released
Closed(12V) when pedal is depressed.
Front Left Wheel Speed
Front Right Wheel Speed
Rear Left Wheel Speed
Rear Right Wheel SpeedMPH(km/h)Start the vehicle and make sure of linear change in each
wheel speed.
Turn each wheel by hand and make sure that each
speed data change.
Wheel Sensor StatusOK/NGTo be OK usually
G-sensorLow/HighTo be Low usually
Transfer Monitor(TOD)2 Wheel Drive
4 Wheel DriveWhen 2WD: 2 Wheel Drive
When 4WD: 4 Wheel Drive
Off-Road Switch
(Transmission Input)
Active/InactiveWhen shift lever position is 1, 2 and R: Active (M/T)
(Transmission Input)When shift lever position is L and R: Active (A/T)
Valve RelayActive/InactiveTo be Active usually
ABS StateON/OFFTo be OFF usually
ABS RelayActive/InactiveTo be Active usually
Return Pump RelayActive/InactiveTo be Inactive usually
Front Left Isolation ValveActive/InactiveTo be Inactive usually
Front Left Dump Valve
Front Right Isolation Valve
Front Right Dump Valve
Rear Isolation Valve
Rear Dump Valve
ABS Warning LampON/OFFTo be ON usually (while engine stopped)

5A–38
BRAKE CONTROL SYSTEM
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking
StepActionYe sNo
1Is this the first time the vehicle is being driven after starting the
engine?It is self checking
sound.
Normal.
Go to Step 2
2Is vehicle speed under 10 km/h (6 mph)?It is self checking
sound.
Normal.
Go to Step 3
3Check for the following condition:
At the time of shift down or clutch operation.
A t t h e t i m e o f l o w drive (ice or snow road) or rough road drive.
At the time of high-speed turn.
At the time of passing curb.
At the time of operating electrical equipment switches.
At the time of racing the engine (over 5000 rpm).
Did it occur under any one condition above?
ABS may
sometime be
actuated even
when brake pedal
is not applied.
Go to Step 4
4Is there play in each sensor/wheel speed sensor rings?
Go to Step 5
Repair.
Go to Step 7
5Damage or powdered iron sticking to each sensor/wheel speed
sensor ring?
Go to Step 6
Repair.
Go to Step 7
6Is each sensor output normal?(Refer to chart C-1 or TC-1).Check harness/
connector for
suspected
disconnection.
If no
disconnection is
found, replace
EHCU.
Go to Step 7
Repair.
Go to Step 7
7Reconnect all components, ensure all components are properly
mounted.
Was this step finished?Repeat the “Basic
diagnostic flow
chart.”
Go to Step 7

5A–43 BRAKE CONTROL SYSTEM
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L)
is not activated.
StepActionYe sNo
1Is W/L fuse C-10 disconnected?Replace fuse.
Go to Step 5
Go to Step 2
2Is W/L burnt out?Replace W/L
bulb.
Go to Step 5
Go to Step 3
31. Turn the key off.
2. Disconnect EHCU connector.
3. Turn the key ON.
4. Measure the voltage between EHCU connector terminal 13
and 14.
Is the voltage equal to the battery voltage?
Go to Step 4
Repair harness
and connector.
Go to Step 5
4Is there continuity between EHCU connector terminals, 12 and 15
and body ground.Check harness
for suspected
disconnection.
No fault found:
Replace EHCU.
Go to Step 5
Repair harness
and connector.
Go to Step 5
5Reconnect all components, ensure all components are properly
mounted.
Was this step finished?Repeat the “Basic
diagnostic flow
chart.”
Go to Step 5
Chart B-2 EHCU Abnormality (DTC 14)
StepActionYe sNo
11. Turn the key off.
2. Disconnect the EHCU connector.
3. Inspect EHCU ground.
Is there resistance between the EHCU connector terminals, 12
and 15 and body ground?
Go to Step 2
Repair the body
ground harness.
Go to Step 3
21. Turn the key off, connect the EHCU.
2. Erase the trouble code.
3. Turn Ignition off, then on, to perform system self-check.
4. If warning light remains on, display trouble codes once again.
Is the check trouble code 14?
Replace EHCU.
Go to Step 3
Inspect in
accordance with
the DTC
displayed.
31. Reconnect all components and ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Repeat the “Basic
diagnostic flow
chart.”
Go to Step 3

6A–1
ENGINE MECHANICAL
ENGINE
CONTENTS
Engine Mechanical 6A. . . . . . . . . . . . . . . . . . . . . .
Engine Cooling 6B. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Fuel 6C. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical 6D1. . . . . . . . . . . . . . . . . . . . . . . .
Ignition System 6D2. . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Charging System 6D3. . . . . . . . . . . . Driveability and Emissions 6E. . . . . . . . . . . . . . . .
Engine Exhaust 6F. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication 6G. . . . . . . . . . . . . . . . . . . . . .
Engine Speed Control System 6H. . . . . . . . . . . .
Inducton 6J. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MECHANICAL
CONTENTS
Service Precaution 6A–2. . . . . . . . . . . . . . . . . . . . . .
General Description 6A–3. . . . . . . . . . . . . . . . . . . . .
Engine Diagnosis 6A–4. . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover LH 6A–18. . . . . . . . . . . . . . . . .
Removal 6A–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover RH 6A–21. . . . . . . . . . . . . . . . .
Removal 6A–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Chamber 6A–24. . . . . . . . . . . . . . . . . . . . . .
Removal 6A–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold LH 6A–26. . . . . . . . . . . . . . . . . . . . .
Removal 6A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold RH 6A–27. . . . . . . . . . . . . . . . . . . .
Removal 6A–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Pulley 6A–28. . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 6A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 6A–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 6A–37. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–37. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Oil Controller , Valve Spring and
Valve Guide 6A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Ring and Connecting Rod 6A–40. . . Removal 6A–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Main Bearings 6A–42. . . . . . . . . . . .
Removal 6A–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal 6A–47. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–47. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly 6A–48. . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A–48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 6A–52. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Associated Parts 6A–52. . . . .
Disassembly 6A–52. . . . . . . . . . . . . . . . . . . . . . . . . .
Clean 6A–53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–53
. . . . . . . . . . . . . . . . . .
Reassembly 6A–53. . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve,
Valve Guide 6A–56. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve,
Valve Guide and Associated Parts 6A–56. . . . . . .
Disassembly 6A–56. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–57. . . . . . . . . . . . . . . . . .
Reassembly 6A–60. . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Clearance Adjustments 6A–61. . . . . . . . . . . . .
Camshaft 6A–63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Associated Parts 6A–63. . . . . . . . .
Disassembly 6A–63. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–64. . . . . . . . . . . . . . . . . .
Reassembly 6A–66. . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 6A–69. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Associated Parts 6A–69. . . . . . . .
Disassembly 6A–69. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–70. . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–71. . . . . . . . . . . . . . . . . .
Reassembly 6A–73. . . . . . . . . . . . . . . . . . . . . . . . . .

6A–2
ENGINE MECHANICAL
Piston and Connecting Rod 6A–77. . . . . . . . . . . . . . .
Piston, Connecting Rod and Associate
Parts 6A–77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 6A–77. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–78. . . . . . . . . . . . . . . . . .
Reassembly 6A–82. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block 6A–85. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block and Associated Parts 6A–85. . . . .
Disassembly 6A–85. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A–86. . . . . . . . . . . . . . . . . .
Reassembly 6A–87. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specification 6A–90. . . . . . . . . . . . . .
Special Tool 6A–96. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

6A–3
ENGINE MECHANICAL
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.
Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance:
When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick–up unit.
The 12–volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.
Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum die–cast casting
for 75
V–type six cylinders. It has a rear plate integrated
structure and employs a deep skint. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width of No.3 bearing
on the body side is different in order to support the thrust
bearing. The bearing cap is made of nodular cast iron and
each bearing cap uses four bolts and two side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent–roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V–type design. The ports are cross–flow
type.
Va l v e Tr a i n
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing belt.
The valves are operated by the camshaft and the valve
clearance is adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct seze selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast–iron. Pins and
journals are graded for correct size selection for their
bearing.
Engine Lubrication
The oil discharged by a trochoid–type oil pump driven by
the crankshaft is fed through full–flow oil filter and to the oil
gallery provided under the crankshaft bearing cap. The oil
is then led to the crankshaft journals and cylinder head.
The crank pins are lubricated with oil from crankshaft
journals through oil holes. Also, an oil jet is fed to each
cylinder from crankshaft juornals on the connecting rod
for piston cleaning. The oil pan flange is dealed with liquid
packing only; do not deform or damage the flange surface
during removal or installation.

6A–4
ENGINE MECHANICAL
Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Condition
Possible causeCorrection
Headlights go out or dim
considerably
Battery run down or under chargedRecharge or replace battery
considerablyTerminals poorly connectedClean battery posts and terminals
and connect properly
Starting motor coil circuit shortedOverhaul or replace
Starting motor defectiveOverhaul or replace
2. Ignition Trouble — Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect an igniton coil from any spark plug. Connect
the spark plug tester 5–8840–0607–0, start the engine,
a n d c h e c k i f a s p a r k i s g e n e r a t e d in t h e s p a r k p l u g t e s t e r.
Before starting the engine, make sure that the spark plugtester is properly grounded. To avoid electrical shock, do
not touch the part where insulation of the igniton coil is
broken while the engine is running.
Condition
Possible causeCorrection
Spark jumps across gapSpark plug defectiveClean, adjust spark gap or replace
Ignition timing incorrectRefer to Ignition System
Fuel not reaching fuel injector(s) or
engineRefer to item 3 (Trouble in fuel
system)
Valve timing incorrectAdjust
Engine lacks compressionRefer to item 4 (Engine lacks
compression)
No sparking takes placeIgnition coil disconnected or brokenConnect properly or replace
Electronic Ignition System with
moduleReplace
Poor connections in engine harnessCorrect
Powertrain Control Module cable
disconnected or defectiveCorrect or replace
3. Trouble In Fuel System
Condition
Possible causeCorrection
Starting motor turns over and spark
occurs but engine does not start
Fuel tank emptyFill
occurs but engine does not start.Water in fuel systemClean
Fuel filter cloggedReplace filter
Fuel pipe cloggedClean or replace
Fuel pump defectiveReplace
Fuel pump circuit openCorrect or replace
Evaporative Emission Control
System circuit cloggedCorrect or replace
Multiport Fuel Injection System faultyRefer to “Electronic Fuel Injection”
section

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)