1998 OPEL FRONTERA check oil

6A – 96 ENGINE MECHANICAL
NOTE: Check to see that the crankshaft turns
smoothly by rotating it manually.
4. Piston Assembly
1) Refer to “Piston and connecting rod” in this
manual.
5. Cylinder Block Side Cover Right and Left
6. Balance Shaft Right.
7. Timing Gear Case
1) Cut out the liquid gasket forced out from
between the contact surface of cylinder block
and crankshaft.
2) Apply liquid gasket (TB1207B or equivalent) to
the fitting surface of the cylinder block and
crankcase.
3) Install timing gear case with gasket to cylinder
block and tighten to specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)8. Crankshaft Gear
Force key into crankshaft and force in crankshaft
gear along the key groove using a special tool (1)
with the crank gear (2) timing mark facing outside.
9. Install timing gear align the timing mark on each
timing gear.
For alignment of timing marks refer to “Timing
Gear” in this manual.
NOTE: Remove the locking bolt or pin from idle gear A
and idle gear C.
10. Assembling the gear case cover.
1) Install the oil seal on the oil pump assembly
before installing the gear case cover.
2) Apply liquid gasket to timing gear case.
NOTE: Be sure to apply liquid gasket evenly.
84159
610
237
012RW027
012RW064
12
2
012RW066
2
2~2.5mm
2~2.5mm
Apply liquid gasket around inside
of the bolt hole
Bolt hole
Inside
Outside
F06HX00001

ENGINE MECHANICAL 6A – 97
11. Use the special tool to install the crankshaft front oil
seal to timing gear case.
Front Oil Seal Installer: 5-8840-2061-0
1) Check fit-of the oil seal and gear case cover at
the front end.
Standard: 0.5 – 2.5 mm (0.0197 – 0.0984 in)
NOTE: Apply engine oil to oil seal lip before installation
of the seal.
12. Install the oil pan assembly to original position and
tighten to specified torque.
Torque: 22 Nꞏm (2.2 kgꞏm/15.9 lb ft)
13. Crankshaft Rear Oil Seal
1) Tighten the adapter to the crankshaft rear end
with 2 bolts.
2) Insert the oil seal into the adapter.
3) Insert the sleeve into the adapter and tighten it
with a bolt (M12 x 1.75L = 70) until the adapter
hits the sleeve.
4) Remove the adapter and the sleeve.
5) With the seal pressed in, check the dimension of
the oil seal outside end and crankshaft end.
Standard Dimension = 12.5 ± 0.3 mm
Oil Seal Installer: 5-8840-2359-014. Cylinder Block Rear Plate (A/T Model)
1) Tighten the cylinder block rear plate fixing bolts
to the specified torque.
Torque: 97 Nꞏm (9.9 kgꞏm/72 lb ft)
15. Flywheel Housing (M/T Model)
1) Install flywheel housing aligned with the dowel
pin on the cylinder block.
2) Tighten the flywheel housing fixing bolts to the
specified torque.
Torque: 97 Nꞏm (9.9 kgꞏm/72 lb ft)
16. Flywheel
1) Refer to “Crankshaft” in this manual.
17. Cylinder Head Assembly
1) Refer to “Cylinder Head” in this manual.
015RW074
12.5 + 0.3–
012RW067

ENGINE MECHANICAL 6A – 99
OIL COOLER
For Europe1
2050R200001
Legend
(1) Oil Cooler Assembly
(2) Oil Filter Cartridge
OIL FILTER CARTRIDGE
REMOVAL
1. Place a receptacle beneath the oil filter to contain
the drained oil.
2. Remove the oil filter cartridge using filter wrench.
Filter wrench : 5-8840-0203-0
INSTALLATION
1, Lightly apply oil to the O-ring of oil filter cartridge.
2. Turn the new oil filter cartridge by hand until the
sealing face is fitted against the O-ring.
3. Use the filter wrench to turn the oil filter an
additional one and 1/8 turns.
4. Start the engine and check for oil leakage from oil
filter.

6A – 100 ENGINE MECHANICAL
REMOVAL
1. Disconnect battery ground cable
2. Drain engine coolant
3. Remove front exhaust pipe
4. Remove heat protector
5. Remove exhaust valve assembly
6. Oil cooler assembly
1) Remove water hoses from inlet and outlet pipe.
2) Put rag beneath side of oil cooler to prevent oil
leaking.
3) Remove fixing bolts and oil cooler assembly.
INSTALLATION
1. Oil Cooler
1) Tighten oil cooler fixing bolt to the specified
torque and connect water hose.
Torque: 29 Nꞏm (3.0 kgꞏm/22 lb ft)
2. Exh. Valve Assembly
1) Install exhaust valve assembly with gasket and
tighten fixing bolts to the specified torque.
Torque: 27 Nꞏm (2.7 kgꞏm/20 lb ft)
3. Heat Protector
4. Front Exhaust Pipe
1) Install front exhaust pipe and tighten fixing bolts
to the specified torque.
Exh. Valve Side: 67 Nꞏm (6.8 kgꞏm/50 lb ft)
Intermediate Pipe Side: 43 Nꞏm (4.4 kgꞏm/32 lb ft)
5. Fill engine coolant.
6. Connect battery ground cable.
7. Start engine and check for oil and water leakage
carefully.

ENGINE COOLING 6B – 5
ENGINE COOLANT CHANGE
PROCEDURE
1. To change engine coolant, make sure that the
engine is cool.
WARNING:
When the coolant is heated to a high temperature,
be sure not to loosen or remove the radiator cap.
Otherwise you might get scalded by hot vapor or
boiling water. To open the radiator cap, put a piece
of thick cloth on the cap and loosen the cap slowly
to reduce the pressure once the coolant has
become cooler.
2. Open radiator cap and drain the cooling system by
loosening the drain valve on the radiator and on the
cylinder body.
NOTE: For best results it is suggested that the engine
cooling system be flushed at least once a year. It is
advisable to flush the interior of the cooling system
including the radiator before using anti-freeze
(ethylene-glycol based).
Replace damaged rubber hoses as the engine anti-
freeze coolant is liable to leak out even minor cracks.
Isuzu recommends using Isuzu genuine anti-freeze
(ethylene-glycol based) or equivalent, for the cooling
system and not add any inhibitors or additives.
CAUTION:
A failure to correctly fill the engine cooling system
in changing or topping off coolant may sometimes
cause the coolant to overflow from the filler neck
even before the engine and radiator are completely
full.
If the engine runs under this condition, shortage of
coolant may possibly result in engine overheating.
To avoid such trouble, the following precautions
should be taken in filling the system.
3. To refill engine coolant, pour coolant up to filler neck
using a filling hose which is smaller in outside
diameter than the filler neck. Otherwise air between
the filler neck and the filling hose will block entry,
preventing the system from completely filling up.
4. Keep a filling rate of 9 liter/min. or less. Filling over
this maximum rate may force air inside the engine
and radiator.
And also, the coolant overflow will increase, making
it difficult to determine whether or not the system is
completely full.
5. After filling the system full, pull out the filling hose
and check to see if air trapped in the system is
dislodged and the coolant level goes down. Should
the coolant level go down, repeat topping-off until
there is no more drop in the coolant level.
6. Directly after filling the radiator, fill the reservoir to
the maximum level.
7. Install and tighten radiator cap and start the engine.
After idling for 2 to 3 minutes, stop the engine and
reopen radiator cap. If the water level is lower,
replenish.WARNING:
When the coolant is heated to a high temperature,
be sure not to loosen or remove the radiator cap.
Otherwise you might get scalded by hot vapor or
boiling water. To open the radiator cap, put a piece
of thick cloth on the cap and loosen the cap slowly
to reduce the pressure once the coolant has
become cooler.
8. After tightening radiator cap, warm up the engine at
about 2,000 rpm.
Set heater adjustment to the highest temperature
position, and let the coolant circulate also into
heater water system.
9. Check to see the thermostat has opened by the
needle position of a water thermometer, conduct a
5-minute idle again and stop the engine.
10. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant be found, check the
coolant system and reservoir tank hose for leakage.
11. Fill the coolant into the reservoir tank up to “MAX”
line.

ENGINE FUEL 6C – 1
ENGINE FUEL
CONTENTS
GENERAL DESCRIPTION
General Description . . . . . . . . . . . . . . . . . . 6C–1
On-Vehicle Service . . . . . . . . . . . . . . . . . . 6C–7
Fuel Filter Assembly . . . . . . . . . . . . . . . . 6C–7
Fuel Filter Cartridge . . . . . . . . . . . . . . . . 6C–7
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–9
Fuel Pump Pipe . . . . . . . . . . . . . . . . . . . 6C–13High Pressure Oil Pump . . . . . . . . . . . . . 6C–15
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . 6C–20
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . 6C–21
Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . 6C–21
To realize the compatibility between low exhaust
emission and high engine output, an HEUI
(Hydraulically actuated Electronically controlled Unit
Injector) system, has been introduced. This system is
comprised of a hydraulic system, fuel system, and
electronic control system, using a high-pressure oil
pump in place of the conventional fuel injection pump.
The oil pressurized by means of this pump and by
signals from the ECM (Electronic Control Module)
actuates the fuel injector provided for each cylinder.
Inside of the fuel injector, fuel pressure is increased due
to the high-pressure oil. The ECM detects the driving
state of the vehicle, forms, signals sent by engine and
other part sensors, which determines the optimum fuel
injection amount and timing, thus controlling the fuel
injectors. Thus high engine output, good fuel economy,
and low exhaust emission are realized.When working on the fuel system, there are several
things to keep in mind:
1) Any time the fuel system is being worked on,
disconnect the negative battery cable except for
those tests where battery voltage is required.
2) Always keep a dry chemical (Class B) fire
extinguisher near the work area.
3) Replace all pipes with the same pipe and fittings
that were removed.
Clean and inspect “O” rings. Replace where
required.
4) Always relieve the line pressure before servicing
any fuel system components.
5) Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
6) After maintenance work, push priming pump and
send enough fuel to the fuel system before starting
the engine.
NOTE: In comparison with the conventional engine,
the capacity of fuel passage in the 4JX1 engine is
larger. It takes the priming pump more time to fill the
engine with fuel.

6C – 4 ENGINE FUEL
HIGH PRESSURE OIL PUMP, OIL FLOW
P
33
32
31
30
1
2
3
4
56
8
97
10
11
12
13
14 23 29
25
28
27262415
16
17 18
19 20 21 22
Legend
(1) Camshaft
(2) Balance Shaft
(3) Crankshaft
(4) Oil Cooler and Oil Filter Assembly
(5) Oil Filter Relief Valve 98 Kpa (1 kg/cm
2/14.2 Psi)
(6) Oil Cooler Relief Valve 245 Kpa (2.5 kg/cm2/
36 Psi)
(7) First Oil Pump
(8) Main Oil Relief Valve 588 Kpa (6 kg/cm
2/ 85 Psi)
(9) To Oil Pan
(10) To Oil Pan
(11) Injector
(12) Oil Rail
(13) Sub Oil Filter Relief Valve 98 Kpa (1 kg/cm
2/
14.2 Psi)
(14) Sub Oil Filter
(15) Relief Valve 588 Kpa (6 kg/cm
2/ 85 Psi)
(16) Second Oil Pump(17) Oil Pan
(18) To Oil Pan
(19) Balance Shaft
(20) Cooling Jet Relief Valve 245 Kpa (2.5 kg/cm
2/
36 Psi)
(21) Cooling Jet
(22) To Oil Pan
(23) Two Way Check Valve
(24) Nipple Filter
(25) Edge Filter
(26) Edge Filter
(27) High Pressure Oil Pump Assembly
(28) To Oil Pan
(29) Pressure Control Valve
(30) To Oil Pan
(31) Turbocharger
(32) Oil Gallery
(33) Timing Gear Train
040RW018

6C – 14 ENGINE FUEL
NOTE:
1) Do not apply oil to the eye bolt.
2) Do not bend the fuel pump pipe.
5. Tifhten cap nut to specified torque.
Torque : 13 Nꞏm (1.3 kgꞏm/113 lb ft)
NOTE: Do not apply oil to the cap nut.
6. Start the engine, check that the fuel leakage is not
found.