1998 OPEL FRONTERA engine

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.

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, as illustrated. The pipe can be removed
with the retainer attached.
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3. For removal of the return pipe (returning fuel to the
tank), hold the pipe in one hand, and pull out the
connentor with the other hand while pressing the
square relieve button of the retainer, as illustrated.
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NOTE: This work should be done by hands. Do not use
any tools. Should the pipe can hardly be removed from
the connector, use a lubricant (light oil) and/or push and
pull the connector longitudinally until the pipe is removed.
141RW021When reusing the delivery pipe retainer, reuse
without removing the retainer from the pipe. If the
retainer is damaged or deformed, however, replace
with a new retainer.
Cover the connectors removed with a plastic bag, etc.
to prevent the entry of dust or rain water.
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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.
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(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.
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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.

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, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission”.
1. Disconnect battery ground cable.
2. Loosen fuel filler cap.
3. Drain fuel.
Tighten drain plug to the specified torque after
draining fuel.
Torque: 20 Nꞏm (2.0 Kgꞏm/14 lb ft) — M8
4. Wiring connector
Disconnect wiring connector(1) from the unit.
5. Fuel gauge unit
Remove the fixing screws, then the fuel gauge
unit(2).
NOTE: After removing fuel gauge unit, cover fuel tank to
prevent any dust entering
Installation
1. Fuel gauge unit(2).
2. Wiring connector(1).
Connect the wiring connector to the fuel gauge unit.
Fill the tank with fuel and tighten fuel filler cap.
Connect battery ground cable.

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 adjust the pressure to prevent
the tank from being damaged.
140RW021
Legend
(1) Vacuum Valve
(2) Pressure Valve
Inspection
Check the seal ring in the filler cap for presence of any
abnormality and for seal condition.
Replace the filler cap, if abnormal.
CAUTION: The fuel filler cap valves have
characteristics.
A defective valve, no valve at all or a valve with the
wrong characteristics will do a lot of harm to engine
operating characteristics; be sure to use the same
fuel filler cap as installed in this vehicle.
Main Data and Specifications
Torque Specification
Nꞏm (Kgꞏm/lb ft)
035RW141

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.

6D1–2
ENGINE ELECTRICAL
Battery
General Description
There are six battery fluid caps on top of the battery.
These are covered by a paper label.
The battery is completely sealed except for the six small
vent holes on the side. These vent holes permit the
escape of small amounts of gas generated by the battery.
This type of battery has the following advantages over
conventional batteries:
1. There is no need to add water during the entire
service life of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an extensive charge.
(A conventional battery will accept an excessive
charge, resulting in gassing and loss of battery fluid.)
3. The battery is much less vulnerable to self discharge
than a conventional type battery.
Diagnosis
1. Visual Inspection
Inspect the battery for obvious physical damage, such as
a cracked or broken case, which would permit electrolyte
loss.
Replace the battery if obvious physical damage is
discovered during inspection.
Check for any other physical damage and correct it as
necessary.
2. Hydrometer Check
There is a built–in hydrometer (Charge test indicator(1))
at the top of the battery. It is designed to be used during
diagnostic procedures.
Before trying to read the hydrometer, carefully clean the
upper battery surface.
If your work area is poorly lit, additional light may be
necessary to read the hydrometer.
a. BLUE RING OR DOT VISIBLE(5) – Go to Step 4.
b . B L U E R I N G O R D O T N O T V I S I B L E ( 4 ) – G o t o S t e p
3.
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3. Fluid Level Check
The fluid level should be between the upper level line(2)
and lower level line(3) on side of battery.
a. CORRECT FLUID LEVEL – Charge the battery.
b. BELOW LOWER LEVEL – Replace battery.
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4. Voltage Check
1. Put voltmeter test leads to battery terminals.
a. VOLTAGE IS 12.4V OR ABOVE – Go to Step 5.
b. VOLTAGE IS UNDER 12.4V – Go to procedure (2)
below.
2. Determine fast charge amperage from specification.
(See Main Data and Specifications in this section).
Fast charge battery for 30 minutes at amperage rate
no higher than specified value.
Take voltage and amperage readings after charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE – Replace battery.
b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE – Drop charging voltage to
15V and charge for 10 – 15 hours. Then go to Step
5.
c. VOLTAGE IS BETWEEN 12V AND 16V –
Continue charging at the same rate for an
additional 3–1/2 hours. Then go to Step 5.
d. VOLTAGE BELOW 12V – Replace Battery.
5. Load Test
1. Connect a voltmeter and a battery load tester across
the battery terminals.
2. Apply 300 ampere load for 15 seconds to remove
surface charge from the battery. Remove load.
3. Wait 15 seconds to let battery recover. Then apply
specified load from specifications (See Main Data
and Specifications in this section).
Read voltage after 15 seconds, then remove load.

ENGINE ELECTRICAL6D1–3
a. VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN THE TABLE – The battery is
good and should be returned to service.
b. VOLTAGE IS LESS THAN MINIMUM LISTED –
Replace battery.
ESTIMATED TEMPERATURE
MINIMUM
VOLTAGE
FCV
70219.6
60169.5
50109.4
4049.3
30–19.1
20–78.9
10–128.7
0–188.5
The battery temperature must be estimated by feel
and by the temperature the battery has been
exposed to for the preceding few hours.
Battery Charging
Observe the following safety precautions when charging
the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during charging
procedure.
Battery charging should be discontinued or the rate of
charge reduced if the battery feels hot to the touch.
Battery charging should be discontinued or the rate of
charge reduced if the battery begins to gas or spew
electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue dot
or ring, it may be necessary to jiggle or tilt the battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be either
quick charged or slow charged in the same manner as
other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
Jump Starting
Jump Starting with an Auxiliary (Booster)
Battery
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: FAILURE TO CAREFULLY FOLLOW THE
JUMP STARTING PROCEDURE COULD RESULT IN
THE FOLLOWING:
1. Serious personal injury, particularly to your eyes.
2. Property damage from a battery explosion, battery
acid, or an electrical fire.
3. Damage to the electronic components of one or both
vehicles particularly.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode.
Remove any rings, watches, or other jewelry before
working around the battery. Protect your eyes by wearing
an approved set of goggles.
Never allow battery fluid to come in contact with your eyes
or skin.
Never allow battery fluid to come in contact with fabrics or
painted surfaces.
Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes, skin,
fabric, or a painted surface, immediately and thoroughly
rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of reach of young children.
Jump Starting Procedure
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector level in the “PARK”
position.
If the vehicle is equipped with a manual transmission,
place the shift lever in the “NEUTRAL” position.
Turn “OFF” the ignition.
Turn “OFF” all lights and any other accessory
requiring electrical power.
2. Look at the built–in hydrometer.
If the indication area of the built–in hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the positive
terminal of the discharged battery.
Do not allow the vehicles to touch each other. This will
cause a ground connection, effectively neutralizing
the charging procedure.
Be sure that the booster battery has a 12 volt rating.