1998 OPEL FRONTERA sensor

6F–4ENGINE EXHAUST
Front Exhaust Pipe
Front Exhaust Pipe and Associated Parts
150RW063
Legend
(1) Front Exhaust Pipe RH Fixing Nuts
(2) Front Exhaust Pipe RH Fixing Bolts and Nuts
(3) O
2 Sensor Terminal Connector (for IGM)
(4) Front Exhaust Pipe LH Fixing Nuts(5) Front Exhaust Pipe LH Fixing Bolts and Nuts
(6) Front Exhaust Pipe LH
(7) Front Exhaust Pipe RH
(8) Three way Exhaust Pipe Fixing Bolts and Nuts
Removal
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety
stands.
3. Disconnect O
2 sensor harness connector (3).
4. Remove front exhaust pipe fixing nuts and three way
Exhaust Pipe Fixing Bolts and Nuts (2)(5)(8).
5. Remove front exhaust pipe fixing three stud nuts from
exhaust manifold (1)(4).
6. Remove front exhaust pipe (6)(7).
Installation
1. Install front exhaust pipe (6)(7) and tighten three stud
nuts (1)(4) and nuts (2)(5)(8) to the specified torque.
To r q u e
Stud Nuts : 67 Nꞏm (6.8 Kgꞏm/49 lb ft)
Nuts : 43 Nꞏm (4.3 Kgꞏm/32 lb ft)
2. Reconnect O
2 sensor harness connector (3).

6J–2
INDUCTION
Air Cleaner Element
Removal
1. Remove positive ventilation hose from connector(1).
2. Remove intake air temperature sensor(2).
3. Remove air flow sensor(3).
4. Remove air cleaner duct cover(4).
5. Remove air cleaner element(5).
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Inspection
Check the air cleaner element for damage or dust
clogging. Replace if it is damaged, or clean if it is clogged.
Cleaning Method
Tap the air cleaner element gently so as not to damage
the paper element, or clean the element by blowing with
compressed air of about 490 kPa (71 psi) from the clean
side if it is extremely dirty.
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Installation
1. Install air cleaner element(5).
2. Attach the air cleaner duct cover (4) to the body
completely, then clamp it with the clip.
3. Install mass air flow sensor(3).
4. Install air temperature sensor(2).
5. Connect positive crankcase ventilation hose to
connector(1).
For General Export Model
130RW003
For Isuzu General Motors (IGM) Model
130RW006

ENGINE MECHANICAL 6A – 13
VALVE CLEARANCE ADJUSTMENT
1. Install 2.80 mm valve adjuster (shim) first when
reassembling the engine.
Thickness mark faces down.
2. Measure the valve clearance after installing cam
carrier assy with camshafts.
3. Change the adjuster using a special tool when the
clearance is out of tolerance.
Valve Clearance Adjusting Tool: 5-8840-2590-0
VALVE CLEARANCE (When cold condition)
Inlet 0.15 ± 0.05 mm
Exh 0.25 ± 0.05 mm
COMPRESSION PRESSURE
MEASUREMENT
1. Start the engine and allow it to idle until the coolant
temperature reaches 70 – 80°C (158 – 176°F).
2. Remove the following parts.
Glow plugs
Fuel cut solenoid connector
QOS (Quick-On Start System) fuse in the fuse
box.
3. Set the adapter and compression gauge to the No.
1 cylinder glow plug hole.
Compression Gauge
(with Adapter): 5-8840-2008-0
4. Turn the engine over with the starter motor and take
the compression gauge reading.
Compression Pressure at 200 rpm
Standard: 3040 kPa (31 kg/cm
2/441 psi)
Limit: 2160 kPa (22 kg/cm
2/313 psi)
5. Repeat the procedure (Steps 3 and 4) for the
remaining cylinders.
QUICK-ON START 4 SYSTEM
Quick-On Start System Inspection Procedure
1. Disconnect the ECT-sensor connection around the
thermostat outlet pipe.
2. Turn the starter switch to the “ON” position.
If the Quick-On Start 4 System is operating
properly, the glow relay will make a clicking sound
within seven seconds after the starter switch is
turned on.
3. Measure the glow plug terminal voltage with a
circuit tester immediately after turning the starter
switch to the “ON” position.
Glow Plug Terminal Voltage: approx. 12V
NOTE: Electrical power to the quick-on start system will
be cut after the starter has remained in the “ON”
position for twenty seconds.
Turn the starter switch to the “OFF” position and back
to the “ON” position.
This will reset the Quick-On Start 4 System.
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ENGINE MECHANICAL 6A – 35
INTAKE MANIFOLD
REMOVAL
1. Drain engine coolant and disconnect water hose
from thermostat hosing.
2. Remove intercooler assembly
Refer to “Intercooler” in this manual.
3. Remove bracket bolt of oil level gauge guide tube.
4. Remove PCV Hose.
5. Remove hoses from EGR, EGR vacuum sensor
and inlet/outlet of heater.
6. Disconnect harness connector form MAP sensor,
EGR vacuum sensor, ETC sensor, water
temperature unit, IAT sensor and EVRV.
7. Remove high pressure oil pipe.
8. Remove the two way valve.
9. Remove fuel pipe from between intake manifold
and high pressure oil pump.
10. Remove fixing bolts and nuts on the intake
manifold, then remove the intake manifold
assembly.
INSTALLATION
1. Install the intake manifold, tighten bolts and nuts to
the specified torque.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) for bolt and nut
2. Install the fuel pipe and tighten to the specified
torque.To r q u e :
M16 bolt (apply engine oil) 4 Nꞏm (0.4 kgꞏm/2.9
lb ft)
Cap nut (M10) 13Nꞏm (1.3 kgꞏm/9.4 lb ft)
Fuel pipe (M10 apply engine oil) 14 Nꞏm (1.4
kgꞏm/10 lb ft)
3. Install two way valve.
Torque : 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
4. Fill with about 300 cc of engine oil from the high
pressure oil pipe installation port of the oil rail using
an oil filler. If assembled without filling the oil rail
with oil, the time for starting the engine will be
longer.
5. Install the high pressure oil pipe immediately and
tighten the sleeve nut to the specified torque.
Torque : 80 Nꞏm (8 kgꞏm/57.9 lb ft)
6. Reconnect harness connector to MAP sensor, EGR
vacuum sensor, ETC sensor, Water temperature
unit, IAT sensor and EVRV.
7. Connect the hoses to EGR valve, EGR vacuum
sensor, and water inlet/outlet pipe for heater.
8. Connect PCV hose.
9. Install the oil level gauge guide tube and tighten
bracket bolt.
10. Install the intercooler assembly.
Refer to “Intercooler” in this manual.
11. Connect the hose to the thermostat housing and fill
with engine coolant.
For Europe
2
1
3
3 1 42
025R200005
Legend
(1) Intake Manifold
(2) Throttle Valve Assembly
(3) EGR Valve
(4) Gasket

6A – 44 ENGINE MECHANICAL
REMOVAL
1. Disconnect battery ground cable.
2. Drain engine coolant.
3. Remove air cleaner and air duct.
4. Remove intercooler assembly.
Refer to “Intercooler” in this manual.
5. Remove oil level gauge guide assembly.
6. Remove PCV hose.
7. Remove EGR vacuum hose.
8. Disconnect harness connector around the cylinder
head.
9. Remove A/C compressor assembly.
10. Remove A/C compressor bracket.
11. Remove generator assembly and take out fan belt.
12. Remove heat protector and remove valve
assembly.
13. Remove water hose and oil pipe from turbocharger.
14. Remove turbocharger assembly.
15. Remove water hose between thermostat and
radiator.
16. Remove cylinder head noise insulator cover.
NOTE: Do not make damage to the harness.
17. Remove high pressure pipe.
18. Remove timing belt cover.
19. Remove CMP sensor bracket.
20. Remove timing belt tensioner and remove timing
belt.
21. Remove camshaft pulley.
22. Remove front plate.
23. Remove water pipe between cylinder head and
water pump.
24. Remove fuel pipe between fuel pump and intake
manifold.
25. Remove fuel return pipe.
26. Remove intake manifold assembly.
27. Disconnect glow plug wiring and remove glow plug.
28. Remove cylinder head cover.
29. Drain oil from oil rail.
30. Disconnect injector harness connector.
31. Disconnect harness connector from oil pressure
sensor and oil temperature sensor on the oil rail.
32. Disconnect injector harness assembly.
33. Remove injector clamp.
34. Remove injector spacer (If equipped.).
35. Remove injector assembly.
36. Remove oil rail assembly.
37. Remove camshaft carrier.
38. Remove cylinder head assembly.
39. Remove cylinder gasket.
INSTALLATION
1. Install cylinder head gasket with top mark up.
NOTE: Determine cylinder head gasket grade by
measuring projection of piston head.2. Selection cylinder head gasket.
1) Measure the piston head projection by dial
gauge.
2) Measure the projection of piston head at the
nearest possible point to the cylinder bore.
3) Obtain the largest measurement from among all
cylinders.
4) Determine cylinder head gasket grade by
maximum value of measuring projection of
piston head.
Legend
(1) Top Mark
(2) Grade Mark
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2 1
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ENGINE MECHANICAL 6A – 45
Cylinder head gasket and piston projection mm
CAUTION:
The projection of each piston should be 0.333
mm or more and less than 0.483 mm.
Maximum difference in projection between
pistons should be less than 0.1 mm.
If the piston projection is without standard,
reassemble the engine all over again.
3. Install cylinder head assembly, tighten bolts by
angular tightening method.
To r q u e :
1st step; 49 Nꞏm (4.9 kgꞏm/35.4 lb ft)
2nd step; 60°
3rd step; 60°
CAUTION: The cylinder head bolts cannot be
reused.
4. Install camshaft carrier assembly.
Refer to “Camshaft” in this manual.
5. Install oil rail and injector assembly.
Refer to “Oil rail and injector” in this manual.
6. Install injector harness to connect harness
connector.
Note: Apply liquid gasket (TB 1207B or equivalent) to
the rubber seal of the camshaft end, injector harness
gasket area and No. 1 camshaft bracket. Refer to the
Cylinder head cover.
7. Install cylinder head cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
8. Install glow plug to tighten specified torque.
Torque: 15 Nꞏm (1.5 kgꞏm/11 lb ft) and connectglow plug harness.
9. Install intake manifold.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
10. Install fuel return pipe.
11. Install fuel pipe in between fuel pump and intake
manifold.
12. Install water pipe in between cylinder head and
water pump.
Tighten flange bolt to the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
13. Install front plate.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft)
14. Install camshaft pulley, tighten with angular
tightening method.
1st step 40 Nꞏm (4.0 kgꞏm/29 lb ft)
2nd step 60°
NOTE: Apply engine oil to camshaft pulley bolt.
15. Align timing mark oil pump pulley and camshaft
pulley to front plate then put the timing belt and
tighten tensioner bolt.
Torque: 20 Nꞏm (2.0 kgꞏm/14.5 lb ft) for M8
50 Nꞏm (5.1 kgꞏm/37 lb ft)
16. Install CMP sensor bracket.
17. Install timing belt cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
18. Fill with about 300 cc of engine oil from the high
pressure oil pipe installing port of oil rail using an oil
filler.
If assembled without filling the oil rail with oil, the
time for engine start will be longer.
19. Immediately install high pressure oil pipe to tighten
with specified torque.
Torque: 80 Nꞏm (8 kgꞏm/57.9 lb ft)
20. Install cylinder head noise insulator cover.
Torque: 9 Nꞏm (0.9 kgꞏm/6.5 lb ft)
Grade A Grade B Grade C
011RW042
Grade Piston projectionGasket
thickness
A more 0.333 to less 0.383 1.35
B more 0.383 to less 0.433 1.40
C more 0.433 to less 0.483 1.45

6A – 52 ENGINE MECHANICAL
TIMING GEAR
REMOVAL
1. Loosen fixing bolt for generator and remove
generator assembly.
2. Remove fixing nuts, then remove cooling fan
assembly and fan pulley.
3. Remove crankshaft damper pulley.
4. Belt cover
1) Disconnect harness connector of CMP
(camshaft position) sensor.
2) Remove CMP sensor.
3) Remove belt cover.
5. Loosen belt tensioner to remove timing belt.
6. Remove camshaft pulley.
7. Remove high pressure oil pump pulley.
8. Remove front plate.
9. Remove vacuum pump.
10. Remove power steering pump.
11. Remove gear cover assembly.
12. Idle gear A.
1) Set two bolts to sub gear of idle gear A and turn
it to align the tooth of idle gear A then lock them
by bolt as show in the illustration.
2) Remove idle gear A fixing bolts.
3) Remove idle gear A.Legend
(1) Sub-Gear
(2) Main Gear
(3) Bar
(4) Locking Bolt
2
3
4
5 8
7
6 91
020RW028
Legend
(1) Idle Gear A
(2) High Pressure Oil Pump Gear
(3) Vacuum Pump Gear
(4) Power Steering Pump Gear(5) Balance Gear LH
(6) Idle Gear C
(7) Crankshaft Gear
(8) Balance Gear RH
(9) Idle Gear B
4 1
2
3
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6A – 58 ENGINE MECHANICAL
14. Camshaft pulley
1) Align TDC mark with crankshaft pulley and gear
case cover.
2) Set camshaft stopper on the end of intake and
exhaust camshaft.
Camshaft Stopper: 5-8840-2592-0
3) Install key to camshaft and install camshaft
pulley.
4) Apply engine oil to camshaft pulley fixing bolt
and tighten bolt with angular tightening method.
First step: 40 Nꞏm (4.0 kgꞏm / 29 lb ft)
Second step: 60° to 90°
15. Timing belt
1) Install tensioner and tighten the bolt temporarily.
2) Align timing mark with camshaft pulley timing
mark and timing gear case timing mark.
3) Set No.1 cylinder TDC position.4) Install the timing belt in the following order
camshaft pulley, oil pump pulley, tensioner.
NOTE:
1) It is recommended for easy installation that the belt
be secured with a double clip after it is installed to
each pulley.
2) The “ISUZU” mark should be read from the front of
the engine when installing the timing belt.
5) Install the belt tensioner.
6) Conform not phase difference each pulley.
7) Tension the timing belt with two turns of the
crankshaft.
8) Tighten the tensioner bolt in order A to B to the
specified torque.
Torque: Bolt A 5 Nꞏm (0.5 kgꞏm/3.6 lb ft)
Bolt B 2 Nꞏm (0.2 kgꞏm/1.4 lb ft)
Legend
(1) Align Mark
(2) Camshaft Pulley
(3) Timing Belt
(4) Oil Pump Pulley
(5) Bolt B
(6) Tensioner Assy
(7) Tensioner Bolt A
(8) Tensioner Spring
16. CMP sensor bracket
1) Install CMP sensor bracket and tighten bolt to
the specified torque.
Torque: 20 Nꞏm (2.0 kgꞏm / 14.5 lb ft)
17. Timing belt cover
1) Install timing belt cover and tighten bolt to the
specified torque.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
2) Tighten CMP sensor to the specified torque.
Torque: 9 Nꞏm (0.9 kgꞏm / 6.5 lb ft)
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1
2
3
8
67
4 5
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