1998 OPEL FRONTERA low oil pressure

ENGINE MECHANICAL 6A – 85
3. Measure the oil clearance between the connecting
rod and the crankshaft.
1) Remove the connecting rod cap nuts and the
rod caps.
Arrange the removed rod caps in the cylinder
number order.
2) Clean the rod bearings and the crankshaft pins.
3) Carefully check the rod bearings.
If even one bearing is found to be damaged or
badly worn, the entire bearing assembly must be
replaced as a set. Reinstall the bearings in their
original positions.
Apply plastigage to the crank pin.
4) Reinstall the rod caps to their original positions.
5) Tighten the cap nuts in 2 steps, using angular
tightening method as shown in the following
specifications.
1st step: 29 Nꞏm (3.0 kgꞏm/22 lb ft)
2nd step: 45°– 60°NOTE: Do not allow the crankshaft to rotate
6) Remove the rod caps.
7) Measure the smallest width of the plastigage
and determine the oil clearance. If the oil
clearance exceeds the limit, replace the rod
bearings as a set.
8) Clean the plastigage from the bearings and the
crankshaft pins
Standard: 0.022 – 0.042 mm (0.0009 – 0.0017 in)
Limit: 0.100 mm (0.0039 in)
REASSEMBLY
1. Connecting Rod
2. Piston
3. Piston Pin
1) Apply a coat of engine oil to the piston pin and
the piston pin hole.
4. Piston Pin Snap Ring
1) Try to insert the piston pin into the piston pin
hole with normal finger pressure.
2) Weight each piston and connecting rod
assembly.
3) Select piston and connecting rod combinations
so that the weight variation of the different four
assemblies is held within the specified limits.
Variance in weight after assembly: Less than 3g
(0.1058 oz)
NOTE: When changing piston/connecting rod
combinations, do not change the piston/piston pin
combination.
4) Attach the piston to the connecting rod with the
piston front mark (2) and the connecting rod
front mark (3) on the same side.
014RW055
012RW075
014RW077

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–8
Fuel Filter Assembly . . . . . . . . . . . . . . . . 6C–8
Fuel Filter Cartridge . . . . . . . . . . . . . . . . 6C–8
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–10High Pressure Oil Pump . . . . . . . . . . . . . 6C–14
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 – 2 ENGINE FUEL
FUEL FLOW
For EC
89
1011141
2
4
12
5 6
7
3
13
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(4) Fuel Supply Pipe
(5) Fuel Filter with Priming Pump
(6) Fuel Pump
(7) High Pressure Oil Pump(8) Cylinder Head
(9) Injector
(10) Orifice
(11) Fuel Return Pipe
(12) Fuel Tank Pressure Release Hose
(13) Intake Air Duct
(14) Fuel Tank Pressure Control Valve
040RX001

ENGINE FUEL 6C – 5
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

ENGINE FUEL 6C – 11
REMOVAL
Prior to removal, be sure to confirm and record the
group code of the injector installed using Tech2.
1. Disconnect battery ground cable.
2. Remove air cleaner cover and air duct.
3. Remove intercooler.
Refer to “Intercooler” in this manual.
4. Remove PCV hose and pipe.
5. Remove cylinder head noise insulator cover.
6. Remove high pressure oil pipe.
CAUTION:
1) Sleeve nut should be loosened with cloth tied
around to prevent oil from spurting due to the
remaining pressure.
2) High oil pressure pipe should be disconnected
with cloth tied around the intake manifold glow
plug to prevent oil from flowing out of the oil
rail.
7. Loosen eye bolt of fuel pipe at fuel pump side.
NOTE: Cloth should be put around the loosened eye
bolt to prevent fuel from flowing out.
8. Remove fuel return hose at chassis side.
9. Remove PCV hose to cylinder head cover.
10. Remove cylinder head cover.
11. Drain the oil from oil rail assembly.
NOTE: Do not drop O-ring
12. Record the grade code of injector for each cylinder
that is indicated on the upper portion of injector.
There are nine kinds of grade code available, one
alphabet letter and one numeral letter.
Grade codeLegend
(1) Part Number
(2) Category Number (Grade code)
(3) Serial Number
(4) Bar Code
13. Remove harness connector from each injector.
14. Loosen nuts and bolts for oil rail.
15. Remove injector fixing bolts.
16. Remove injector clamp.
17. Remove injector assembly.
INSTALLATION
1. Install oil rail, tighten temporarily
2. Install injector assembly.
NOTE:
1) Do not forget to install O-ring between injector and
oil rail.
2) Use new O-ring
3) Clean O-ring groove and fitting surface of parts.
4) Apply engine oil to O-ring.
3. Install injector fixing bolts, tighten temporarily.
4. Install injector clamp, tighten nut temporarily.
5. Tighten injector fixing bolts to the specified torque.
Torque: 6.5 Nꞏm (0.7 kgꞏm / 5.1 lb ft)
6. Tighten injector clamp nut to the specified torque
with special method.
Torque: 30 Nꞏm (3.1 kgꞏm / 22.4 lb ft) then loosen a
time again tighten as following torque.
Torque: 25 Nꞏm (2.4 kgꞏm / 17.4 lb ft)
7. Tighten oil rail to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
1
4
32
055RW00001
Category number
A– 1
A– 2
A– 3
B – 1
B – 2
B – 3
C – 1
C – 2
C – 3

6C – 18 ENGINE FUEL
HIGH PRESSURE OIL PIPE INSTALLATION
1. Install the nipple filter
1) Wash thread of the nipple filter, remove engine
oil and foreign material and air blow it.
2) Install nipple filter to high pressure oil pump inlet
port, tighten to the specified torque.
Torque : 90 Nꞏm (9.2 kgꞏm/66.5 lb ft)
2. Install the edge filter.
1) Wash thread, O-ring groove and fitting surface
of edge filter, remove engine oil and foreign
materials.
2) Install edge filter to high pressure oil pump,
tighten edge filter to the specified torque.
Torque : 90 Nꞏm (9.2 kgꞏm/66.5 lb ft)
3. Install upper bracket to two way valve, tighten them
temporarily.
4. Install pipe A to two way valve, tighten pipe A
temporarily with union nut D.
5. Install two way valve assembly to cylinder block,
tighgten with union nut C temporarily.6. Install pipe B to two way valve, tighten union nut E
and union nut F temporarily.
7. Tighten upper bracket to specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
8. Tighten union nut in the following order, union nut
C, D, F, and E to the specified torque.
Torque : 80 Nꞏm (8.1 kgꞏm/57.9 lb ft)
9. Tighten lower bracket to the specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
NOTE:
1) Wash inside pipe, inside union nut and O-ring seal
surface to remove engine oil and foreign materials.
2) It is recommended to check and replace the edge
filter when overhauling the engine, or if it is broken
inside the engine.
1
2
3
5
6
8 9
7
104
Legend
(1) Union Nut F
(2) Pipe B
(3) Union Nut E
(4) Upper Bracket
(5) Union Nut D(6) Pipe A
(7) Union Nut C
(8) Lower Bracket
(9) To Oil Rail
(10) To High Pressure Oil Pump through Edge Filter
040RW015

6E–3 4JX1–TC ENGINE DRIVEABILITY AND EMISSIONS
Action Taken When the DTC Sets 6E–90. . . . . . .
Conditions for Clearing the MIL/DTC 6E–90. . . . .
Diagnostic Aids 6E–90. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1196
(Flash DTC 62) Rail Pressure System
High Warning 6E–92. . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–93. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–93. . . . . . .
Conditions for Clearing the MIL/DTC 6E–93. . . . .
Diagnostic Aids 6E–93. . . . . . . . . . . . . . . . . . . . . . . .
Test Description 6E–93. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0197
(Flash DTC 16) Oil Temp Sensor Low
Voltage 6E–94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–94. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–94. . . . . . .
Conditions for Clearing the MIL/DTC 6E–94. . . . .
Diagnostic Aids 6E–94. . . . . . . . . . . . . . . . . . . . . . . .
Test Description 6E–95. . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Temperature Sensor 6E–95. . . . . . . . .
Diagnostic Trouble Code (DTC) P0198
(Flash DTC 16) Oil Temp Sensor High
Voltage 6E–96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–96. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–96. . . . . . .
Conditions for Clearing the MIL/DTC 6E–96. . . . .
Diagnostic Aids 6E–96. . . . . . . . . . . . . . . . . . . . . . . .
Test Description 6E–97. . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Temperature Sensor 6E–97. . . . . . . . .
Diagnostic Trouble Code (DTC) P0201
(Flash DTC 51) Injector # 1 Circuit Fault 6E–99. . .
Circuit Description 6E–99. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–99. . . . . . .
Conditions for Clearing the MIL/DTC 6E–99. . . . .
Diagnostic Aids 6E–99. . . . . . . . . . . . . . . . . . . . . . . .
Test Description 6E–99. . . . . . . . . . . . . . . . . . . . . . .
Injector Test 6E–99. . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0202
(Flash DTC 52) Injector # 2 Circuit Fault 6E–101. . .
Circuit Description 6E–101. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–101. . . . . . .
Conditions for Clearing the MIL/DTC 6E–101. . . . .
Diagnostic Aids 6E–101. . . . . . . . . . . . . . . . . . . . . . . .
Test Description 6E–101. . . . . . . . . . . . . . . . . . . . . . .
Injector Test 6E–101. . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0203
(Flash DTC 52) Injector # 3 Circuit Fault 6E–103. . .
Circuit Description 6E–103. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–103. . . . . . .
Conditions for Clearing the MIL/DTC 6E–103. . . . .
Diagnostic Aids 6E–103. . . . . . . . . . . . . . . . . . . . . . . .
Test Description 6E–103. . . . . . . . . . . . . . . . . . . . . . .
Injector Test 6E–103. . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Trouble Code (DTC) P0204
(Flash DTC 54) Injector # 4 Circuit Fault 6E–105
. . .
Circuit Description 6E–105. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–105. . . . . . .
Conditions for Clearing the MIL/DTC 6E–105. . . . .
Diagnostic Aids 6E–105. . . . . . . . . . . . . . . . . . . . . . . .
Test Description 6E–105. . . . . . . . . . . . . . . . . . . . . . .
Injector Test 6E–105. . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0217
(Flash DTC 22) High Coolant Temp Waring 6E–107
Circuit Description 6E–107. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–107. . . . . . .
Conditions for Clearing the MIL/DTC 6E–107. . . . .
Diagnostic Aids 6E–107. . . . . . . . . . . . . . . . . . . . . . . .
Test Description 6E–107. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P1217
(Flash DTC 36) High Oil Temp Warning 6E–109. . . .
Circuit Description 6E–109. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–109. . . . . . .
Conditions for Clearing the MIL/DTC 6E–109. . . . .
Diagnostic Aids 6E–109. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0219
(Flash DTC 11) Engine Over Speed Warning 6E–111
Circuit Description 6E–111. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–111. . . . . . .
Conditions for Clearing the MIL/DTC 6E–111. . . . .
Diagnostic Aids 6E–111. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0336
(Flash DTC 43) CKP (Crank Position)
Sensor Out of Synchro 6E–114. . . . . . . . . . . . . . . . . .
Circuit Description 6E–114. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–114. . . . . . .
Conditions for Clearing the MIL/DTC 6E–114. . . . .
Diagnostic Aids 6E–114. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0337
(Flash DTC 43) CKP (Crank Position)
Sensor No Signal 6E–116. . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–116. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–116. . . . . . .
Conditions for Clearing the MIL/DTC 6E–116. . . . .
Diagnostic Aids 6E–116. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0341
(Flash DTC 41) CMP (Cam Position)
Sensor Out of Synchro 6E–119. . . . . . . . . . . . . . . . . .
Circuit Description 6E–119. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–119. . . . . . .
Conditions for Clearing the MIL/DTC 6E–119. . . . .
Diagnostic Aids 6E–119. . . . . . . . . . . . . . . . . . . . . . . .
Test Description 6E–119. . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) P0342
(Flash DTC 41) CMP (Cam Position)
Sensor No Signal 6E–122. . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 6E–122. . . . . . . . . . . . . . . . . . . . .
Action Taken When the DTC Sets 6E–122. . . . . . .
Conditions for Clearing the MIL/DTC 6E–122. . . . .